2002 Seadoo PDF

2002
Shop Manual
Volume 1
GTI, GTI LE, GTX, GTX RFI,

XP, RX, RX DI, LRV DI
Legal deposit:
National Library of Quebec

2nd trimester 2002
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. 2002
Technical Publications
Bombardier Inc.
Valcourt (Quebec) Canada
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
SAFETY NOTICE .................................................................................................................................. III
INTRODUCTION ................................................................................................................................... IV
01 SERVICE TOOLS 01 - Table of contents ...................................................................... 01-01-1

AND PRODUCTS 02 - Mandatory service tools............................................................ 01-02-1
03 - Optional service tools................................................................ 01-03-1
04 - Service products ....................................................................... 01-04-1
02 MAINTENANCE 01 - Table of contents ...................................................................... 02-01-1

02 - Periodic inspection chart ........................................................... 02-02-1
03 - Flushing and lubrication............................................................. 02-03-1
04 - Water-flooded engine................................................................ 02-04-1
05 - Storage...................................................................................... 02-05-1
03 TROUBLESHOOTING 01 - Troubleshooting chart ............................................................... 03-01-1
04 ENGINE 01 - Table of contents ...................................................................... 04-01-1

02 - Leak test ................................................................................... 04-02-1
03 - Removal and installation ........................................................... 04-03-1
04 - Magneto system ....................................................................... 04-04-1
05 - Top end ..................................................................................... 04-05-1
06 - Bottom end ............................................................................... 04-06-1
07 - Rotary valve............................................................................... 04-07-1
08 - Exhaust system......................................................................... 04-08-1

MANAGEMENT (RFI) 02 - Overview................................................................................... 05-02-1
03 - Diagnostic procedures .............................................................. 05-03-1
04 - Component inspection .............................................................. 05-04-1
05 - Troubleshooting summary ........................................................ 05-05-1
06 - Adjustment................................................................................ 05-06-1

MANAGEMENT (DI) 02 - Overview................................................................................... 06-02-1
03 - Component inspection and adjustment .................................... 06-03-1
07 COOLING SYSTEM 01 - Table of contents ...................................................................... 07-01-1

02 - Circuit, components and care ................................................... 07-02-1
08 FUEL SYSTEM 01 - Table of contents ...................................................................... 08-01-1

02 - Fuel circuit................................................................................. 08-02-1
03 - Air intake ................................................................................... 08-03-1
04 - Carburetor ................................................................................. 08-04-1
09 LUBRICATION 01 - Table of contents ...................................................................... 09-01-1

SYSTEM 02 - Oil injection system................................................................... 09-02-1
03 - Oil injection pump ..................................................................... 09-03-1
10 ELECTRICAL 01 - Table of contents ...................................................................... 10-01-1

SYSTEM 02 - Ignition system.......................................................................... 10-02-1
03 - Charging system ....................................................................... 10-03-1
04 - Starting system ......................................................................... 10-04-1
05 - Instruments and accessories .................................................... 10-05-1
06 - Digitally encoded security system (DESS) ................................ 10-06-1
SMR2002_015_00A2.FM I
TABLE OF CONTENTS
11 PROPULSION 01 - Table of contents ...................................................................... 11-01-1

SYSTEM 02 - Jet pump................................................................................... 11-02-1
03 - Drive system............................................................................. 11-03-1
04 - Reverse system........................................................................ 11-04-1
05 - Variable trim system ................................................................. 11-05-1
12 STEERING SYSTEM 01 - Table of contents ...................................................................... 12-01-1

02 - Steering system........................................................................ 12-02-1
03 - Alignment ................................................................................. 12-03-1
13 SUSPENSION 01 - Table of contents ...................................................................... 13-01-1

02 - Direct action suspension .......................................................... 13-02-1
14 HULL/BODY 01 - Table of contents ...................................................................... 14-01-1

02 - Adjustment and repair .............................................................. 14-02-1
15 TECHNICAL DATA 01 - GTI and GTI LE models............................................................. 15-01-1

02 - GTX RFI model.......................................................................... 15-02-1
03 - XP model .................................................................................. 15-03-1
04 - RX DI model.............................................................................. 15-04-1
05 - LRV DI models.......................................................................... 15-05-1
06 - GTX and RX models.................................................................. 15-06-1
16 WIRING DIAGRAMS 01 - Wiring diagrams........................................................................ 16-01-1
II SMR2002_015_00A2.FM
SAFETY NOTICE
SAFETY NOTICE 0
This manual has been prepared as a guide to correctly service and repair all 2002 SEA-DOO watercraft.
See model list below.
This edition was primarily published to be used by watercraft mechanical technicians who are already
familiar with all service procedures relating to Bombardier made watercraft. Mechanical technicians
should attend training courses given by Bombardier Training Dept.
Please note that the instructions will apply only if proper hand tools and special service tools are used.
This Shop Manual uses technical terms which may be slightly different from the ones used in the Parts
Catalog.
It is understood that this manual may be translated into another language. In the event of any discrepancy,
the English version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at time of writing. Service
and Warranty Bulletins may be published to update the content of this manual. Make sure to read and
understand these.
In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the
general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas
of the parts.
The use of Bombardier parts is most strongly recommended when considering replacement of any com-
ponent. Dealer and/or distributor assistance should be sought in case of doubt.
The engines and the corresponding components identified in this document should not be utilized on
product(s) other than those mentioned in this document.
Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking tab,
self-locking fasteners, etc.) must be installed or replaced with new ones. If the efficiency of a locking
device is impaired, it must be renewed.
This manual emphasizes particular information denoted by the wording and symbols:
 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 vehicle components.
NOTE: Indicates supplementary information needed to fully complete an instruction.
Although the mere reading of such information does not eliminate the hazard, your understanding of the
information will promote its correct use. Always use common shop safety practice.
Bombardier Inc. disclaims liability for all damages and/or injuries resulting from the improper use of the
contents. We strongly recommend that any services be carried out and/or verified by a highly skilled
professional mechanic. It is understood that certain modifications may render use of the vehicle illegal
under existing federal, provincial and state regulations.
SMR2002_015_00A2.FM III
INTRODUCTION
INTRODUCTION 0
This Shop Manual covers the following BOMBAR- HULL IDENTIFICATION NUMBER
DIER made SEA-DOO® 2002 watercraft models.
(H.I.N.)
ENGINE MODEL It is located on footboard at the rear of watercraft.
MODELS
TYPE NUMBER
GTS, GTI and RX Series
XP 947 5578
XP International 947 5577
GTI (ultraviolet) 717 5559
GTI International
717 5558
(ultraviolet)
GTI LE International
717 5560
(earthen clay)
GTI LE (earthen clay) 717 5561
GTI California (ultraviolet) 717 6116
GTI LE California
717 6117
(earthen clay)
GTX (yellow) 947 5588
GTX International (yellow) 947 5587
GTX RFI (blue) 787 5566
GTX RFI International
787 5565
(blue)
RX (blue) 947 5580
F00L2EA 1
RX International (blue) 947 5579
1. Hull Identification Number (H.I.N.)
RX (yellow) 947 5582
All Other Models
RX International (yellow) 947 5581
RX DI (blue) 947 DI 5584
RX DI International
947 DI 5583
(blue)
RX DI (yellow) 947 DI 5586
RX DI International
947 DI 5585
(yellow)
RX DI International (blue) 947 DI 5591
RX DI International
947 DI 5592
(yellow)
LRV DI 947 DI 5460
F08L0QA 1
TYPICAL
IV SMR2002_015_00A2.FM
INTRODUCTION
All Models 787 RFI Engine

The Hull Identification Number is composed of 12 The Engine Identification Number is located on the
digits: upper crankcase on PTO side.
ZZN12345L495
Model year
Serial
number* Year of production
Month of production
Manufacturer
F00A0CB
*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. F01D87A 1
1. Engine Identification Number (E.I.N.)
947 Engine
1
The Engine Identification Number is located on the
upper crankcase on MAGNETO side.
F01D01A
TYPICAL
F06D15A 1
SMR2002_015_00A2.FM V
INTRODUCTION
ARRANGEMENT OF THIS
MANUAL
The manual is divided into 16 major sections:
01 SERVICE TOOLS AND PRODUCTS
02 MAINTENANCE
03 TROUBLESHOOTING
04 ENGINE
05 ENGINE MANAGEMENT (RFI)
06 ENGINE MANAGEMENT (DI)
07 COOLING SYSTEM
08 FUEL SYSTEM
09 LUBRICATION SYSTEM
10 ELECTRICAL SYSTEM
11 PROPULSION SYSTEM
12 STEERING SYSTEM
13 SUSPENSION
14 HULL/BODY
15 TECHNICAL DATA
16 WIRING DIAGRAM
Several sections are divided in various subsections.
There is a table of contents at the beginning of
many sections.
VI SMR2002_015_00A2.FM
INTRODUCTION
TYPICAL PAGE
Page heading
indicates section
and subsection
detailed.
Subsection title
indicates
beginning of the
subsection. Subsection 04 (MAGNETO SYSTEM)
Italic sub-title
above exploded
view indicate
pertaining models.
Drop represents
a liquid product
to be applied to a
surface. In this case
Loctite 243 to
screw threads.
Loctite
243
Loctite
243
Dotted box
contains parts of
a particular
Exploded view assits Loctite model or an
243
you in identifying exploded view.
parts and related
positions. Loctite
243
Loctite
243
Bold face number

indicates special
procedure
concerning this part.
Loctite
648
145 Nm
(107 lbfft)
Anti-seize
lubricant
F01D4WS
Illustration number
for publishing
process.
03-04-1
Page numbering system:

03: ENGINE section
04: MAGNETO SYSTEM subsection
1: First page of this subsection
F01A0CS
SMR2002_015_00A2.FM VII
INTRODUCTION
TYPICAL PAGE
Sub-title with part

name(s) from
exploded view.
Section 06 FUEL SYSTEM

Subsection 03 (CARBURETORS)
Title indicates main

procedure to be CARBURETOR REMOVAL DISASSEMBLY AND INSPECTION
carried-out. To remove carburetors from engine, proceed as fol- Inspect parts for corrosion dammage (shaft, butterfly,
lows: spring screw, check valve housing, etc.).
Remove air vent tube support.
Sub-sub-title in
Unlock retaining slides holding air intake silencer base.
Diaphragm capital indicates a
Remove air intake silencer base from watercraft. PUMP DIAPHRAGM LEAK TEST particular testing,
Remove screws holding flame arrester base support Using a suitable pump gauge tester, perform the fol- adjustment or
lowing test proceeding as follows:
to cylinder head cover.
- Install pump gauge tester (P/N 295 000 083) on pulse
repair procedure.
Unscrew base retaining screws then remove base from
Service tool to be carburetors and move to front of watercraft. nipple.
used to perform a Turn the valve to OFF position. - Pump tester until it reaches 28 kPa (4 PSI).
certain procedure. NOTE: For fuel line removal, use pliers (P/N 295
000 054). 1 A
Disconnect pulse line from fuel pump.
Disconnect fuel fuel supply line from fuel pump. Illustration
Disconnect fuel return line. always follows
Title in italic indicates a Disconnect oil injection pump cable, throttle cable and text it is
particular procedure choke cable.
pertained to.
concerning a model. XP Model Only
Remove screws no. 6 and lock washers no. 7 retaining
carburetors.
Sub-sub-title in this All Others Models

case indicates that Remove 4 bolts no. 8 and lock washers no. 12 from
rotary valve cover then move carburetors and rotary 2 1 2 TYPICAL mention
particular procedure valve cover on top of engine.
F01F0XB
indicates a general
for XP is finished, so NOTE: When removing rotary valve cover , pay
TYPICAL
view which does not
from this point, all
1
attention that the rotary valve stay in place, other-wise
represent full detail.
2
it must be timed.
others models are
Remove carburetors from intake manifold.
concerned. Diaphragm must stand pressure for 10 seconds. If
Disconnect fuel bypass line between carburetors (twin
carburetors). pressure drops, replace diaphragm. Numbers in a frame
Remove carburetor(s) from rotary valve cover. are used to give a
sequence to be
perfomed.
Letters are used for

any measures.
06-03-4
Bold numbers in the

text refer to the parts Numbers are used
shown in the exploded for description of
view at the beginning components.
of the subsection.
F01A0BS
VIII SMR2002_015_00A2.FM
INTRODUCTION
LIST OF ABBREVIATIONS USED GENERAL INFORMATION

IN THIS MANUAL The use of RIGHT (starboard) and LEFT (port) indi-
cations in the text, always refers to driving position
DESCRIPTION
(when sitting on watercraft).
ADC Analog to Digital Conversion
Besides, in the marine industry, FRONT is called
AC Alternate Current
BOW and REAR is called STERN.
APS Air Pressure Sensor
ATS Air Temperature Sensor
Bombardier Utility and Diagnostic 1 2
B.U.D.S.
Software
CDI Capacitor Discharge Ignition
CPS Crankshaft Position Sensor
CSI Cooling System Indicator
DC Direct Current
DESS Digitally Encoded Security System
DI Direct Injection
E.I.N. Engine Identification Number
F01L45B
ECU Electronic Control Unit
EPA Environmental Protection Agency (USA) 1. Left (port)
2. Right (starboard)
HP Horse Power
The information and component/system descrip-
LED Light Emitting Diode
tions contained in this manual are correct at time
MAG Magneto of writing. Bombardier Inc. however, maintains a
MPEM Multi-Purpose Electronic Module policy of continuous improvement of its products
MPH Mile Per Hour without imposing upon itself any obligation to in-
MPI Multi Protocol Interface stall them on products previously manufactured.
N.A. Not Applicable Bombardier Inc. reserves the right at any time to
OPT Optional
discontinue or change specifications, designs,
features, models or equipment without incurring
P/N Part Number obligation.
PFD Personal Flotation Device
This Shop Manual uses technical terms which
PSI Pound Per Square Inch may be different from the ones of the Parts Cata-
PTO Power Take Off logs.
RAVE Rotax Adjustable Variable Exhaust When ordering parts always refer to the specific
RFI Rotax Fuel Injection model Parts Catalogs.
RPM Revolution Per Minute
STD Standard ILLUSTRATIONS AND
TBD To Be Determined PROCEDURES
TDC Top Dead Center The illustrations show the typical construction of
TPS Throttle Position Sensor the different assemblies and, in all cases, may not
VDC Volt Direct Current reproduce the full detail or exact shape of the parts
VCK Vehicle Communication Kit shown, however, they represent parts which have
the same or a similar function.
VDC Volt Direct Current
CAUTION: These watercraft are designed with
VTS Variable Trim System
parts dimensioned mostly in the metric system.
WTS Water Temperature Sensor However some components may be from the impe-
rial system. When replacing fasteners, make sure to
use only those recommended by Bombardier.
SMR2002_015_00A2.FM IX
INTRODUCTION
As many of the procedures in this manual are in- EPA Emission Regulations
terrelated, we suggest, that before undertaking
All new 1999 and more recent Sea-Doo water-
any task, you read and thoroughly understand the
crafts manufactured by Bombardier are certified
entire section or subsection in which the proce-
to the EPA as conforming to the requirements of
dure is contained.
the regulations for the control of air pollution from
A number of procedures throughout the book renew watercraft engines. This certification is con-
quire the use of special tools. Before undertaking tingent on certain adjustments being set to factory
any procedure, be sure that you have on hand all standards. For this reason, the factory procedure
the tools required, or approved equivalents. for servicing the product must be strictly followed
and, whenever practicable, returned to the original
ENGINE EMISSIONS intent of the design.
INFORMATION The responsibilities listed above are general and in no
way a complete listing of the rules and regulations
Manufacturer’s Responsibility pertaining to the EPA requirements on exhaust emis-
Beginning with 1999 model year engines, PWC sions for marine products. For more detailed informa-
manufacturers of marine engines must determine tion on this subject, you may contact the following
the exhaust emission levels for each engine horse- locations:
power family and certify these engines with the
United States of America Environmental Protec- VIA U.S. POSTAL SERVICE:
tion Agency (EPA). An emissions control informa-
tion label, showing emission levels and engine Office of Mobile Sources
specifications, must be placed on each vehicle at Engine Programs and Compliance Division
the time of manufacture. Engine Compliance Programs Group (6403J)
401 M St. NW
Dealer Responsibility Washington, DC 20460
When performing service on all 1999 and more re-

cent Sea-Doo watercrafts that carry an emissions VIA EXPRESS or COURIER MAIL:
control information label, adjustments must be Office of Mobile Sources
kept within published factory specifications. Engine Programs and Compliance Division
Replacement or repair of any emission related Engine Compliance Programs Group (6403J)
component must be executed in a manner that 501 3rd St. NW
maintains emission levels within the prescribed Washington, DC 20001
certification standards.
Dealers are not to modify the engine in any man- EPA INTERNET WEB SITE:
ner that would alter the horsepower or allow emis- http:/www.epa.gov/omswww
sion levels to exceed their predetermined factory
specifications.
Exceptions include manufacturer’s prescribed SELF-LOCKING FASTENERS
changes, such as altitude adjustments for exam- PROCEDURE
ple.
The following describes the most common appli-
Owner Responsibility cation procedures when working with self-locking
fasteners.
The owner/operator is required to have engine
Use a metal brush or a screwtap to clean the hole
maintenance performed to maintain emission lev-
properly then use a solvent (Methyl-Chloride), let
els within prescribed certification standards.
act during 30 minutes and wipe off. The solvent
The owner/operator is not to, and should not allow utilization is to ensure the adhesive works properly.
anyone to modify the engine in any manner that
would alter the horsepower or allow emissions
levels to exceed their predetermined factory spec-
ifications.
X SMR2002_015_00A2.FM
INTRODUCTION
LOCTITE APPLICATION Blind Holes

PROCEDURE
cation procedures when working with Loctite 1
products.
NOTE: Always use proper strength Loctite prod- 2
uct as recommended in this Shop Manual.
THREADLOCKER
Uncovered Holes (bolts and nuts)
A00A3MA
1. On threads
2. On threads and at the bottom of hole
1
1. Clean threads (bolt and hole) with solvent.
2. Apply Loctite Primer N (P/N 293 800 041) on
threads (bolt and nut) and allow to dry for 30
seconds.
3. Choose proper strength Loctite threadlocker.
4. Apply several drops along the threaded hole and
at the bottom of the hole.
2 5. Apply several drops on bolt threads.
A00A3LA
6. Tighten as required.
1. Apply here
2. Do not apply
Stud in Blind Holes
1. Clean threads (bolt and nut) with solvent.
threads and allow to dry.
1 3
4. Fit bolt in the hole.
2
5. Apply a few drops of threadlocker at proposed
tightened nut engagement area.
6. Position nut and tighten as required.
A00A5RA
1. On threads
2. On threads and in the hole
3. Onto nut threads
SMR2002_015_00A2.FM XI
INTRODUCTION
1. Clean threads (stud and hole) with solvent. Adjusting Screw

3. Put several drops of proper strength Loctite 2
threadlocker on female threads and in hole. 1
4. Apply several drops of proper strength Loctite
on stud threads.
5. Install stud.
6. Install cover, etc.
7. Apply drops of proper strength Loctite on un-
covered threads.
8. Tighten nuts as required.
A00A3PA
Preassembled Parts
1. Apply here
2. Plunger
1. Adjust screw to proper setting.

2. Apply drops of proper strength Loctite thread-
1 locker on screw/body contact surfaces.
3. Avoid touching metal with tip of flask.
NOTE: If it is difficult to readjust, heat screw with
a soldering iron (232°C (450°F)).
STRIPPED THREAD REPAIR

Stripped Threads
2
A00A3OA 5
1. Apply here 1
2. Do not apply 6
8
1. Clean bolts and nuts with solvent.
2
2. Assemble components.
3. Tighten nuts.
4. Apply drops of proper strength Loctite on bolt/nut 3
contact surfaces.
A00A3QA 4 7
NOTE: For preventive maintenance on existing
equipment, retighten nuts and apply proper strength 1. Release agent
2. Stripped threads
Loctite on bolt/nut contact surfaces. 3. Form-A-Thread
4. Tape
5. Cleaned bolt
6. Plate
7. New threads
8. Threadlocker
XII SMR2002_015_00A2.FM
INTRODUCTION
Standard Thread Repair NOTE: Avoid grinding.

1. Follow instructions on Loctite FORM-A-THREAD 2. Clean both mating surfaces with solvent.
81668 package. 3. Spray Loctite Primer N on both mating surfaces
2. If a plate is used to align bolt: and on both sides of gasket. Allow to dry 1 or 2
a. Apply release agent on mating surfaces. minutes.
b. Put waxed paper or similar film on the surfaces. 4. Apply GASKET ELIMINATOR 518 (P/N 293 800
038) on both sides of gasket, using a clean ap-
3. Twist bolt when inserting it to improve thread plicator.
conformation.
5. Place gasket on mating surfaces and assemble
NOTE: NOT intended for engine stud repairs. immediately.
Repair of Small Holes/Fine Threads NOTE: If the cover is bolted to blind holes (above),
Option 1: Enlarge damaged hole, then follow Stan- apply proper strength Loctite in the hole and on
dard Thread Repair procedure. threads. Tighten.
Option 2: Apply FORM-A-THREAD on the screw If holes are sunken, apply proper strength Loctite
and insert in damaged hole. on bolt threads.
Permanent Stud Installation (light duty) 6. Tighten as usual.
1. Use a stud or thread on desired length.
MOUNTING ON SHAFT
2. DO NOT apply release agent on stud.
3. Do a Standard Thread Repair. Mounting with a Press
4. Allow to cure for 30 minutes.
5. Assemble.
GASKET COMPOUND
All Parts
1 2 1
A00A3UA
1 1. Bearing
2. Proper strength Loctite
3. Shaft
Standard
1. Clean shaft external part and element internal
part.
2. Apply a strip of proper strength Loctite on shaft
A00A3SA 1 3 circumference at insert or engagement point.
1. Proper strength Loctite NOTE: Retaining compound is always forced out
2. Loctite Primer N (P/N 293 800 041) and Gasket Eliminator 518 when applied on shaft.
(P/N 293 800 038) on both sides of gasket
3. Loctite Primer N only 3. DO NOT use anti-seize Loctite or any similar
1. Remove old gasket and other contaminants product.
with Loctite Chisel remover (P/N 413 708 500). 4. No curing period is required.
Use a mechanical mean if necessary.
SMR2002_015_00A2.FM XIII
INTRODUCTION
Mounting in Tandem TIGHTENING TORQUES

1. Apply retaining compound on internal element
Tighten fasteners to torque mentioned in explod-
bore.
ed views and text. When they are not specified
2. Continue to assemble as shown above. refer to following table.The table also gives the
metric conversion.
CASE-IN COMPONENTS N•m FASTENER SIZE (8.8) Lbf•in
Metallic Gaskets 1 9
2 M4 18
3 27
4 M5 35
5 44
6 53
7 62
8 71
9 80
10 M6 89
11 97
12 106
13 115
A00A3VA 1 14 124
1. Proper strength Loctite 15 133
16 142
1. Clean inner housing diameter and outer gasket
diameter. 17 150
2. Spray housing and gasket with Loctite Primer N 18 159
(P/N 293 800 041). 19 168
3. Apply a strip of proper strength Loctite on lead-
N•m FASTENER SIZE (8.8) Lbf•ft
ing edge of outer metallic gasket diameter.
20 15
NOTE: Any Loctite product can be used here. A
21 15
low strength liquid is recommended as normal
strength and gap are required. 22 16
23 M8 17
4. Install according to standard procedure.
24 18
5. Wipe off surplus.
25 18
6. Allow it to cure for 30 minutes. 26 19
NOTE: Normally used on worn-out housings to 27 20
prevent leaking or sliding. 28 21
It is generally not necessary to remove gasket 29 21
compound applied on outer gasket diameter. 30 22
31 23
32 24
33 24
34 25
35 26
36 27
37 27
XIV SMR2002_015_00A2.FM
INTRODUCTION
N•m FASTENER SIZE (8.8) Lbf•ft N•m FASTENER SIZE (8.8) Lbf•ft
38 28 83 61
39 29 84 62
40 30 85 63
41 30 86 63
42 31 87 64
43 32 88 65
44 32 89 66
45 33 90 66
46 34 91 67
47 35 92 68
48 M10 35 93 69
49 36 94 69
50 37 95 70
51 38 96 71
52 38 97 72
53 39 98 72
54 40 99 73
55 41 100 74
56 41 101 74
57 42 102 75
58 43 103 76
59 44 104 77
60 44 105 77
61 45 106 78
62 46 107 79
63 46 108 80
64 47 109 80
65 48 110 81
66 49 111 82
67 49 112 83
68 50 113 83
69 51 114 84
70 52 115 85
71 52 116 86
72 53 117 86
73 54 118 87
74 55 119 88
75 55 120 89
76 56 121 89
77 57 122 90
78 58 123 91
79 58 124 91
80 M12 59 125 92
81 60 126 93
82 60 127 94
SMR2002_015_00A2.FM XV
INTRODUCTION
N•m FASTENER SIZE (8.8) Lbf•ft

128 94
129 95
130 96
131 97
132 97
133 98
134 99
135 M14 100
136 100
137 101
138 102
139 103
140 103
141 104
142 105
143 105
144 106
145 107
146 108
147 108
148 109
149 110
150 111
TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTS
Bombardier Inc.
Valcourt (Quebec), Canada
XVI SMR2002_015_00A2.FM
Section 01 SERVICE TOOLS AND PRODUCTS
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS 0
MANDATORY SERVICE TOOLS ........................................................................................... 01-02-1
ENGINE .............................................................................................................................. 01-02-1
COOLING/FUEL/OIL SYSTEMS ........................................................................................ 01-02-4
PROPULSION SYSTEM..................................................................................................... 01-02-5
OPTIONAL SERVICE TOOLS ................................................................................................ 01-03-1

ENGINE .............................................................................................................................. 01-03-1
WATERCRAFT HANDLING................................................................................................ 01-03-6
SERVICE PRODUCTS ............................................................................................................ 01-04-1
SMR2002-052_01_01ATOC.FM 01-01-1
Subsection 02 (MANDATORY SERVICE TOOLS)
MANDATORY SERVICE TOOLS 0

ENGINE
Degree wheel Air compressor ring compressor PTO flywheel remover/installer
P/N 529 035 607 P/N 529 035 713 P/N 295 000 001
350 360 10 20
340 30
33
0 10 360 350 3
20 40 40
30 33
3 20 40 0
32
50
50
0
0
31
60
60
31
0
0
70
30
300
70
80
290
290
80
110 100 90
F01J0T4
280
280 270 26
90 100 11
APPLICATION
270 260
120
717 engine.
0
0
250
F12B0L4
130
250
12 0
0
24
NOTE: This tool is also used for

14
24
APPLICATION
0
13
0
2
0 30
0
15
23
22 40
the impeller.
0
16 0 0
0 22 210 15
200 190 180 17
947 DI engine.
0 0
21 160
170 00
180 190 2
Starter drive bearing pusher

A00B334 Carbon dam guide
APPLICATION P/N 529 035 715 P/N 290 876 502
717 and 787 engines.
Piston circlip installer

A) P/N 529 035 562 F06B054
B) P/N 529 035 563 F12B0M4 APPLICATION

APPLICATION 947 and 947 DI engines.
947 DI engine.
Piston pin puller
Carbon dam compressor P/N 529 035 503
P/N 529 035 716 Expansion sleeve
F06B014 P/N 295 000 117 (787 engine)
APPLICATION
A) 717 and 787 engines.
B) 947 and 947 DI engines.
Sleeve set
F12B0N4
A) P/N 529 035 542
(20 mm sleeve) APPLICATION
B) P/N 529 035 543 947 DI engine. F00B0T4
(21 mm sleeve) APPLICATION

Bearing pusher All engines.
P/N 420 876 501
F00B0U4
F00B074
APPLICATION
APPLICATION
A) 717 and 787 engines.
B) 947 and 947 DI engines.
SMR2002-016_01_02A.FM 01-02-1
Puller Puller ass’y Adapter

P/N 529 035 547 P/N 290 876 488 P/N 529 035 590
1) Screw P/N 290 240 860
2) Hexagonal nut P/N 290 242 210
A00C1A4 F00B124
Puller plate 2 1
APPLICATION
P/N 420 876 080 XP model.
F01B0I4
APPLICATION
VCK (Vehicle Communication Kit)
P/N 529 035 676
Alignment support plate kit

P/N 529 035 506
A00C1R4
1) Alignment plates
Extension handle
A) P/N 529 035 507
P/N 295 000 125
B) P/N 529 035 508
2) Support
F01D164
P/N 529 035 511
3) Screw (2)
Screw M8 x 35 (3) P/N 207 182 544
P/N 420 841 591
4) Lock washer (2)
P/N 234 181 601
F00A094
5) Flat washer (2)
P/N 234 081 410
Sleeve (3)
P/N 290 847 220
F12H0A4
APPLICATION
All models.
F00A0A4
Flywheel extractor
APPLICATION
717 engine. P/N 295 000 156
F00B0F4
Puller is also used for PTO fly-
wheel on 947 and 947 DI engines. APPLICATION
All models.
Pusher A) 155.6 mm jet pump.
P/N 420 876 605 B) 139.5 mm jet pump.
Alignment shaft
P/N 295 000 141
F00B044
A00C0Y4
APPLICATION APPLICATION
717 engine. XP model.
F00B0G4
APPLICATION
All models.
01-02-2 SMR2002-016_01_02A.FM
Engine leak tester kit Ring gear puller tool Ring gear blocking tool kit
P/N 295 500 352 P/N 420 976 235 (puller ass’y) P/N 529 035 846
Pump only P/N 529 035 549 (puller bolt)
P/N 529 021 800
F15B014
APPLICATION
F01B294
787 engine.
APPLICATION
F01B2Q5 787, 947 and 947 DI engines.
Rotary valve shaft pusher
APPLICATION
P/N 290 876 609
717, 787, 947 and 947 DI engines. Crankshaft protective cap
A) P/N 420 876 557
Supplementary engine leak test B) P/N 290 877 414
kit
P/N 295 500 780
1) 787 RFI Intake plate
P/N 296 000 024
2) 947 Intake plate F01B2B4
P/N 296 000 025 APPLICATION

3) 947 Rave plate 787 engine.
P/N 296 000 026 A B
4) 947 Exhaust plate F00B194
P/N 296 000 027 Oil seal pusher

APPLICATION
P/N 290 877 740
APPLICATION A) 717 and 787 engines.
787 RFI and 947 engines. B) 947 and 947 DI engines.
NOTE: This kit is supplementary
to P/N 295 500 352.
Polygonal wrench
P/N 529 035 505
Handle
P/N 420 877 650 F01B2C4
APPLICATION
787 engine.
F00B0Y4
A00C3V4
Intake plug
APPLICATION P/N 529 035 708
APPLICATION
Exhaust system of the 947 and
Use with pushers (P/N 290 876 947 DI engines.
609 and 290 877 740). APPLICATION
947 DI engine.
SMR2002-016_01_02A.FM 01-02-3
COOLING/FUEL/OIL SYSTEMS
Gear holder Fuel pressure gauge 1. Fuel pressure gauge
P/N 420 277 905 P/N 529 035 591 P/N 529 035 709
2. Fuel pressure gauge T-fitting
P/N 529 035 710
3. Fuel pressure gauge pressure
relief valve
P/N 529 035 711
4. Fuel pressure gauge air com-
pressor adapter
A00C164
P/N 529 035 712
APPLICATION
717 engine.
F02B0B4 1
Pliers APPLICATION
P/N 295 000 070 787 RFI engine.
Oetiker 1099
Fuel line disconnect tool
P/N 529 035 714
3 2 4
F01D174 F12R014
All models. 947 DI engine.
F12B0G4
Pliers
APPLICATION
P/N 295 000 054
947 DI engine.
Caillau
F01B1T4
APPLICATION
All models.
NOTE: This tool is also used for
the propulsion system.
01-02-4 SMR2002-016_01_02A.FM
PROPULSION SYSTEM
Impeller remover/installer Bearing/seal installer Pliers
P/N 295 000 001 P/N 295 000 107 P/N 295 000 054
Caillau
F01J0T4
APPLICATION F01B1T4
All models. APPLICATION

NOTE: This tool is also used for All models.
F01J4K4
the PTO flywheel (on some mod-
APPLICATION NOTE: This tool is also used for
els). the fuel system.
All models except GTX and XP.
Pliers VTS tool
P/N 295 000 069 Inner seal installer
P/N 295 000 133
Oetiker 1090 P/N 529 035 609
F01B2P4
APPLICATION
XP models.
F01D184
Drive shaft alignment tool
APPLICATION
P/N 529 035 590
All models.
Impeller shaft holder

P/N 295 000 082
F08B014
APPLICATION
155.6 mm (6-1/8 in) jet pump.
Impeller shaft guide

F01B0W4 P/N 295 000 002
APPLICATION
All models.
Jet pump bearing remover F08B024
P/N 295 000 144

F01J1O4 APPLICATION
APPLICATION XP model.
All models.
F01J114
APPLICATION
All models.
SMR2002-016_01_02A.FM 01-02-5
NEW
OPAS cylinder nut wrench

P/N 529 035 840
F18B0A4
APPLICATION
GTI LE.
01-02-6 SMR2002-016_01_02A.FM
Subsection 03 (OPTIONAL SERVICE TOOLS)
OPTIONAL SERVICE TOOLS 0

ENGINE
Coil centering tool Stroboscopic timing light Digital/induction type
P/N 420 876 922 P/N 529 031 900 tachometer
P/N 529 014 500
A01B1V4
APPLICATION
717 engine. A00B4F4
APPLICATION F01B1G4
Cylinder aligning tool All models. APPLICATION

P/N 420 876 904 All models.
A) Four-pin magneto harness
P/N 295 000 131
Timing mark pointer
B) Six-pin magneto harness
A00B084
P/N 295 000 136 P/N 295 000 130
APPLICATION
717 engine.
Distance gauge
F01B284
A) P/N 529 034 800,
14 mm (.551 in) APPLICATION
B) P/N 529 034 900, A) 717 engine.
15.4 mm (.606 in) B) 787, 947 and 947 DI engines.
C) P/N 529 035 100, F01B2O4
11.5 mm (.453 in) Dial indicator (TDC gauge) APPLICATION

D) P/N 529 035 000, P/N 295 000 143 717 engine.
7.5 mm (.295 in)
Timing mark pointer
P/N 295 000 135
A00B4E4
APPLICATION
All models.
F01B0H4
APPLICATION
A) 717 engine.
F01H544
B) 787 engine.
APPLICATION
C) 947 and 947 DI engines (MAG).
787, 947 and 947 DI engines.
D) 947 and 947 DI engines (PTO).
SMR2002-016_01_03A.FM 01-03-1
Crimping tool Safety lanyard switch tool Gear/bearing puller

P/N 295 100 164 P/N 529 034 600 P/N 290 877 665
F01B244
F00B0E4 APPLICATION
APPLICATION All models.
Contacts of AMP plug connectors. F04B034
Slide hammer puller
APPLICATION
Terminal (Packard) remover Not sold by Bombardier
787 engine.
Not sold by Bombardier Snap-on:
Handle: CJ93-1
Snap-on Hammer: CJ125-6
TT 600-4 Exhaust outlet tool
Claws: CJ93-4
P/N 295 000 132
F01B1J4
F01J0Z4
APPLICATION
APPLICATION
All models.
NOTE: This tool is also used to
Joint connector tool F01B2A4
pull out impeller shaft seal.
Not sold by Bombardier APPLICATION
Deutsch All models.
114010 Protective mat
P/N 295 000 128
Engine lifting device
Not sold by Bombardier
Do it yourself
Refer to REMOVAL AND INSTAL-
LATION section of engine.
F02B0A4
APPLICATION
F12B0C4
All models.
APPLICATION
DI models.
F01D0A4
APPLICATION
717 engine and DI models.
01-03-2 SMR2002-016_01_03A.FM
Feeler gauge 45° MPEM programmer 9 9

8 8 7 7
Not sold by Bombardier P/N 529 035 878
Snap-on
FB 300 A
1
5
2
4
3
F01B1K4
A01B5B4
6 4
717 and 787 engines. All models.
Steering cable tool Piston ring compressor (2)

P/N 295 000 145 A) P/N 290 876 965 (88 mm) MAG side PTO side
B) P/N 290 876 979 (82 mm) F01D885
F01B2P4 1) Puller ass’y

All models.
2) Protective cap
Rubber pad P/N 420 876 557
F01B1T4
P/N 295 000 101 P/N 290 877 414 (947 and 947
APPLICATION DI engines)
A) 947 and 947 DI engines.
3) Ring (both ends)
B) 717 and 787 engines.
P/N 420 977 490
Digital multimeter P/N 420 977 480 (947 and 947
DI engines)
P/N 529 035 868
F01B0J4
4) Ring halves (PTO)
APPLICATION P/N 420 977 475 (2)
717 and 787 engines. P/N 420 876 330 (947 and 947
DI engines)
Rubber pad
5) Distance ring (MAG)
P/N 290 877 032
P/N 420 876 569
6) Ring halves (MAG)

P/N 420 276 025 (2)
7) Screw M8 x 40
F06B064
P/N 420 840 681 (2)
APPLICATION 8) Screw M8 x 70
947 and 947 DI engines. P/N 420 841 201 (2)
APPLICATION
All models. 9) Puller bolt
P/N 420 940 755
APPLICATION
All engines.
SMR2002-016_01_03A.FM 01-03-3
Pump gauge tester Spring compressor Flushing adapter
P/N 295 000 114 P/N 529 035 504 P/N 295 500 473
10
20
5
1
15
2
30
25
3
35
4
60
40
50
F01B0X4
APPLICATION
All models except RFI and DI mod- F00B104
els.
APPLICATION
All models.
Lighted adjustable mirror A01B4O4 Use with coupler hose (P/N 295
Not sold by Bombardier APPLICATION 500 258).
Snap-on
50101 XP model.
Hose pincher
Suspension adjustment wrench P/N 295 000 076
P/N 529 012 200
F01B1I4
APPLICATION
All models.
Hose pincher
P/N 529 032 500
A01B2I4
APPLICATION
A25A014
All models.
APPLICATION
XP model.
Flexible spout (oil)

F01B234 P/N 414 837 300
APPLICATION
All models.
F04B044
APPLICATION
All models.
01-03-4 SMR2002-016_01_03A.FM
PROPULSION SYSTEM
Fitting
P/N 295 000 086
F01B0Z4
APPLICATION
All models.
Slide hammer puller

Snap-on:
Handle: CJ93-1
Hammer: CJ125-6
Claws: CJ93-4
F01J0Z4
APPLICATION
All models.
NOTE: This tool is also used to re-
move rotary valve shaft bearing.
Hacksaw
Snap-on
HS3
F01B1M4
APPLICATION
All models.
SMR2002-016_01_03A.FM 01-03-5
WATERCRAFT HANDLING
Dolly (with wheels) Tie-down with ratchet
P/N 295 000 126 3.60 m (12 ft) long
P/N 295 100 104
APPLICATION
All models.
Tie-down
1.50 m (5 ft) long
P/N 295 100 103
F01B014
Beach wheels (set of 2 wheels)

P/N 295 000 005
F00B014
F01B074 APPLICATION
Dolly.
01-03-6 SMR2002-016_01_03A.FM
Subsection 04 (SERVICE PRODUCTS)
SERVICE PRODUCTS 0
Loctite® is a trademark of Loctite™ Corporation.
Permatex® is a trademark of Loctite™ Corporation.
Dow Corning® is a trademark of Dow Corning Corporation.
Medium strength threadlocker High temperature threadlocker Retaining compound
P/N 293 800 060 P/N 420 899 788 P/N 413 703 100
Loctite 243 (blue) Loctite 648 (green) Loctite RC/609 (green)
(10 mL) (5 g) (10 mL)
A00B3D4 A00B2S4
High temperature retaining General purpose instant

compound adhesive
F00A0O4 P/N 293 800 054 P/N 293 800 021
Loctite 642 Loctite 495
High strength threadlocker (50 mL)
P/N 293 800 005

Loctite 271 (red)
(10 mL)
A00B2V4
Gasket eliminator
P/N 293 800 038
Loctite 518
(50 mL)
F00B024
F01B124
A00B2U4
SMR2002-016_01_04A.FM 01-04-1
Flange sealant Thread sealant Primer for gasket eliminator

P/N 293 800 081 P/N 293 800 050 P/N 293 800 041
Loctite 5910 Loctite 577 Loctite 764
(300 mL) (250 mL)
F00B0W4
Solvent
P/N 413 711 809
Loctite Safety Solvent
320 g (11 oz) A00B3N4
Pipe sealant
A) P/N 293 800 018
F00B1A4 B) P/N 293 800 013
A) Loctite 592 (50 mL)
Chisel gasket remover B) Loctite 567 (250 mL)
P/N 413 708 500

(510 mL)
A00B2W4
Hylomar sealant
P/N 293 800 001
A00B4X4
PL-32
(100 g)
Molykote 111
P/N 413 707 000
111
A00B3F4
A00B574 A00B3W4 Sealant

P/N 293 530 011
NEW Sikaflex 221 (black)
(350 mL)
RTV silicone sealant

P/N 293 800 066
Loctite 5900 (300 mL) F01B1D4
A02B0B4
01-04-2 SMR2002-016_01_04A.FM
Dielectric grease Grease NEW
P/N 293 550 004 P/N 293 550 005

Dow Corning (400 g) Grease Isoflex
(150 g)
(P/N 293 550 021)
(50 g)
A00B2L4
A00B1X4
Synthetic grease
NEW P/N 293 550 010
(400 g)
High temperature RTV sealant
(P/N 293 800 090)
Ultra Copper (80 mL)
F01B154
Super Lube grease

P/N 293 550 030
A00B554
BOMBARDIER LUBE
R
P/N 293 600 016

(12 x 14 oz)
A00B5A4
A00B474
Deoxit contact lubricant

Anti-seize lubricant
P/N 293 550 015
P/N 293 800 070
(200 mL)
Loctite 76764
454 g (16 oz)
A00B624
F00B0X4
A00B594
SMR2002-016_01_04A.FM 01-04-3
BOMBARDIER storage oil NEW Sealant adhesive

P/N 413 711 600 P/N 293 800 086
(12 x 350 g) Premixed coolant 50/50 Loctite 5150
-37°C (-35°F) (29647)
P/N 293 600 038
(16 x 1 L)
A00B5S4
NEW
Instant gasket
P/N 293 800 088
(7 oz)
A00B634
Sea-Doo fuel stabilizer

P/N 413 408 600 A00B5X4
236 mL (8 oz)
NEW
BOMBARDIER FORMULA XP-S II

synthetic injection oil
P/N 293 600 245
(12 x 1 liter)
Ao2B0C4
Jet pump oil

A00B604 P/N 293 600 011 (12 x 6 oz)
Sea-Doo
synthetic jet pump oil
732 Multi-purpose sealant
P/N 293 800 033
Dow Corning (90 mL) A00B5T4
(clear)
P/N 293 600 246
(3 x 4 liter)
F01B1C4
F01B0P4
NEW
A00B5U4 Jet pump grease

P/N 293 600 247 P/N 293 550 032
(205 liter) (110g)
01-04-4 SMR2002-016_01_04A.FM
Sea-Doo Cleaner
P/N 293 110 001 (400 g)
P/N 293 110 002 (4 L)
F01B2J4
NEW
Pulley flange cleaner

P/N 413 711 809
A00B5V4
SMR2002-016_01_04A.FM 01-04-5
Section 02 MAINTENANCE
TABLE OF CONTENTS 0
PERIODIC INSPECTION CHART ........................................................................................... 02-02-1
FLUSHING AND LUBRICATION ........................................................................................... 02-03-1

GENERAL ........................................................................................................................... 02-03-1
PROCEDURE ...................................................................................................................... 02-03-1
WATER-FLOODED ENGINE .................................................................................................. 02-04-1

GENERAL ........................................................................................................................... 02-04-1
PROCEDURE ...................................................................................................................... 02-04-1
STORAGE............................................................................................................................... 02-05-1
ENGINE DRAINING ........................................................................................................... 02-05-1
FUEL SYSTEM ................................................................................................................... 02-05-3
ENGINE OIL CHANGE AND FILTER ................................................................................. 02-05-4
COOLING SYSTEM FLUSHING AND ENGINE INTERNAL LUBRICATION .................... 02-05-4
ENGINE LUBRICATION ..................................................................................................... 02-05-4
BATTERY............................................................................................................................ 02-05-5
WATERCRAFT CLEANING ................................................................................................ 02-05-5
ADDITIONAL RECOMMENDED PROTECTION ................................................................ 02-05-5
ANTICORROSION TREATMENT ....................................................................................... 02-05-14
CHECKLIST ........................................................................................................................ 02-05-14
NOTE: The maintenance section of this manual was copied from the 2003 manual since the section was missing from the 2002
manual. Most information is near identical between the two manuals.
SMR2003-049_02_01ATOC.FM 02-01-1
Subsection 02 (PERIODIC INSPECTION CHART)
PERIODIC INSPECTION CHART 0

The schedule should be adjusted according to operating conditions and use.
NOTE: The chart gives an equivalence between number of hours and months/year. Perform the maintenance
operation to whatever time comes first.
IMPORTANT: Schedule for watercraft rental operations or higher number of hour use, will require greater
frequency of inspection and maintenance.
2-Stroke Models
DESCRIPTION FREQUENCY
3 MONTHS
6 MONTHS
HOURS OR
HOURS OR
OR 1 YEAR
EVERY 100
I: Inspect, verify, clean, adjust, lubricate, replace if necessary
EVERY 25
EVERY 50
FIRST 10
C: Clean
HOURS
HOURS
L: Lubricate
R: Replace
GENERAL
Lubrication/corrosion protection ➀ C
ENGINE
Support and rubber mount I I
Exhaust system fasteners ➄ I I
RAVE valve (if so equipped) ➄ C C
Top end (leak test, piston and ring clearance) (DI models only) ➄ ➈
Counterbalance shaft oil level (if so equipped) I I
Spark plug I➃ R
Ignition timing (all models except DI) ➄ I
TDC setting (DI models only) ➄ ➈
COOLING SYSTEM
Flushing C➂
Hose and fasteners I I
Engine drain tubes I➀
Water flow regulator valve (if so equipped) I
FUEL SYSTEM
Carburetor including choke/throttle cable (carburetor-equipped models) I I
Throttle/choke cables (carburetor-equipped models) ➀ I
Fuel filter (except RFI models) and lines I I
Fuel filter (except DI and RFI models) R
Fuel filter (DI models only) ➇
Oil leakage between cylinder head and injector (DI models) ➄ I I
Fuel injection system sensors (except throttle body), (RFI and DI models) ➄ I I
Throttle body and their sensors (DI models) ➄ ➅ I I
Fuel vent line pressure relief valve I
Fuel lines, connections (DI models), check-valve and fuel system pressurization ➄ I I
Carburetors/throttle bodies, sensors, fuel lines, fuel rail and fittings
(if so equipped) ➄ I I
Air intake silencer fit/tightness I I
Fuel tank straps I I
SMR2003-003_02_02A.FM 02-02-1
HOURS OR
3 MONTHS
HOURS OR
6 MONTHS
OR 1 YEAR
EVERY 100
EVERY 25
EVERY 50
FIRST 10
C: Clean
HOURS
HOURS
L: Lubricate
R: Replace
LUBRICATION SYSTEM
Oil injection pump ➄ I I
Oil filter and lines I I
Oil filter R
Oil reservoir straps I
ELECTRICAL SYSTEM
Electrical connections and fastening (ignition system, electrical box(es), starting
I I
system, fuel injectors (RFI and DI models), etc.)
MPEM mounting brackets/fasteners I
Digitally Encoded Security System I I
Monitoring beeper I I
Battery and strap(s)/fasteners I I
STEERING SYSTEM
Steering cable I I
O.P.A.S. SYSTEM
O.P.A.S. system I I
PROPULSION SYSTEM
Drive shaft boot and splines (if so equipped) I➁
Drive shaft protection hose I➁
PTO flywheel L L
Shifter system/cable I I
VTS (Variable Trim System) (if so equipped) I I
Jet pump reservoir oil and oil level R I R
Jet pump cover pusher (if so equipped) I
Impeller shaft seal ➆
Impeller and impeller/wear ring clearance R➁
Water intake grate I➁
HULL/BODY
Bailer pick-ups, check for obstructions I I
Hull I I
➀ Every 10 hours in salt water use.

➁ These items have to be initially checked after 25 hours. Thereafter, servicing to be made as specified in
this chart.
➂ Daily flushing in salt water or foul water use.
➃ Except DI models.
➄ Emission-related component.
➅ In salt water use.
➆ Replace at 150 hours.
➇ Replace at 250 hours.
➈ Check at 350 hours or 5 years.
02-02-2 SMR2003-003_02_02A.FM
4-TEC Models
HOURS OR
HOURS OR
3 MONTHS
6 MONTHS
OR 1 YEAR
EVERY 100
EVERY 25
EVERY 50
FIRST 10
C: Clean
HOURS
HOURS
L: Lubricate
R: Replace
GENERAL
Lubrication/corrosion protection L
ENGINE
Engine oil and filter (including cover’s O-rings) R R
Support and rubber mount I I
Seals and fasteners I I
Exhaust system fasteners ➄ I I
Spark plug ➄ R
Supercharger slipping moment I
Supercharger drive gear, shaft and lock washer I➈
COOLING SYSTEM
Flushing (exhaust system) C➂
Hose and fasteners I I
Coolant ➆
Coolant expansion tank cap/cooling system pressure test ➃
FUEL SYSTEM
Throttle cable I
Fuel injection system sensors I I
Throttle body. Fault code reading ➄ ➀ I
Fuel vent line pressure relief valve I
Fuel lines, connections and fuel system pressurization ➄ I I
Throttle body, sensors, fuel lines, fuel rail and fittings ➄ I I
Air intake silencer fit/tightness I I
Fuel tank straps I I
ELECTRICAL SYSTEM
Electrical connections and fastening
I I
(ignition system, starting system, fuel injectors etc.)
Check fault codes I I
MPEM and EMS ECU connectors I➀
MPEM mounting brackets/fasteners I
Digitally Encoded Security System and safety lanyard/post I I
Monitoring beeper I I
Battery and fasteners I I
STEERING SYSTEM
Steering cable I I
O.P.A.S. SYSTEM
O.P.A.S. system including filter I I➇ I
SMR2003-003_02_02A.FM 02-02-3
3 MONTHS
6 MONTHS
HOURS OR
HOURS OR
OR 1 YEAR
EVERY 100
EVERY 25
EVERY 50
FIRST 10
C: Clean
HOURS
HOURS
L: Lubricate
R: Replace
PROPULSION SYSTEM
Drive shaft protection boot I➁
Grease splines in jet pump L
Shifter system/cable I I
Impeller shaft seal, sleeve and O-ring ➅
Impeller and impeller/wear ring clearance I➁
Water intake grate I➁
Ride plate including coolant leak I I
Drive shaft/hull sealing system I I
HULL/BODY
Bailer pick-ups, check for obstructions I I
Hull I I
Ski/wake board post and fasteners I I
➀ In salt water use.

➁ These items have to be initially checked after 25 hours. Thereafter, servicing to be made as specified in
this chart.
➃ Perform every 200 hours or 2 years.
➄ Emission-related component.
➅ Replace after the vehicle completed 100 hours of use or 2 years.
➆ Replace for storage period or after 100 hours of use whichever comes first.
➇ Every 25 hours when riding in weed areas.
➈ Every 200 hours of use, not every 2 years.
02-02-4 SMR2003-003_02_02A.FM
Subsection 03 (FLUSHING AND LUBRICATION)
FLUSHING AND LUBRICATION 0

GENERAL
Flushing the cooling system with fresh water is
essential to neutralize corroding effects of salt or
other chemical products present in water. It will
help to clean up sand, salt, shells or other particles
in water jackets (engine, exhaust manifold, tuned
pipe) and/or hoses.
Cooling system flushing and engine internal lubri-
cation should be performed when the watercraft
is not expected to be used further the same day
or when the watercraft is stored for any extended
time.
CAUTION: Failure to flush cooling system, when 1
F06E01A
necessary, will severely damage engine and/or
exhaust system. Never flush a hot engine. Make 1. Install flushing adaptor
sure engine operates during entire procedure.
Connect a garden hose to the flushing adaptor.
PROCEDURE NOTE: A quick connect adapter can be used to
ease garden hose installation.
 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 lubri-
F00E05A 1 2
cant.
1. Quick connect adapter
 WARNING 2. Flushing adaptor (P/N 295 500 473)
Always remove safety lanyard cap from post to

prevent accidental engine starting before
cleaning the jet pump area. Engine must not be
running for this operation.
Install flushing adapter (P/N 295 500 473) to the

water outlet located at the rear of the watercraft.
F07E01B 1 2
1. Garden hose installed
2. Quick connector adaptor
SMR2003-003_02_03A.FM 02-03-1
All Models except 4-TEC Models

Start the engine then immediately open the water
tap.
 WARNING
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. F12F01A 1
Spray BOMBARDIER LUBE lubricant through air 1. Partially pull tube out of air box to inject BOMBARDIER LUBE
lubricant or equivalent. Push tube in when finished
intake silencer keeping engine at fast idle for ap-
proximately one minute. All Models except 4-TEC Models
All Models except 947 DI and 4-TEC Models Close the water tap then stop the engine.
CAUTION: Always close the water tap before
1 2 3 stopping the engine.
Disconnect the garden hose.
CAUTION: Remove quick connect adapter after
flushing operation (if used).
Wipe up any residual water from the engine.
Remove spark plug cables and connect them on
the grounding device.
F01F25A  WARNING
717 AND 787 RFI ENGINES
Always use spark plug cable grounding de-
1. Air intake silencer vice when removing spark plugs.
2. Pull plug
3. Spray BOMBARDIER LUBE here
947 DI Models
Spray, through hole of air intake silencer.
NOTE: An increase of engine RPM may be noticed
while spraying the lubricant in the air intake silencer.
F01H7CA 1
GTI AND GTI LE MODELS
1. Grounding device
02-03-2 SMR2003-003_02_03A.FM
All Models except 4-TEC

Apply anti-seize lubricant on spark plug threads
then reinstall them.
Reinstall plug on air intake silencer cover (if so
equipped, on 717 and 787 RFI engines).
NOTE: Engine fogging should be done with
BOMBARDIER LUBE lubricant whenever the water-
craft is to be stored for a few days or a long period.
CAUTION: Never leave rags or tools in the en-
F01H7DA 1 gine compartment or in the bilge.
787 RFI AND 947 DI MODELS
1. Grounding device 4-TEC Engines
Remove both spark plugs and spray BOMBARDIER Closed Loop Cooling System
LUBE lubricant into each cylinder. 4-TEC engines are equipped with a closed loop
All Carburetor-Equipped Models cooling system which does not need to be flushed
even after salt water use.
Connect safety lanyard cap to the post.
Open Loop Cooling System
Fully depress the throttle lever then press the
start/stop button to crank the engine a few turns Flushing the exhaust cooling system with fresh wa-
to distribute the oil onto cylinder wall. ter is essential to neutralize corroding effects of salt
or other chemical products present in water. It will
787 RFI Models help to remove sand, salt, shells or other particles in
Fully depress throttle lever and connect the safety water jackets and/or hoses.
lanyard to the switch. Flushing should be performed when the watercraft is
Press the start/stop button to crank the engine a not expected to be used further the same day or
few turns and distribute the lubricant onto cylinder when the watercraft is stored for any extended time.
walls.
NOTE: Proceeding in this order, no fuel will be in-  WARNING
jected into the engine. Perform this operation in a well ventilated area.
Do not touch any electrical part or jet pump
947 DI Models area when engine is running.
NOTE: Proceeding in this order, no fuel will be in-
jected and no ignition will occur in the engine. Proceed as follows:
While engine is stopped, fully depress throttle le- Clean jet pump by spraying water in its inlet and
ver and HOLD for cranking. outlet and then apply a coating of BOMBARDIER
LUBE lubricant or equivalent.
Wait 2 seconds then press the start/stop button
to crank the engine a few turns and distribute the
lubricant onto cylinder walls.  WARNING
Always remove safety lanyard cap from post to
NOTE: A 1 second beep every second indicates the prevent unexpected engine starting before
drowned mode is active. cleaning the jet pump area. Engine must not be
SMR2003-003_02_03A.FM 02-03-3
Models without a Flushing Connector in Models with a Flushing Connector in Engine

Engine Compartment Compartment
Connect a garden hose to connector located at the rear This flushing connector allows flushing while wa-
of watercraft on jet pump support. Do not open water tercraft is on a lift or if you prefer to flush from this
tap yet. location. Either flushing connector can be used to
 WARNING flush the exhaust cooling system. The one at the
jet pump support (see above) or the one in the en-
When operating the engine while the water- gine compartment (see below).
craft is out of the water, the heat exchanger in Remove seat to gain access.
the ride plate may become very hot. Avoid any
contact with ride plate as burns may occur.
NOTE: An optional quick connect adapter can be

used. No hose pincher is required to flush engine.
F00E05A 1 2
1. Quick connect adapter
2. Flushing adaptor (P/N 295 500 473)
F18E1TA
1. Flushing connector
F07E01C 3 2 1 2. Dust cap
TYPICAL Remove dust cap from flushing connector and at-

1. Hose adapter tach coupler hose (supplied in rear storage com-
2. Quick connect adapter (optional, not mandatory)
3. Garden hose partment). Make sure coupler hose is properly
locked to flushing connector.
02-03-4 SMR2003-003_02_03A.FM
Install a hose pincher (supplied inside tool kit in CAUTION: Never flush a hot engine. Always
rear storage compartment) on water outlet hose. start the engine before opening the water tap.
NOTE: This prevents water from directly exiting Open water tap immediately after engine is
exhaust cooling system. started to prevent overheating.
Run the engine about 20 seconds at a fast idle
2 1 between 4000 - 5000 RPM.
CAUTION: Never run engine without supplying
water to the exhaust cooling system when wa-
tercraft is out of water.
Ensure water flows out of jet pump while flushing.
CAUTION: Never run engine longer than 5 min-
utes. Drive line seal has no cooling when water-
craft is out of water.
Close the water tap, then stop the engine.
stopping the engine.
Disconnect the garden hose.
F18E1UA
CAUTION: Remove quick connect adapter after
1. Coupler hose
2. Hose pincher flushing operation (if used).
Attach other end of coupler hose to a garden hose. NOTE: Engine valves fogging should be done
Do not open water tap yet. whenever the watercraft is to be stored for a long
period. Refer to STORAGE section.
All 4-TEC Models
Flushing
To flush the exhaust cooling system, start the en-
gine then immediately open the water tap.
 WARNING
Certain components in the engine compartment
may be very hot. Direct contact may result in skin
burn. Do not touch any electrical part or jet pump
SMR2003-003_02_03A.FM 02-03-5
Subsection 04 (WATER-FLOODED ENGINE)
WATER-FLOODED ENGINE 0
GENERAL
If engine is water-flooded, it must be serviced
within a few hours after the event. Otherwise en-
gine will have to be overhauled.
CAUTION: A water-flooded engine must be prop-
erly lubricated, operated then lubricated again,
otherwise parts will be seriously damaged.
PROCEDURE
F01H7DA 1
2-Stroke Models
787 RFI AND 947 DI MODELS
Check fuel and oil reservoirs for water contamina- 1. Grounding device
tion. If necessary, siphon and refill with fresh fluids.
Remove spark plugs and dry them with a clean
Turn fuel valve to OFF position (carburetor- cloth. A contact cleaner spray can be used. It may
equipped models) then drain fuel filter bowl. Re- be preferable to replace spark plugs. Do NOT in-
fer to FUEL CIRCUIT. stall spark plugs on engine yet.
Drain bilge if water is present. Cover spark plug holes with a rag.
the grounding device.  WARNING
Be careful when cranking engine in the fol-
 WARNING lowing procedure, water will spray out from
Never crank engine with spark plugs removed spark plug holes.
unless spark plug cables are connected to the
grounding device. Carburetor-Equipped Models
Fully depress the throttle lever then crank the en-
gine to drain crankcase.
NOTE: Ensure choke lever is completely pushed in.
787 RFI Models
NOTE: Proceeding in the following order, no fuel
will be injected into the engine.
Remove safety lanyard from its post.
Depress and hold the throttle lever at full throttle
position. Wait 2 seconds then, reinstall the safety
F01H7CA 1 lanyard cap.
GTI AND GTI LE MODELS
Press the start/stop button to crank the engine to
1. Grounding device allow water to escape from spark plug openings.
SMR2003-004_02_04A.FM 02-04-1
947 DI Models 787 RFI Engines

Remove the air pressure hose from the compres- Remove the filler plug of the counterbalance shaft
sor. on the engine crankcase.
CAUTION: Failure to remove the air pressure
hose from the compressor will result in the
bending of the compressor connecting rod,
when cranking the engine.
1
F07D06A
1
787 RFI ENGINES
1. Remove filler plug
Insert a wire through oil filler hole to check oil con-

F18D1AA dition. A whitish oil indicates water contamination
1. Disconnect this hose and must be replaced.
Remove the flywheel guard and turn the PTO fly- In order to replace the oil, remove the drain plug
wheel several times, by hand. of the counterbalance shaft located on the PTO
side of the lower crankcase.
NOTE: Proceeding in the following order, no fuel
will be injected into the engine and ignition will be
cut.
While engine is stopped, fully depress throttle le-
ver and HOLD for cranking.
Crank engine several times to drain crankcase.
NOTE: A 1 second beep every second indicates
the drowned mode is active.
If water does not completely go out, it may be nec-
essary to remove the air intake silencer then to
lean the vehicle so that water can flow out from
throttle bodies. F07D07A 1
All Models except 4-TEC 787 RFI ENGINES
1. Drain plug
Spray BOMBARDIER LUBE lubricant (P/N 293 600
016) into spark plug holes. Drain completely the crankcase oil of the counter-
Crank engine again. balance shaft. Reinstall drain plug with Loctite 515.
Reinstall spark plugs and spark plug cables. Add 30 mL (1 oz) of SAE 30 motor oil.
Reinstall filler plug.
02-04-2 SMR2003-004_02_04A.FM
Carburetor-Equipped Models 947 DI Models

Turn fuel valve to ON position. Spray, through hole of air intake silencer.
Start engine. It may be necessary to use the NOTE: An increase of engine RPM may be noticed
choke. If engine does not start, repeat previous while spraying the lubricant in the air intake silencer.
steps as necessary.
787 RFI and 947 DI Models
Start engine according to normal starting procedure.
All Models except 4-TEC
CAUTION: To avoid starting motor overheating,
the cranking period should not exceed 5 - 10 sec-
onds and a rest period of 30 seconds should be
observed between cranking cycles.
NOTE: If engine does not start after several at-
tempts, check ignition system for spark occur-
rence. Refer to IGNITION SYSTEM for 717 and 787
RFI engines and refer to ENGINE MANAGEMENT
for 947 DI engines. F12F01A 1
Check crankshaft if needed, it may be misaligned 1. Partially pull tube out of air box to inject BOMBARDIER LUBE
or deflected. Refer to BOTTOM END.
Run engine until it reaches its normal operating
After engine has started, spray BOMBARDIER
temperature.
LUBE lubricant for one minute through air intake
silencer while engine is running. CAUTION: Engine must be cooled using the flush
kit.
All Models except 947 DI and 4-TEC Models
4-TEC Models
1 2 3
Check fuel reservoir for water contamination. If
necessary, siphon and refill with fresh fuel.
To limit damages to the engine, perform the fol-
lowing procedure as soon as possible.
Drain bilge if water is present.
If it was submerged in salt water, spray bilge and
all components with fresh water using a garden
hose to stop the salt corroding effect.
F01F25A CAUTION: Never try to crank or start the
engine. Water trapped in the intake manifold
1. Air intake silencer
would enter the combustion chamber through
2. Pull plug the intake valves and may cause damage to the
3. Spray BOMBARDIER LUBE here engine.
SMR2003-004_02_04A.FM 02-04-3
Whenever the engine is stopped, all the valves Oil Change Procedure
close thus preventing water from being ingested (water-contaminated oil)
in the engine.
1. Using the oil VAC (P/N529 035 880), siphon oil
Supercharged 4-TEC Engines from reservoir through dipstick hole.
Inlet duct should be disconnected from super- CAUTION: Never crank or start engine when si-
charger inlet tube to validate presence of water. phon tube is in dipstick hole. Never start engine
when there is no oil in engine.
2. Remove the oil vac tool from the dipstick hole.
3. While in drowned engine mode, crank the en-
gine for 5 seconds.
4. Remove the oil filter cap and the oil filter.
5. Again, siphon oil from the reservoir.
6. Put a rag under the scavenge oil pump cover.
7. Remove the scavenge oil pump cover drain plug
and install a fitting (P/N 293 710 037).
F18D2OA 3 2 1
1. Inlet duct
2. Inlet hose
3. Outlet hose
If water is suspected to be in the supercharger,

remove its outlet hose and siphon water out. En-
sure that siphon tube is inserted to the lowest
point in the supercharger.
If necessary, remove supercharger housing.
All 4-TEC Engines F18D19A 1
If water is suspected to be in the intake and the 1. Scavenge oil pump cover drain plug
exhaust system, it must be drained as follows:
Remove the intake manifold and drain it. Then
suck out the water from the intake valve ports.
Refer to subsection INTAKE SYSTEM.
Remove the water from oil/air separator breather
hose.
Remove the exhaust pipe and drain it. Then either
remove the mufflers to drain them or siphon the
water out of them. Refer to subsection EXHAUST
SYSTEM.
If water gets in the oil (oil will be milky), change F18D2PA
the engine oil and filter as follows.

8. Connect the oil vac tool Bombardier (P/N 529
035 880) to the fitting.
9. The front of the engine must be tilted down ap-
proximately 15 degrees to facilitate the removal
of the oil. Raise the rear of the boat accordingly.
Siphon the oil from the fitting.
02-04-4 SMR2003-004_02_04A.FM
10. Level the engine.

1
11. Remove the oil vac tool and the fitting. Apply
Loctite 243 and reinstall the drain plug.
NOTE: If spillage occurs, clean immediately with
the Pulley flange cleaner (P/N 413 711 809) to pre-
vent oil stains.
12. Install a new oil filter and reinstall the oil filter
cap.
13. Fill up the reservoir with fresh oil.
14. Boil out the remaining water as follows:
a. Recommended procedure: BOIL OUT PRO-
CEDURE IN A TEST TANK OR TIED TO A
F18E1QA
TRAILER WITH WATERCRAFT IN WATER.
b. Optional procedure: BOIL OUT PROCE- 1. Oil cooler coolant inlet hose
DURE CONNECTED TO A FLUSH KIT. 3. Continue to run the engine at 3500 RPM for 15
Refer to instructions below. more minutes (20 minutes total run time).
4. Shut the engine off.
Boil Out Procedure
5. Remove the hose pincher on the coolant line
Procedure in a Test Tank or Tied to a Trailer with going to the oil cooler.
Watercraft in Water CAUTION: Hose pincher must be removed pri-
1. Run the engine for 5 minutes at 3500 RPM. or to operating the watercraft. Failure to do this
will result in damage to the engine.
 WARNING 6. Change the oil and filter again.
Make sure to safely secure the watercraft. 7. Procedure is now completed.
2. With the engine still running at 3500 RPM, in- Procedure Connected to a Flush Kit
stall a hose pincher to the coolant line going to 1. On drive shaft, remove the C-Clip then move
the oil cooler. forward the ring seal carrier. Refer to DRIVE
SYSTEM section.
 WARNING CAUTION: Make sure that the ring seal carrier
Certain components in the engine compart- is not in contact with the PTO seal assembly,
ment may be very hot. Direct contact may re- neither with the carbon ring.
sult in skin burn. Do not touch any electrical
parts or jet pump area when engine is run- 2. Connect a flush kit to the coolant line.
ning. CAUTION: Never run engine without supplying
3. Run the engine for 5 minutes at 3000 RPM.
SMR2003-004_02_04A.FM 02-04-5
4. With the engine still running at 3000 RPM, in- Water in Supercharger
stall a hose pincher to the coolant line going to
the oil cooler. Supercharged 4-TEC Engines
If there was water in Tthe oil and presence of wa-
 WARNING ter is suspected in the shaft and bearing area of
Certain components in the engine compart- the supercharger, it is recommended to take the
ment may be very hot. Direct contact may re- supercharger apart, dry all the components includ-
sult in skin burn. Do not touch any electrical ing the slip clutch and replace both ball bearings.
parts or jet pump area when engine is run- Refer to INTAKE SYSTEM.
ning.
Finalizing the Procedure
1 All 4-TEC Engines
The watercraft should be ridden as soon as possi-
ble to dry it out.
F18E1QA
1. Oil cooler coolant inlet hose
5. Continue to run the engine at 3000 RPM for 15

more minutes (20 minutes total run time).
6. Shut off the engine
going to the oil cooler
CAUTION: Hose pincher must be removed pri-
or to operating the watercraft. Failure to do this
will result in damage to the engine.
8. Change the oil and filter again.
9. Move rearward the Ring Seal Carrier and rein-
stall the C-Clip. Refer to DRIVE SYSTEM sec-
tion.
02-04-6 SMR2003-004_02_04A.FM
Subsection 05 (STORAGE)
STORAGE 0
ENGINE DRAINING
All Carburetor-Equipped Engines
Check engine drain hose (lowest hose of engine).
Make sure there is no sand or other particles in it
and that it is not obstructed so that water can exit
the engine. Clean hose and fitting as necessary.
CAUTION: Water in engine drain hose must be
free to flow out, otherwise water could be trapped
in engine. Should water freeze in engine, severe
damage will occur. Check engine drain hose for
obstructions.
F17E0AA
TYPICAL
1. Press tabs here and disconnect hose
Water should flow out of the fitting (magneto cooling

circuit) and hose (crankcase heat exchanger).
Push and hold hose against bilge so that draining
F07E0MA 1
can take place.
TYPICAL 2
1. Engine drain hose
RFI Models
Disconnect the water supply hose used to cool the
magneto. It features a quick connect fitting. Press
both tabs and pull fitting in order to disconnect
hose.
This hose is located at the bottom of the magneto
cover beside the engine support.
F17E0BA 1
1. Fitting
2. Hose
SMR2003-005_02_05A.FM 02-05-1
CAUTION: Water in heat exchanger system must

be free to flow out. Should water freeze in engine,
severe damage will occur.
Reconnect hose when done.
DI Models
Disconnect the quick connect fitting. Press both
tabs and pull fitting.
F18E02A
GTX DI MODELS — DISCONNECT THIS HOSE
F07E0HA
RX DI MODELS — DISCONNECT THIS HOSE
F08E0FA
XP DI MODELS — DISCONNECT THIS HOSE

1. Disconnect engine drain hose (crankcase cooling outlet)
2. Air compressor drain line
02-05-2 SMR2003-005_02_05A.FM
Lower hose as necessary so that draining can take SEAL CARRIER

place.
XP DI Models
Reconnect fitting when done.
Lubricate seal carrier of drive shaft support with
Also ensure air compressor drain line is not ob- synthetic grease. Stop lubricating when grease is
structed. Clean as necessary. just coming out of seal.
All Models except 4-TEC Models

PROPULSION SYSTEM
Jet Pump
Lubricant in impeller shaft reservoir should be
drained. Reservoir should be cleaned and refilled
with SEA-DOO synthetic 75W90 GL5 polyolester
oil. Refer to JET PUMP for proper procedure.
CAUTION: Use only SEA-DOO jet pump oil or
equivalent synthetic gear oil, otherwise compo-
nent service life could be reduced. Do not mix
oil brands or types.
PTO Flywheel
All 2-Stroke Models except XP DI
Remove PTO flywheel guard.
Lubricate PTO flywheel at grease fitting with syn-
thetic grease (P/N 293 550 010).
CAUTION: Do not lubricate excessively. Imme- 1
diately stop when a slight movement is noticed
on rubber boot.
F08E0BA
1. Grease seal carrier
FUEL SYSTEM
All Models
Verify fuel system. Check fuel hoses and carbure-
tor(s), if so equipped, for leaks. Replace damaged
hoses or clamps if necessary.
Sea-Doo Fuel Stabilizer (P/N 413 408 600) or equiv-
alent should be added in fuel tank to prevent fuel
deterioration and, if so equipped, carburetor(s)
F01I0BA 1 gumming. Follow manufacturer’s instructions for
proper use.
1. Grease PTO flywheel
On RFI and DI models, fill up fuel tank completely.
CAUTION: Never leave any clothing, tool or Ensure there is no water inside fuel tank.
other objects near PTO flywheel and drive shaft. CAUTION: Should any water be trapped inside
fuel tank, severe internal damage will occur to
the fuel injection system (if so equipped).
SMR2003-005_02_05A.FM 02-05-3
CAUTION: Fuel stabilizer should be added prior ENGINE LUBRICATION

to engine lubrication to ensure fuel system com-
ponents protection against varnish deposits. 4-TEC Engines
Fogging of the engine is recommended at the end
 WARNING of the season and before any extended storage
Fuel is inflammable and explosive under cer- period to provide additional corrosion protection.
tain conditions. Always work in a well ventilat- This will lubricate the engine intake valves, the cyl-
ed area. Do not smoke or allow open flames or inders and the exhaust valves.
sparks in the vicinity. Fuel tank may be pres- To fog the engine intake valves, proceed as fol-
surized, slowly turn cap when opening. Never lows:
use an open flame to check fuel level. When
fueling, keep watercraft level. Do not overfill or – Remove the two bolts that hold the fuel rail on.
top off the fuel tank and leave watercraft in the – Remove the rail along with the three fuel injec-
sun. As temperature increases, fuel expands tors.
and might overflow. Always wipe off any fuel – Spray BOMBARDIER LUBE lubricant into the
spillage from the watercraft. Periodically in- intake ports.
spect fuel system. Always turn the fuel tank
valve (if so equipped) to OFF position when – Crank engine at wide open throttle to put it in
storing the watercraft. the drown engine mode. This will prevent fuel
injection and ignition.
– Carefully inspect O-rings condition before rein-
Carburetor-Equipped Models stalling fuel injectors. Replace O-rings with new
Always turn the fuel valve to OFF position when ones if damaged. Lubricate O-rings with injec-
storing the watercraft. tion oil prior to installing.
– Reinstall the injectors.
ENGINE OIL CHANGE AND FILTER – Apply Loctite 243 and torque the two bolts to
4-TEC Engines 10 N•m (89 lbf•in) that hold the fuel rail on.
Change engine oil and filter. Refer to LUBRICA- – Make sure there is no leak at injectors when
TION in ENGINE section. cranking the engine in the upcoming steps.
All Models  WARNING

If a leak is present, immediately stop the en-
COOLING SYSTEM FLUSHING gine. Do not start engine until the leak is re-
AND ENGINE INTERNAL paired.
LUBRICATION
Cooling system (exhaust cooling system on 4-TEC  WARNING
models) has to be flushed with fresh water to At preseason preparation, ensure to perform a
prevent salt, sand or dirt accumulation which will fuel pressure test and ensure there is no leak.
clog water passages. Also run engine and check for leaks. Refer to
Engine must be lubricated to prevent corrosion on ENGINE MANAGEMENT section.
internal parts.
– Pull engine cover upward to remove it.
For proper procedure, refer to FLUSHING AND
– Disconnect ignition coil connectors.
LUBRICATION.
 WARNING
When disconnecting coil from spark plug, al-
ways disconnect coil from main harness first.
Never check for engine ignition spark from an
open coil and/or spark plug in the engine
compartment as spark may cause fuel vapor
to ignite.
02-05-4 SMR2003-005_02_05A.FM
IMPORTANT: Never cut the locking ties of coil WATERCRAFT CLEANING

connectors. This would allow mixing the wires be-
tween cylinders. Clean the bilge with hot water and mild detergent
or with bilge cleaner. Rinse thoroughly. Lift front
– Remove ignition coils.
end of watercraft to completely drain bilge. If any
CAUTION: Ensure there is no dirt in coil holes repairs are needed to body or to the hull, touch up
prior to removing the spark plugs. Otherwise, paint and Gelcote® repair kit are available. Replace
dirt would fall into cylinders and will damage damaged labels/decals.
the internal components.
Wash the body with soap and water solution (only
– Remove the spark plugs. use mild detergent). Rinse thoroughly with fresh
– Apply BOMBARDIER LUBE lubricant into the water. Remove marine organisms from the hull.
cylinders. Apply a nonabrasive wax.
– Reinstall spark plugs and ignition coils. CAUTION: Never clean fiberglass and plastic
parts with strong detergent, degreasing agent,
– Reconnect ignition coil connectors.
paint thinner, acetone, etc.
NOTE: Prior to inserting the ignition coil in its loca-
If the watercraft is to be stored outside, cover it with
tion, apply some Molykote 111 grease (P/N 413
an opaque tarpaulin to prevent sun rays and grime
707 000) around the seal area that touches the
from affecting the plastic components, watercraft
spark plug hole. After installation, ensure the seal
finish as well as preventing dust accumulation.
seats properly with the engine top surface.
CAUTION: The watercraft must never be Ieft in
– To reinstall engine cover, push it downward until
water for storage. Never leave the watercraft
it snaps.
stored in direct sunlight.
– Crank engine several times while keeping throt-
tle fully depressed to distribute lubricant on ex- ADDITIONAL RECOMMENDED
haust valves.
PROTECTION
1
All 2-Stroke Models
In cool regions (where freezing point may be en-
countered), cooling system should be filled with
water and antifreeze solution (40% water, 60%
antifreeze).
CAUTION: Remaining water in cooling system
will freeze. If antifreezing is not performed ade-
quately engine/exhaust system may freeze and
cause severe engine damage. Always use ethyl-
ene glycol antifreeze containing corrosion inhib-
itors specifically recommended for aluminum
engines.
NOTE: When available, it is recommended to use
F18M01A
biodegradable antifreeze compatible with internal
1. Engine intake ports combustion aluminum engines. This will contrib-
ute to protect the environment.
All Models NOTE: The engine will not have to run during this
BATTERY operation.
For battery removal, cleaning and storage, refer to All 2-Stroke Models except DI
CHARGING SYSTEM. NOTE: This procedure requires approximately 2.5 L
(2.6 U.S. qt) of antifreeze.
SMR2003-005_02_05A.FM 02-05-5
Hose Pinchers Installation NOTE: On RFI models, make sure the hose is
properly connected to the magneto cover.
Some hoses have to be plugged to prevent drain-
ing, before filling cooling system jackets with the
antifreeze.
All 2-Stroke Models except DI
F17E05A
GTI AND GTI LE MODELS — 717 ENGINES

1
F17E0AB
1. Engine drain hose
1. Fitting properly connected
Install hose pincher on injection hose going to

tuned pipe.
F17E03A 1
GTI AND GTI LE MODELS — 717 ENGINES
1. Hose pincher on injection hose going to tuned pipe
F15E01A 1
RFI MODELS — 787 ENGINES
1. Hose pincher installed on engine drain hose
02-05-6 SMR2003-005_02_05A.FM

Insert a funnel into hose and pour antifreeze mixed
with water (40% water, 60% antifreeze) in engine
until the colored solution appears at the cooling sys-
tem bleed outlet.
F17E01A 1
1. Engine water outlet hose
Hose Disconnection F07E0LA
Some hoses have to be disconnected. Disconnect

hoses at the following location. 787 RFI Engines
Disconnect hose just above T-fitting as shown.
F06E0EB 1
1. Disconnect engine water inlet hose
717 Engines F15E02A 1 2

Temporarily install a short piece of hose to engine 1. Hose connecting to cylinder head inlet fitting
2. Disconnect hose above T-fitting
water inlet at cylinder head.
787 RFI Engines
Install a hose pincher just below T-fitting.
SMR2003-005_02_05A.FM 02-05-7
F15E03A 1
1. Hose pincher below T-fitting
Pour approximately 300 mL (10 oz) of antifreeze in

1
the water regulator valve supply hose to allow an-
tifreeze flowing through the valve and into muffler
to protect them.
Reconnect hose to T-fitting and remove hose
pincher (if applicable).
Remove temporary hose on 717 engines and re-
connect engine water outlet hose.
Remove hose pinchers.
F18E05A
All DI Models except XP DI GTX DI MODELS

Hose Pinchers Installation 1. Water outlet hose
Some hoses have to be plugged to prevent drain- 1

antifreeze.
Install hose pinchers at the following location:
F07E0NB
LRV DI MODELS
1. Water outlet hose
F12E02A 1
RX DI MODELS
02-05-8 SMR2003-005_02_05A.FM
F12E0AA 1 F07E0JA 1
RX DI AND LRV DI MODELS RX DI, GTX DI AND LRV DI MODELS
1. Crankcase cooling cover outlet hose 1. Engine cylinder drain hose
Hose Disconnection
Disconnect water INLET hose at engine between
T-fitting and cylinder head fitting.
1 F12E0BA 1
RX DI AND LRV DI MODELS
1. Disconnect this side of the T-fitting
F18E0FA
GTX DI MODELS
1. Crankcase cooling cover outlet hose
SMR2003-005_02_05A.FM 02-05-9
At this point, install a hose pincher on bleed outlet

hose.
1
F18E0BA
GTX DI MODELS F07E0OA

RX DI MODELS
Temporarily install a short piece of hose to replace 1. Bleed outlet hose
the one removed.
Antifreeze
Insert a funnel into the temporary hose and pour
antifreeze mix in engine until the colored solution
appears at cooling system bleed outlet.
F18E0EA 1
GTX DI AND LRV DI MODELS
1. Bleed outlet hose
F07E0LA
02-05-10 SMR2003-005_02_05A.FM
Continue to pour until antifreeze flows in air com- All 2-Stroke Models except XP DI
pressor water outlet hose. Most of the antifreeze will drain out when removing
the hose pinchers. Use a container to recover it. DIS-
POSE ANTIFREEZE AS PER YOUR LOCAL LAWS
AND REGULATIONS.
NOTE: Although antifreeze will mainly drain out,
the antifreeze has mixed with the water that was
possibly trapped in the water jackets and thus pre-
venting freezing problems.
At preseason preparation, drain the remaining an-
tifreeze from cooling system prior to using the wa-
tercraft. Ensure no hose pincher was forgotten at
storage.
XP DI Models
F07E0NC 1 NOTE: This procedure requires approximately 2.8 L
(3 U.S. qt) of antifreeze.
RX DI AND LRV DI MODELS
1. Air compressor water outlet hose Hose Pinchers Installation
Some hoses have to be plugged to prevent drain-
antifreeze.
Install hose pinchers at the following location:
F18E1VA 1
GTX DI MODELS
1. Air compressor water outlet hose
Remove pinchers in this order to allow proper flow

of antifreeze.
1. Bleed outlet hose. 1
2. Crankcase cooling cover outlet hose.
3. Engine cylinder drain hose.
4. Water outlet hose. 2
Pour approximately 200 mL (7 oz) of antifreeze in
the water regulator valve supply hose to allow an-
tifreeze flowing through the valve and into muffler F08E0GA
to protect them.
XP DI MODELS
Remove temporary hose and reconnect engine 1. Water inlet hose
water outlet hose. 2. Engine cylinder drain hose (coming from underneath engine)
SMR2003-005_02_05A.FM 02-05-11
Antifreeze
Insert a funnel into the temporary hose.
Ensure to hold the funnel approximately 1 m (3 ft)
above the deck when pouring the antifreeze to cre-
ate enough pressure so that it flows properly.
F08E0PA
XP DI MODELS
1. Water outlet hose underneath tuned pipe
Hose Disconnection
F08E0TA
Disconnect the bottom hose at the water regulator
valve on muffler. A. 1 m (3 ft) to ease antifreeze flow
Pour antifreeze mix in engine until the colored so-

lution appears at cooling system bleed outlet.
At this point, install a hose pincher on bleed outlet
hose.
F08E0SA 1
XP DI MODELS
1. Disconnect the bottom hose from water regulator valve
Temporarily install a hose of approximately 1 m

(3 ft) with an internal diameter of 12.7 mm (1/2 in)
over the previously disconnected hose.
02-05-12 SMR2003-005_02_05A.FM
F08E0JA
1. Engine drain hose (crankcase cooling outlet)
Continue to pour until antifreeze flows in air com-

F08E0MA
pressor water outlet hose.
XP DI MODELS
1. Bleed outlet hose 1
Continue to pour until antifreeze appears at the en-

gine drain hose (crankcase cooling outlet). Then,
install a hose pincher on this hose.
F08E0EA
XP DI MODELS
SMR2003-005_02_05A.FM 02-05-13
The pouring operation is over. All Models

Remove pinchers in this order to allow proper flow ANTICORROSION TREATMENT
of antifreeze.
NOTE: Most of the antifreeze will drain out when re- Wipe off any residual water in the engine compart-
moving the hose pinchers. Use a container to recover ment.
it. DISPOSE ANTIFREEZE AS PER YOUR LOCAL Spray BOMBARDIER LUBE lubricant over all me-
LAWS AND REGULATIONS. tallic components in engine compartment.
1. Bleed outlet hose. Lubricate the throttle cable with BOMBARDIER
2. Engine drain hose (crankcase cooling cover out- LUBE lubricant.
let). The seat should be partially left opened during
3. Engine cylinder drain hose. storage (the engine cover for the XP DI models).
This will avoid engine compartment condensation
4. Water outlet hose. and possible corrosion.
5. Water inlet hose.
Install a temporary hose on the open fitting of the CHECKLIST
water regulator valve.
Pour approximately 200 mL (7 oz) of antifreeze in OPERATION ✔
the temporary hose to allow antifreeze flowing Check engine drain hose(s).
through the water regulator valve and into muffler
to protect them. Drain and clean impeller shaft reservoir
(except 4-TEC engines).
Remove temporary hoses and reinstall the factory
hose to water regulator valve. Lubricate PTO flywheel or seal carrier.
NOTE: Although antifreeze will mainly drain out, Verify fuel system.
possibly trapped in the water jackets and thus pre- Add Sea-Doo fuel stabilizer.
venting freezing problems. Flush the cooling system
At preseason preparation, drain the remaining an- (except 4-TEC engines).
tifreeze from cooling system prior to using the wa-
Change engine oil and filter (4-TEC engines).
tercraft. Ensure no hose pincher was forgotten at
storage. Flush the exhaust cooling system by running
the engine (4-TEC engines).
4-TEC Engines
Refer to the COOLING SYSTEM section. Lubricate the engine.
Antifreeze should be replaced for the storage pe- Remove, clean and store the battery.
riod to prevent antifreeze deterioration. Clean the bilge.
Make sure to perform an antifreeze density test.
Wash the body.
CAUTION: Improper antifreeze mixture might
allow freezing of the liquid in the cooling system Add antifreeze solution to the cooling system
if vehicle is stored in area where freezing point (in cool regions)
is reached. This would seriously damage the en- (except 4-TEC engines).
gine. Failure to replace the antifreeze for storage Replace antifreeze. Check solution
may allow its degradation that could result in concentration in the cooling system
poor cooling when engine will be used. (in cool regions) (4-TEC engines).
Spray BOMBARDIER LUBE over all metallic
components in engine compartment and in
throttle cable.
Spray BOMBARDIER LUBE in oil injection
pump cable (except 4-TEC engines).
02-05-14 SMR2003-005_02_05A.FM
Section 03 TROUBLESHOOTING
Subsection 01 (TROUBLESHOOTING CHART)
TROUBLESHOOTING CHART 0
The following is provided to help in diagnosing the probable source of troubles. It is a guideline and should
not be assumed to have all causes for all problems.
NOTE: On RFI and DI models, always check for fault codes recorded in the MPEM first using the VCK
(vehicle communication kit (P/N 529 035 844). The MPEM programmer (P/N 529 035 878) can be used
on the RFI models. If a fault code is detected, service the fault code and recheck operating conditions.
Refer to Diagnostic Procedures in ENGINE MANAGEMENT section.
ENGINE WILL NOT START
OTHER OBSERVATION POSSIBLE CAUSE REMEDY
• DESS operation non functional • If 2 short beeps are not heard when
installing safety lanyard, refer to
ELECTRICAL SYSTEM and ENGINE
MANAGEMENT
• Wrong safety lanyard • Use one that has been programmed
for that watercraft
• Safety lanyard switch faulty or discon- • Replace
nected or harness damaged
• Burnt fuse on MPEM or in rear elec- • Check wiring then replace fuse
trical box: battery, starting system,
fuel pump (RFI models)
• Starting system fuse keeps on burn- • Check wiring, starting system solenoid
ing and MPEM
• Discharged or disconnected battery • Check/recharge
Engine does not turn over • Defective or disconnected start/stop • Check, refer to STARTING SYSTEM or
switch ENGINE MANAGEMENT
• Battery connections • Check/clean/tighten
• Water/fuel hydrolock • Check, refer to section MAINTENANCE
• Starter malfunction • Check, refer to section ELECTRICAL
SYSTEM
• Starter solenoid • Check, refer to section ELECTRICAL
SYSTEM
• Seized or obstructed engine • Check/repair, refer to section ENGINE
• Hydraulically locked air compressor • Check/repair as needed
(DI models)
• Seized jet pump • Check, refer to section PROPULSION
SYSTEM
• Faulty sensor (RFI and DI models) • Check faulty codes in MPEM memory,
or MPEM refer to section ENGINE MANAGEMENT
• Loose battery cable connections • Check/clean/tighten
• Discharged/weak battery • Check/charge/replace
• Restriction in jet pump • Check/clean pump
• Partial seizure in jet pump • Inspect, refer to section PROPULSION
SYSTEM
Engine turns slowly • Partial engine hydrolock • Check, refer to section MAINTENANCE
• Partial engine seizure • Check compression, refer to section
ENGINE
• Worn starter • Check, refer to section ELECTRICAL
SYSTEM
• Outside temperature too low • Battery capacity is not sufficient for
cold temperature
SMR2002-020_03_01A.FM 03-01-1
ENGINE WILL NOT START (cont’d)

• Faulty component in the fuel injection • Check for fault codes with the VCK
system (RFI and DI models) (vehicle communication kit). Refer to
DIAGNOSTIC PROCEDURES in ENGINE
MANAGEMENT
• Engine drowned mode is active • Release throttle lever
• Low battery voltage • Recharge or replace battery
• Low or no fuel pressure • Check fuel pump operation
(RFI and DI models) • Check fuel pump pressure output
• Check air/fuel rail
• Check fuel pump fuse
• Check wiring harness
• Fuel injectors not working • Check fuel injector operation. Replace as
(RFI and DI models) necessary
• Check output signal from MPEM
• Low or no air pressure (DI models) • Check air/fuel rail
• Check air compressor system
• Check RAVE valve system for leaks
• Direct injector not working • Check direct injector operation
(DI models) • Check output signal from MPEM
• No spark at the spark plug • Check spark plugs condition and replace
as necessary
• Check ignition system and repair
Engine turns over • Defective MPEM • Replace MPEM
• Defective crankshaft position sensor • Check operation of CPS and replace if
necessary
• Water-contaminated fuel • Check/siphon and refill
• Dirty fuel filter • Clean/replace
• Fouled or defective spark plug • Replace
• Water in engine • Check, refer to section MAINTENANCE
• Carburetion (carburetor models) • Check, refer to section FUEL SYSTEM
• Defective ignition circuit • Check, refer to section ELECTRICAL
SYSTEM
• Flooded engine • Check, refer to section FUEL SYSTEM
– Carburetor needle valve stuck open
(carburetor models)
• Excessive rotary valve clearance • Check, refer to section ENGINE
(if so equipped)
• Incorrect rotary valve timing • Check, refer to section ENGINE
(if so equipped)
• Internal engine damage • Check, refer to section ENGINE
• Defective encoder wheel • Check, refer to section ENGINE
MANAGEMENT
• Insufficient engine compression • Replace defective part(s)
• Incorrect rotary valve timing • Check, refer to section ENGINE
(if so equipped)
• Faulty rev limiter in MPEM • Replace MPEM
(carburetor models)
• Spark plug faulty, fouled or worn out • Check spark plug condition
No spark at spark plugs
• Ignition • Check, refer to section ELECTRICAL
SYSTEM
• Faulty MPEM • Replace MPEM
03-01-2 SMR2002-020_03_01A.FM
ENGINE HARD TO START

• Water in fuel reservoir or • Flush reservoir and refill with fresh gas
contaminated fuel
• Mechanical engine failure • Check cylinder compression
• Check for cylinder head leaks
• Check starting system
• Wrong throttle body mechanical • Refer to ENGINE MANAGEMENT
adjustment of cable
• Temperature too low for available • Battery capacity is not sufficient for
battery capacity cold temperature
• Low fuel pressure • Check fuel pump operation. Refer to
(RFI and DI models) ENGINE MANAGEMENT
• Check fuel pressure regulator. Refer to
ENGINE MANAGEMENT
• Low air pressure (DI models) • Check air/fuel rail. Refer to ENGINE
MANAGEMENT
• Check air compressor system. Refer to
ENGINE MANAGEMENT
• Check RAVE valve for leaks
ENGINE STARTS BUT RUNS ONLY AT IDLE SPEED

• DI models: The system is in limp • Refer to section ENGINE and check
home mode. the fault codes in the MPEM
• Broken or loose throttle cable • Change/readjust
ENGINE MISFIRES, RUNS IRREGULARLY

• Fouled, defective, worn spark plugs • Check/verify heat range/gap/replace
• Faulty MPEM • Check, refer to section ELECTRICAL
SYSTEM or ENGINE MANAGEMENT
on RFI and DI models
Weak spark MANAGEMENT
• Too much oil supplied to engine • Adjust oil injection pump
• Bad ignition coil wiring • Check wiring condition and proper
grounding of ignition coil
• Faulty ignition coil, or bad connector • Check coil. Refer to ENGINE
MANAGEMENT
SMR2002-020_03_01A.FM 03-01-3
ENGINE MISFIRES, RUNS IRREGULARLY (cont’d)

• Low fuel level • Check/refill
• Low fuel pressure • Check pump, regulator, injectors and
(RFI and DI models) hose pinchers or if filter is plugged.
Replace if necessary
• Stale or water fouled fuel • Check/siphon and refill
• Fuel filter dirty or restricted • Check/clean/replace
• Carburetion dirty or out of adjustment • Check/clean/adjust, refer to section
(carburetor models) FUEL SYSTEM
• Clogged fuel injectors • Remove and clean fuel injectors
Lean fuel mixture (RFI and DI models)
Dry spark plug (except
when water fouled) • Clogged direct injectors • Remove and clean direct injectors
(DI models)
• Defective sensor or MPEM • Check faulty codes in MPEM
(RFI and DI models) memory, refer to section ENGINE
MANAGEMENT
• Leaking crankshaft seal(s) or intake • Pressure check engine, refer to section
(carburetor models) ENGINE
• Restricted fuel valve • Check/replace
(carburetor models)
• Loose carburetor • Tighten carburetors
(carburetor models)
03-01-4 SMR2002-020_03_01A.FM

• Partially closed choke • Check/adjust choke cable
(carburetor models)
• Flame arrester dirty or restricted • Check/replace
(if so equipped)
• Carburetor adjustment • Check/adjust, refer to section FUEL
(carburetor models) SYSTEM
• Loose main jet (carburetor models) • Check, refer to section FUEL SYSTEM
• Improper air/fuel rail pressure • Check pressures, refer to ENGINE
(DI models) MANAGEMENT
• Faulty fuel injector(s) • Remove and replace fuel
(RFI and DI models) injector(s), refer to section ENGINE
MANAGEMENT
• Faulty direct injector(s) (DI models) • Remove and replace direct
injector(s), refer to section
ENGINE MANAGEMENT
• Defective sensor or MPEM • Check faulty codes in MPEM
(RFI and DI models) memory, refer to section ENGINE
MANAGEMENT
Rich fuel mixture
Fouled spark plug • Rotary valve shaft seal leaking • Check/replace, refer to ENGINE
(if so equipped)
• Damaged reed valve (if so equipped) • Check, refer to Bottom End in ENGINE
SECTION
(DI models) ENGINE
• Leak in RAVE valve system • Check, refer to ENGINE MANAGEMENT
(DI models)
• Oil injection pump adjustment • Check/adjust, refer to section
LUBRICATION SYSTEM
• Worn needles and seals • Check, refer to section FUEL SYSTEM
(carburetor models)
• Excessive rotary valve clearance • Check, refer to ENGINE
(if so equipped)
• Fuel pressure fluctuating (DI models) • Inspect fuel pressure regulators. Refer
to ENGINE MANAGEMENT
• High fuel pressure • Check pump, regulator, injectors, hose
(RFI and DI models) pinchers or if filter is plugged. Replace
if necessary
• RFI and DI models: Check spark plug • Check, refer to section ENGINE
condition, check fault codes in the MANAGEMENT. If some work has
Start but run poorly MPEM memory, check fuel pressure, been performed on the unit, make sure
check RAVE valves operation injector wire connectors were not
mixed. Refer to the wiring diagram for
wire colors and positions
• DI models: Bent or missing tooth on • Check, refer to ENGINE
encoder wheel MANAGEMENT under COMPONENT
• RFI models: Bent or missing tooth on INSPECTION AND ADJUSTMENT
Also fuel injection trigger wheel
misinjecting • Injector wiring reversed • Check, refer to ENGINE
MANAGEMENT
• Damaged fuel injector • Check, refer to ENGINE
MANAGEMENT
• Incorrect rotary valve timing • Check/adjust, refer to ENGINE
(if so equipped)
• Excessive rotary valve clearance • Check, refer to ENGINE
(if so equipped)
SMR2002-020_03_01A.FM 03-01-5
ENGINE CONTINUALLY BACKFIRES

Weak spark • Fouled, defective spark plugs • Clean/replace
Spark plugs • Ignition coil leads or wiring reversed • Check with wiring diagram
• Incorrect setting • Check/reset, refer to section
ELECTRICAL SYSTEM
Ignition timing/TDC setting
• Defective encoder wheel • Check/replace, refer to section
ENGINE MANAGEMENT
Rotary valve • Incorrect timing • Check/reset, refer to ENGINE
(if so equipped)
Carburetor • Carburetion too lean • Check/adjust, refer to section FUEL
(if so equipped) SYSTEM
Engine • Intake leak/crankshaft seal failure • Pressure check engine, refer to section
(carburetor models) ENGINE
ENGINE DETONATION OR PINGING

• Timing too far advanced • Check/reset
Ignition
• Spark plug heat range too high • Check/change to correct range
• Engine overheats and exhaust • Check, see engine overheats
overheats
• Fuel octane too low of poor quality • Use good quality fuel
Engine/exhaust high • KS disconnected or faulty • Check, refer to ENGINE

MANAGEMENT
temperature
• Bad KS connection • Check, refer to ENGINE
MANAGEMENT
• Bad Kostal connection (on engine) • Check, refer to ENGINE
MANAGEMENT
03-01-6 SMR2002-020_03_01A.FM
ENGINE LACKS ACCELERATION OR POWER

• Weak spark • Check/replace, refer to section
ELECTRICAL SYSTEM
• Carburetion, jetting too rich/lean • Check/adjust, refer to section FUEL
• Throttle does not open fully • Check/readjust, refer to section FUEL
SYSTEM
• Low compression • Check/repair, refer to section ENGINE
• Water in fuel • Check/siphon/replace
• Debris in carburetor needle valve • Check/clean, refer to section FUEL
• Impeller leading edge damaged • Check/replace, refer to section
PROPULSION SYSTEM
• Twisted crankshaft • Check, refer to section ENGINE
• Poor quality • Siphon, then refill with fresh fuel
• Clogged direct injectors • Remove and clean direct injectors
(DI models)
(RFI and DI models)
• Low fuel pressure • Check fuel line and fuel pump pressure
(RFI and DI models)
• Incorrect throttle position sensor • Check and adjust TPS, refer to section
(TPS) adjustment ENGINE MANAGEMENT
(RFI and DI models)
• Overheated engine • See ENGINE OVERHEATS in this chart
Engine revs lower than • RAVE valve does not open • Check, refer to section ENGINE
its maximum operational (if so equipped)
RPM • Limp home mode activated • Refer to ENGINE MANAGEMENT
Peak performance is • RAVE valve is stuck opened • Check, refer to section ENGINE
delayed until higher (if so equipped)
RPM range is reached
ENGINE STOPS RUNNING

Engine dies during regular • Improper ignition timing (DI models) • Check/reset
operation (piston seizure) • Compression ratio is too high • Install genuine parts
• Poor oil quality • Use proper BOMBARDIER oil
Engine was running below • Electrical noise (DI models) • Refer to section ENGINE
2000 RPM. MANAGEMENT
No maintenance light
• Low air pressure (DI models) • Check air delivery circuit for leaks
Engine stalls at idle
• Check air compressor
• Engine running out of fuel • Check fuel delivery system for proper
fuel pressure (RFI and DI models) and
Engine start but stops after delivery (all models)
approximately 2 seconds • Air in fuel rail • Refill fuel tank
• Low air pressure (DI models) • Check air system
(compressor, air/fuel rail etc.)
SMR2002-020_03_01A.FM 03-01-7
ENGINE CANNOT REACH MAXIMUM RPM

• RAVE valve does not open • Check, refer to section ENGINE and
COOLING SYSTEM
• Faulty water regulator valve • Check, refer to COOLING SYSTEM
• DI models: The system is in limp • Refer to section ENGINE and COOLING
home mode. “MAINT” is displayed SYSTEM and check the fault codes in
on Information Center the MPEM
• Low fuel pressure • Check fuel pump pressure output
(RFI and DI models)
• Jet pump related problem • Check propulsion components.
Refer to JET PUMP
• Limp home mode activated • Refer to ENGINE MANAGEMENT
• Exhaust gases in bilge (leak) • Check exhaust system for leaks
• Exhaust system blockage/muffler • Check and repair
damage (DI models)
ENGINE RUNS TOO FAST (vehicle cannot reach its top speed)
• Faulty rev limiter in MPEM • Check, refer to section ENGINE
MANAGEMENT
Engine RPM too high • Improper impeller pitch (too low) • Check/replace, refer to section
• Incorrect throttle position sensor PROPULSION SYSTEM
(TPS) adjustment (RFI models) • Check and adjust TPS, refer to ENGINE
MANAGEMENT
• Damaged impeller • Replace impeller. Refer to
PROPULSION
• Damaged leading or trailing edge of • Check/replace
impeller NOTE: Leading edge damage contributes
to poor performance from start. Trailing
Jet pump cavitation edge damage contributes to poor top per-
formance and stator vanes erosion.
• Sealing of ride plate, jet pump support • Check/reseal, refer to section
or jet pump PROPULSION SYSTEM or HULL/BODY
O.P.A.S.TM side vanes • Clogged filter, square rings damaged, • Refer to STEERING SYSTEM
do not go up while leakage in hoses or mechanical
watercraft is at speed. malfunction.
O.P.A.S. side vanes • Broken spring inside side vane • Refer to STEERING SYSTEM
do not go down while cylinder.
engine is at idle.
03-01-8 SMR2002-020_03_01A.FM
ENGINE OVERHEATS
• Temperature sensor defect • Check/replace. Refer to ENGINE

MANAGEMENT
• Worn water pump impeller • Check/replace
• Damaged ride plate or hoses • Check. Refer to COOLING SYSTEM
Monitoring beeper sounds and HULL/BODY
continuously • Restricted jet pump water intake • Check/clean
• Cooling system restriction • Check/flush, refer to section

MAINTENANCE
• Grounded temperature sensor or
• Check/repair/replace
sensor wire (carburetor models)
O.P.A.S. SYSTEM FAULTS

Watercraft is more • Side vanes do not go up while • Refer to STEERING SYSTEM.
responsive than usual watercraft is at speed.
while turning.
Watercraft pulls on one • One side vane does not go up while • Refer to STEERING SYSTEM.
side. watercraft is at speed.
O.P.A.S. side vanes do not • Clogged filter, square rings damaged, • Refer to STEERING SYSTEM.
go up while watercraft is at leakage in hoses or mechanical
speed. malfunction.
O.P.A.S. side vanes do not • Broken spring inside side vane cylinder. • Refer to STEERING SYSTEM.
go down while engine is at
idle.
ABNORMAL NOISE FROM PROPULSION SYSTEM

• Weeds/debris caught in intake grate • Check/clean
or impeller
• Low oil level in jet pump • Check/troubleshoot source of leak/
refill supply, refer to section
PROPULSION SYSTEM
• Worn anti-rattle system • Check/replace pusher in cover, refer to
section PROPULSION SYSTEM
• Damaged or bent drive shaft • Check/replace, refer to section
PROPULSION SYSTEM
• Broken engine mounts • Check/replace, refer to section ENGINE
NOTE: Prior to replacing a MPEM, refer to the MPEM section or MPEM REPLACEMENT in the ENGINE
MANAGEMENT section and read carefully the tests to do before replacing a MPEM that could otherwise
be good.
SMR2002-020_03_01A.FM 03-01-9
Section 04 ENGINE
TABLE OF CONTENTS 0
LEAK TEST............................................................................................................................. 04-02-1
GENERAL ........................................................................................................................... 04-02-1
PREPARATION ................................................................................................................... 04-02-1
TESTING PROCEDURE ..................................................................................................... 04-02-1
ENGINE LEAKAGE DIAGNOSTIC FLOW CHART ............................................................ 04-02-7
REMOVAL AND INSTALLATION.......................................................................................... 04-03-1

GENERAL ........................................................................................................................... 04-03-1
ENGINE REMOVAL............................................................................................................ 04-03-1
CLEANING ......................................................................................................................... 04-03-5
INSTALLATION .................................................................................................................. 04-03-6
MAGNETO SYSTEM ............................................................................................................. 04-04-1

DISASSEMBLY .................................................................................................................. 04-04-5
CLEANING ......................................................................................................................... 04-04-11
ASSEMBLY......................................................................................................................... 04-04-12
TOP END ................................................................................................................................ 04-05-1

GENERAL ........................................................................................................................... 04-05-5
DISASSEMBLY................................................................................................................... 04-05-7
CLEANING ......................................................................................................................... 04-05-16
INSPECTION ...................................................................................................................... 04-05-16
USED PISTON MEASUREMENT ...................................................................................... 04-05-17
ASSEMBLY......................................................................................................................... 04-05-20
ADJUSTMENT ................................................................................................................... 04-05-29
BOTTOM END........................................................................................................................ 04-06-1

DISASSEMBLY................................................................................................................... 04-06-5
CLEANING ......................................................................................................................... 04-06-13
INSPECTION ...................................................................................................................... 04-06-14
ASSEMBLY......................................................................................................................... 04-06-18
ROTARY VALVE ..................................................................................................................... 04-07-1

GENERAL ........................................................................................................................... 04-07-2
INSPECTION ON WATERCRAFT....................................................................................... 04-07-2
DISASSEMBLY................................................................................................................... 04-07-3
CLEANING ......................................................................................................................... 04-07-5
INSPECTION ...................................................................................................................... 04-07-5
ASSEMBLY......................................................................................................................... 04-07-6
ROTARY VALVE TIMING ................................................................................................... 04-07-9
SMR2002-052_04_01ATOC.FM 04-01-1
Section 04 ENGINE
EXHAUST SYSTEM ............................................................................................................... 04-08-1

REMOVAL ........................................................................................................................... 04-08-7
TUNED PIPE REPAIR .......................................................................................................... 04-08-12
INSTALLATION ................................................................................................................... 04-08-13
04-01-2 SMR2002-052_04_01ATOC.FM
Section 04 ENGINE
Subsection 02 (LEAK TEST)
LEAK TEST 0
GENERAL NOTE: If a leak is found, it is important to continue
testing as there is the possibility of having more
A Sea-Doo Engine Leak Test Kit (P/N 295 500 352) than one leak. Continue pumping to compensate
and Supplementary Engine Leak Test Kit (P/N 295 for the air lost to find another leak.
500 780) are available to help diagnose engine
problems such as engine seizure, poor perfor- PREPARATION
mance, oil leakage, etc.
Before disassembling any components of the en- Verify fuel system for leaks.
gine, it is important to perform a leakage test to
determine which part is defective.  WARNING
It is also very important after servicing the engine, If any fuel leak is found, do not start the en-
even for a complete engine rebuilt, to perform an- gine. Correct the leak and wipe off any fuel
other leakage test; at this stage, it may avoid fur- spillage. Do not use electric powered tools
ther engine problems and minimizing the risk of unless fuel system has passed pressure test.
having to remove and reinstall the engine again.
Disconnect battery BLACK negative cable.
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
 WARNING
engine surfaces and should be avoided whenever Always disconnect battery cables in the speci-
possible. fied order, BLACK negative cable first.
On the 717 engine, cylinders can not be verified Disconnect battery RED positive cable.
individually due to leakage from one cylinder to an-
other through a common intake manifold. TESTING PROCEDURE
When installing hoses of the Engine Leak Test Kit
or Supplementary Engine Leak Test Kit, use the Engine Cooling System
collars provided in the kit to ensure a proper seal-
Remove the tuned pipe. Refer to EXHAUST SYS-
ing.
TEM.
When pressurizing the engine, first confirm that
Remove the exhaust manifold gasket and ensure
the components of the Engine Leak Test Kit or
the surface is clean.
Supplementary Engine Leak Test Kit are not leak-
ing by spraying a solution of soapy water on all Disconnect engine cooling hoses.
hoses, connections, fittings, plates, etc. If there is Install the appropriate exhaust manifold plate from
a leak, bubbles will indicate leak location. the Engine Leak Test Kit (P/N 295 500 352) or Sup-
Three areas of the engine will be tested in se- plementary Engine Leak Test Kit (P/N 295 500 780).
quence as per the diagnostic flow chart (see the Tighten plate using fasteners provided in the kit.
end of this subsection). NOTE: Do not torque plate excessively.
1. Engine Cooling System. Install a hose pincher on engine drain hose.
2. Bottom End and Top End.
3. Rotary Valve Shaft (except all 947 engines).
SMR2002-021_04_02A.FM 04-02-1
Section 04 ENGINE
Use hoses provided in the kit and install them on

the engine. 2 1
Install pump using reducer and appropriate tube(s)

as necessary.
F02E0DA 3
787 RFI ENGINE — REAR VIEW
1. Loop hose and use clamps
2. Hose with clamps. Install pump to the end
3. Block engine drain hose with a hose pincher
F01B2UB 1
717 ENGINE — REAR VIEW
1. Engine drain hose blocked with a hose pincher
2
1
F02D0WA 1
787 RFI ENGINE — FRONT VIEW
1. Exhaust manifold plate
F01B2VA 3
717 ENGINE — FRONT VIEW
1. Loop hose and use clamps
2. Use two washers with exhaust manifold stud
3. Hose with adapter and nipple
04-02-2 SMR2002-021_04_02A.FM
Section 04 ENGINE
2 2
F08E06A 1 F12E08A 1
947 CARBURETOR-EQUIPPED ENGINE — REAR VIEW 947 DI ENGINE — SIDE VIEW
1. Block engine drain hose with a hose pincher 1. Block engine drain hose with a hose pincher
2. Install pump to water inlet hose 2. Install pump to water inlet hose
F08D04A 1 F12E07A
947 CARBURETOR-EQUIPPED ENGINE — FRONT VIEW 947 DI ENGINE — FRONT VIEW

1. Exhaust manifold plate 1. Exhaust manifold plate
NOTE: Water is not required for testing.

DI models, it is not necessary to pressurize the
bottom crankcase cover nor the magneto cover.
There is no possible water leak path toward the
internal components of the engine.
SMR2002-021_04_02A.FM 04-02-3
Section 04 ENGINE
Activate pump and pressurize engine cooling sys- NOTE: Engines with the RAVE system, the boot
tem to 34 kPa (5 PSI). (carburetor-equipped engines) and O-ring can
Wait 3 minutes and check if pressure drops; if so, be checked for leakage with the valve in place.
verify all testing components. Simply remove the cover to expose the parts.
– If kit components are not leaking and pressure Make sure the spark plugs (and the air/fuel rail on
drops, verify all external jointed surfaces, tem- DI engines) are installed and tightened.
perature sensor and the O-ring between the Block pulse hose (carburetor-equipped engines)
spark plug area and the engine cylinder head using a hose pincher.
cover. If none of these components are leaking, NOTE: Do not block the rotary valve shaft hoses
there is an internal leak and it can be detected (if so equipped).
with Bottom End and Top End testing.
Install pump to the exhaust plate fitting.
Bottom End and Top End
3
Carburetor-Equipped Models
Remove the carburetor(s) and gasket(s). Make
sure the surface of the intake manifold (717 and
947 engines) or rotary valve cover (787 RFI en-
gine) are clean.
Install the intake plate(s) with fasteners from the
kit and tighten adequately.
NOTE: For the 787 RFI and 947 engines, use the 1
intake and exhaust plates included in the Supple-
mentary Engine Leak Test Kit (P/N 295 500 780).
DI Models
Remove throttle bodies on DI models.
2
Install intake manifold plugs (P/N 529 035 708). F01B2ZA
717 ENGINE
1. Intake plates
2. Pulse hose blocked with a hose pincher
3. Exhaust plate
F12D14A 1 1
1. Intake manifold plugs
All Models 3
F01B30A
On engines with the RAVE system, remove the
RAVE valves and gaskets. 787 RFI ENGINE
1. Intake plates
Install the RAVE valve plates with fasteners from 2. RAVE valve plates
the kit and tighten adequately. 3. Pulse hose blocked with a hose pincher
4. Exhaust plate
04-02-4 SMR2002-021_04_02A.FM
Section 04 ENGINE
Check also small oil injection pump lines and fit-

1 2
tings; check for air bubbles or oil column going to-
ward pump, which indicate a defective check valve.
Check for leak through counterbalancing shaft
seal toward air compressor (DI engines). Air bub-
bles in lowest fitting (oil return line) underneath
compressor indicates a seal leakage.
If the above mentioned components are not leak-
ing, block both oil hoses of the rotary valve shaft
(if so equipped) using hose pinchers.
NOTE: If leakage stops at this point, proceed with
Rotary Valve Shaft testing (if so equipped).
If there is still some leakage, remove the PTO fly-
wheel to verify outer seal.
If no leak is found on the PTO side outer seal, re-
move magneto flywheel and verify crankshaft out-
er seals.
Proceed with the Rotary Valve Shaft testing (if
so equipped) if the crankshaft outer seals are not
leaking.
F08D05A 3
947 ENGINE
Rotary Valve Shaft (if so equipped)
1. Exhaust plate NOTE: It is mandatory to drain the injection oil
2. Rave valve plates from the rotary valve shaft.
3. Intake plates
Block oil return hose of the rotary valve shaft with
Activate pump and pressurize engine to 34 kPa a hose pincher.
(5 PSI).
CAUTION: Do not exceed this pressure.
Wait 3 minutes and check if pressure drops; if so,
verify all testing components.
If kit components are not leaking, verify engine
jointed surfaces as per following areas:
– spark plugs
– direct injector sealing (DI engines)
– cylinder head gasket
– cylinder base gasket
– crankcase halves
– rotary valve cover (except all 947 engines)
– engine plugs
– exhaust manifold F01B31A 1
– intake manifold (717 engine) 717 ENGINE
1. Oil return hose blocked with hose pincher
– intake flanges (DI engine)
– oil injection pump (717 engine).
SMR2002-021_04_02A.FM 04-02-5
Section 04 ENGINE
F01B33A 1 F01B34A
787 RFI ENGINE 787 RFI ENGINE

1. Oil return hose blocked with hose pincher 1. Pump with reducer and nipple
Install pump with reducer and nipple to the oil sup- Activate pump and pressurize to 34 kPa (5 PSI).
ply hose of the rotary valve shaft. Check plug of the rotary valve shaft in crankcase.
Remove PTO side spark plug. If pressure drops, it
1 indicates a defective PTO side crankshaft inner seal
or crankcase is not sealed correctly.
Remove MAG side spark plug. If pressure drops, it
indicates a defective MAG side crankshaft inner
seal or crankcase is not sealed correctly.
If the above mentioned components are not leaking
and there is a pressure drops, remove the rotary
valve cover. Check the seal of the rotary valve shaft.
If the rotary valve shaft is not leaking, it could indi-
cates a defective engine casting. Disassemble en-
gine and carefully check for defects in castings. Pay
attention to tapped holes which may go through
F01B32A
sealed areas of engine and thus lead to leakage.
717 ENGINE
1. Pump with reducer and nipple
04-02-6 SMR2002-021_04_02A.FM
Section 04 ENGINE
ENGINE LEAKAGE DIAGNOSTIC FLOW CHART

717 and 787 RFI Engines
PRESSURIZE ENGINE
COOLING SYSTEM
YES
IS SYSTEM LEAKING? CHECK TESTING KIT
NO
PRESSURIZE ENGINE REPLACE O-RING OF CYLINDER HEAD

AND/OR CYLINDER BASE GASKET
NO
IS ENGINE LEAKING?
RECHECK ENGINE SEALING
YES
CHECK TESTING KIT
CHECK ALL JOINTED SURFACES,

SCREW/STUD THREADS. MOUNTING
FLANGES ETC.
YES REPLACE GASKET OR O-RING,

ANY LEAK FOUND?
RE-SEAL LEAKING AREA
NO
CHECK SMALL OIL LINES OF
INJECTION PUMP
AIR BUBBLES FOUND YES

OR OIL MOVING REPLACE CHECK VALVE(S) / LINE(S)
TOWARD PUMP?
NO
BLOCK LARGE HOSES OF
ROTARY VALVE GEAR
LUBRICATION SYSTEM
NO
IS ENGINE STILL LEAKING?
YES
CHECK TESTING KIT
CHECK CRANKSHAFT OUTER

SEAL OF PTO AND
MAG SIDES
YES
PRESSURIZE ROTARY VALVE GEAR ARE SEALS LEAKING? REPLACE DEFECTIVE SEAL(S)
RESERVOIR IN CRANKCASE
NO
PRESSURIZE ROTARY VALVE GEAR

RESERVOIR IN CRANKCASE
YES
IS RESERVOIR LEAKING? RECHECK ENGINE SEALING
NO
UNSEAL PTO CYLINDER AND MAG CYLINDER
SEPARATELY BY REMOVING THE
APPROPRIATE SPARK PLUG
YES REPLACE DEFECTIVE SEAL(S)

IS RESERVOIR LEAKING?
NO
CHECK TESTING KIT CHECK FOR LEAKAGE AT ROTARY

VALVE SHAFT CRANKCASE PLUG
YES REPLACE OIL SEAL OF ROTARY

ANY LEAK FOUND? VALVE SHAFT END, OR
YES REPLACE CAP
IS RESERVOIR LEAKING? NO
REMOVE ROTARY VALVE COVER, CHECK

NO SEAL OF ROTARY VALVE SHAFT
YES
IS SEAL LEAKING? REPLACE DEFECTIVE SEAL
NO
CAREFULLY INSPECT ENGINE CASTINGS,

PARTICULARLY THE THREADED HOLE AREAS
YES
ANY LEAK FOUND? REPLACE DEFECTIVE PARTS
NO
ENGINE IS PERFECTLY SEALED
INTERNALLY
F00D07S
SMR2002-021_04_02A.FM 04-02-7
Section 04 ENGINE
947 Engine
F00D28S
04-02-8 SMR2002-021_04_02A.FM
Section 04 ENGINE
Subsection 03 (REMOVAL AND INSTALLATION)
REMOVAL AND INSTALLATION 0

GENERAL
On some models, it is not necessary to remove
engine from watercraft to service TOP END, PTO
FLYWHEEL or MAGNETO. However, engine remov-
al is necessary to repair BOTTOM END.
ENGINE REMOVAL
DI Models
Use the VCK (Vehicle Communication Kit) (P/N 529
035 844) and release the fuel pressure in the fuel
system. Refer to ENGINE MANAGEMENT section.
All Models F06D0FA 1
In order to remove engine from watercraft proceed
787 RFI ENGINE
as follows.
1. Unplug connector
First, disconnect battery cables from battery.
 WARNING
Always disconnect battery cables exactly in
the specified order, BLACK negative cable
first then the RED positive battery cable last.
Electrical Connections
It is recommended to disconnect electrical con-
nections prior to disconnecting fuel lines.
Disconnect temperature sensor wire and spark plug
cables.
Disconnect magneto wiring harness.
F07D08A 1
947 ENGINE
1. Unplug connector
GTX RFI Models

Disconnect throttle position sensor (TPS), air pres-
sure sensor (APS) and air temperature sensor (ATS).
Disconnect crankshaft position sensor (CPS).
Disconnect connectors from fuel injectors.
Refer to FUEL INJECTION for location of sensors
and connectors.
DI Models
F01D8RA 1 Disconnect both throttle position sensors (TPS),
manifold air pressure sensor (MAPS) and manifold
717 ENGINE air temperature sensor (MATS).
1. Unplug connector
SMR2002-022_04_03A.FM 04-03-1
Section 04 ENGINE
Disconnect connectors from fuel injectors and di- Tuned Pipe

rect injectors.
To remove tuned pipe, refer to EXHAUST SYSTEM.
Disconnect connector from knock sensor.
Disconnect RAVE valve hose where shown. Inspect Air Intake Silencer
hose. If it has hardened or is slit, replace hose. To remove air intake silencer, refer to AIR INTAKE.
Carburetor/Throttle Body
Turn fuel valve to OFF.
Disconnect fuel supply and fuel return hoses.
To remove carburetor(s), refer to CARBURETOR for
proper procedure.
GTX RFI Models
Disconnect fuel supply hose from fuel rail.
F16D04A 1
1. Disconnect hose here
Refer to ENGINE MANAGEMENT for location of sen-

sors and connectors.
Unplug air compressor lines (inlets and outlets):
cooling, oil (outlet only) and air (inlet only on throt-
tle body side).
Disconnect vent hose from balancing shaft gear
housing.
F07F11A 1
Jet Pump Removal
PRESS TABS AND PULL CONNECTOR
All Models 1. Fuel rail
To withdraw jet pump, refer to JET PUMP.

CAUTION: Whenever removing engine from  WARNING
watercraft, engine/jet pump alignment must be The fuel hose may be under pressure. Cover
performed at reinstallation. the fuel line connection with an absorbent
shop rag. Slowly disconnect the fuel hose to
Drive System release the pressure. Wipe off any fuel spill-
age inside bilge.
To withdraw driveshaft(s), refer to DRIVE SYSTEM.
Cooling System DI Models

Disconnect the engine water supply hose. Remove air/fuel rail. Refer to ENGINE MANAGE-
MENT.
Disconnect the engine water return hose.
NOTE: Engine will have to be raised inside bilge
to disconnect drain hose before removing from
bilge.
Refer to COOLING SYSTEM for proper water hose
location.
04-03-2 SMR2002-022_04_03A.FM
Section 04 ENGINE
All Models
Engine Support
NOTE: Be careful when removing engine sup-
port(s) or rubber mount adapters, shims could
have been installed underneath. Shims control
engine/jet pump alignment. Always note position
of shims for reinstallation, to avoid altering engine
alignment.
Remove engine support mount screws.
F07F12C 1
787 RFI AND 947 ENGINES — REAR SUPPORT
1. Remove screws
Lifting Engine
717 Engine
Engine can be easily lifted using the following sug-
gested tools:
– Cut porcelain from two old spark plugs.
F02D08A 1 – Weld a lock washer approximately 20 mm (3/4 in)
717 ENGINE diameter on each spark plug as shown.
1. Remove screw of each engine support
F01D0AA 2
1. Weld a lock washer
2. Old spark plug
F06D35A 1
Remove spark plugs and replace by special tools.
787 RFI AND 947 ENGINES — FRONT SUPPORT
1. Remove screw
Hook a sling into holes of special tools.
Using a chain block, a hoist or other suitable equip-
ment, slightly lift engine to ease the remaining
component removal.
CAUTION: Take care not to damage cable or oil
injection hoses.
SMR2002-022_04_03A.FM 04-03-3
Section 04 ENGINE
787 RFI and 947 Engines Removal of Remaining Components

Engine can be easily lifted by inserting a hook into Lift up engine slowly until oil injection hoses can be
exhaust manifold eyelet. reached.
All Engines
Install a hose pincher to oil supply hoses of oil in-
jection pump and rotary valve shaft (except the
947 engine); then, disconnect hoses.
F01D7OA
TYPICAL

ment, slightly lift engine to ease the remaining com- A01B2JB
ponent removal. TYPICAL

CAUTION: Take care not to damage cable or oil 1. Hose pincher (P/N 295 000 076)
injection hoses. Install a hose pincher to oil return hose of rotary
Remove rear engine support. valve shaft (except the 947 engine); then, discon-
nect hose.
1
1
F07F12A
F01D3ZA
TYPICAL
1. Rear support TYPICAL — 717 ENGINE
1. Rotary valve oil supply line
2. Hose pincher installed
04-03-4 SMR2002-022_04_03A.FM
Section 04 ENGINE
F04D10A 3 2 1
TYPICAL — 787 RFI ENGINE
F06H35A 1
1. Rotary valve oil supply line 1. Positive starter cable
2. Hose pincher installed 2. Ground cable
3. Disconnect RED positive cable
Carry on engine lifting then tilt engine so that it can
Disconnect RED positive cable from starter post. be removed from the body opening.
CAUTION: Be careful not to scratch body or to
hit any component.
F01H1JB 1
TYPICAL
Disconnect BLACK negative cable from engine

F01D7RA
crankcase.
TYPICAL
CLEANING
Wipe off any spillage in bilge. Clean with a bilge
cleaner.
Clean external parts of engine.
SMR2002-022_04_03A.FM 04-03-5
Section 04 ENGINE
INSTALLATION 1
Installation of engine in watercraft is essentially
the reverse of removal procedures. However pay
particular attention to the following.
Rubber Mount, Shim and Screw

Check tightness and condition of rubber mounts.
If they have been removed, apply Loctite 243
(blue) on screw threads. Torque screws to 25 N•m
(18 lbf•ft).
CAUTION: Strict adherence to this torque is im-
portant to avoid damaging threads of alumi-
num insert in bilge.
F07F12B
Engine Support
TYPICAL
717 Engine 1. Torque engine support screws to 24 N•m (17 lbf•ft)
Torque front and rear engine supports as shown in
DI Engine
the following illustration.
Install and torque the engine support screws to
24 N•m (17 lbf•ft) in the indicated order. Refer to
Loctite the following illustration.
243 1
4
1 2
3 5
Loctite
243
1 Loctite
F02D09B 243 2
1. Torque screws to 22 N•m (16 lbf•ft) F12D13A

2. Torque nuts to 39 N•m (29 lbf•ft)
TORQUE TO 24 N•m (17 lbf•ft) AS PER SEQUENCE
787 RFI and 947 Engines except DI Engine
NOTE: Remember to install sleeves and flat washers.
Apply Loctite 243 (blue) to rear engine support
screws and install them with flat washers and 2 1 2 1 2
torque to 24 N•m (17 lbf•ft).
F12D13B
1. Sleeves
2. Flats washers
04-03-6 SMR2002-022_04_03A.FM
Section 04 ENGINE
Oil Injection Hoses All Models except XP

717 and 787 RFI Engines To verify alignment proceed as follows:
Make sure to reinstall hoses before completely low- – Install the appropriate plate with the support to
ering engine in bilge. hull with four nuts.
Positive Starter Cable

Torque nut of positive starter cable to 6 N•m
(53 lbf•in). Apply dielectric grease on nut.
Engine/Jet Pump Alignment

Alignment is necessary to eliminate possible vi-
bration and/or damage to components. Check
alignment of engine using the following alignment
tools.
F00B0HA
Support plate kit (P/N 529 035 506).
NOTE: Use plate (P/N 529 035 508) for the 139.5 mm – Carefully slide shaft through support.
(5-1/2 in) jet pump and plate (P/N 529 035 507) for – Insert shaft end into PTO flywheel.
the 155.6 mm (6-1/8 in) jet pump. NOTE: Ensure the protective hose and carbon
ring (or seal carrier) is removed to check engine
alignment. If the alignment is correct, the shaft will
slide easily without any deflection in PTO flywheel.
F00B0FA 1 2
1. Plate
2. Support F07D05A 2 1
Alignment shaft (P/N 295 000 141). TYPICAL
1. Alignment shaft
2. PTO flywheel
If the alignment is incorrect loosen engine support

screws to enable to align PTO flywheel with shaft
end.
F00B0GA 1
1. Alignment shaft
SMR2002-022_04_03A.FM 04-03-7
Section 04 ENGINE
NOTE: Use shim(s) (P/N 270 000 024 or P/N 270 – alignment shaft (P/N 295 000 141)
000 025) as necessary between engine supports
and rubber mounts to correct alignment.
F00B0GA 1
1. Alignment shaft
– PTO flywheel adapter (P/N 529 035 590).
F00D0CA 1
TYPICAL
1. Shim F00B11B 1
1. Adapter
CAUTION: Whenever shims are used to correct
alignment, never install more than 1.3 mm Install support plate at rear of watercraft.
(0.051 in) shim thickness on the 947 engines and Install adapter on shaft.
3 mm (0.12 in) on the 717 and 787 engines.
NOTE: Ensure the mid bearing is loosened to
XP Models check engine alignment.
Use: Carefully slide alignment shaft (P/N 295 000 141)
– plate (P/N 529 035 507) for the 155.6 mm (6-1/8 in) through support plate and seal carrier.
jet pump
F05I08A 1 2
TYPICAL
F00B0FA 1 2 1. Alignment tool
2. Seal carrier
1. Plate
2. Support
04-03-8 SMR2002-022_04_03A.FM
Section 04 ENGINE
Place grease fitting on the top and torque seal car- NOTE: Use shim(s) (P/N 270 000 024 or P/N 270
rier nuts in a criss-cross sequence in two steps as 000 025) as necessary between engine supports
per following illustration. and rubber mounts to correct alignment.
NOTE: It is very important to tighten nuts of seal
carrier in a criss-cross sequence to maintain its
alignment.
1 6
8 11
3 4
10 9
F00D0CA 1
TYPICAL
1. Shim
5 2
F05I0EB 12 7 CAUTION: Whenever shims are used to correct
alignment, never install more than 1.3 mm (0.051 in)
Step 1 : 1 to 6, torque to 3 N•m (26 lbf•in) as per sequence shim thickness.
Step 2 : 7 to 12, torque to 10 N•m (88 lbf•in) as per sequence
Engine Support Screws
All Models
Apply Loctite 243 (blue) on screw threads.
Torque engine support screws to 25 N•m (18 lbf•ft)
when procedure is completed.
Loctite Loctite
243 243
1 1
F08I06A 2 1
1. Alignment shaft
2. Adapter
1
After the mid bearing is torqued, continue to slide
the alignment shaft (P/N 295 000 141) forward and Loctite
243
install PTO adapter (P/N 529 035 590). Insert
adapter end into PTO flywheel.
F02D0KB
end. 717 ENGINE
1. Torque to 25 N•m (18 lbf•ft)
SMR2002-022_04_03A.FM 04-03-9
Section 04 ENGINE
Final Inspection
Check throttle cable condition and lubricate cable
with BOMBARDIER LUBE lubricant.
After its installation, properly adjust and bleed oil in-
jection pump as specified in OIL INJECTION PUMP
and adjust throttle cable as specified in ENGINE
MANAGEMENT (DI models).
Check hose condition and pressure test fuel sys-
tem, refer to FUEL CIRCUIT.
 WARNING
Whenever doing any type of repair on water-
F06D35A 1 craft or if any components of the fuel system
are disconnected, a pressure test must be done
FRONT ENGINE SUPPORT — 787 RFI AND 947 ENGINES
before starting engine.
Verify all electrical connections.

Run engine and ensure there is no leakage.
CAUTION: If watercraft is out of water, engine
must be cooled using the flush kit.
F07F12C 1
REAR ENGINE SUPPORT — 787 RFI AND 947 ENGINES
04-03-10 SMR2002-022_04_03A.FM
Section 04 ENGINE
Subsection 04 (MAGNETO SYSTEM)
MAGNETO SYSTEM 0
717 Engine
24
5 Nm
Loctite (44 lbfin)
243 9 Nm
16
(80 lbfin)
Loctite 243
6 22 6 Nm
(53 lbfin)
4
7
Loctite
243
23 6 Nm
(53 lbfin)
Loctite
243
15 6 Nm
(53 lbfin)
2
10 Nm 2.6 Nm
Loctite (88 lbfin) (23 lbfin)
14 243 11
3
Anti-seize
lubricant
13
150 Nm 10 Nm
Loctite (110 lbfft) 11 (88 lbfin)
648
12 Anti-seize
lubricant
25 11
1 10 Nm (88 lbfin)
F02D12S
SMR2002-023_04_04A.FM 04-04-1
Section 04 ENGINE
787 RFI Engine
9 Nm
(80 lbfin)
Anti-seize Dielectric
lubricant Molykote grease
111
Anti-seize
5 lubricant
28
Loctite
243
Molykote 19 9 Nm
111 (80 lbfin)
8
24 17 10 Nm
(88 lbfin)
Loctite 243
14
13 120 Nm
(89 lbfft)
Loctite
4 Nm 243
(35 lbfin)
20 3
4 Nm 27
(35 lbfin) Loctite
243
9
Anti-seize
lubricant
26
Anti-seize
lubricant
Dielectric 11 9 Nm
grease (80 lbfin)
25
Dielectric
grease 1 6 Nm
Molykote
111 Anti-seize (53 lbfin)
lubricant
9 Nm
(80 lbfin)
Ground 9 Nm
cable Anti-seize
11 lubricant (80 lbfin)
F06D3KS Dielectric grease
04-04-2 SMR2002-023_04_04A.FM
Section 04 ENGINE
947 Carburetor-Equipped Engines
9 Nm Molykote
(80 lbfin) Loctite 111
11 243
Loctite 9
243
Loctite
243
Dielectric
grease 13 Nm
(115 lbfin)
20
Dielectric
Ground grease
cable 1
29
Loctite
243
25
5 Nm 16
(44 lbfin)
10
Loctite
243 21
9 Nm
14 8 (80 lbfin)
115 Nm Loctite
(85 lbfft) 13 648
3
13 Nm
(115 lbfin) 17
Loctite
648
F08D0AS
SMR2002-023_04_04A.FM 04-04-3
Section 04 ENGINE
947 DI Engines
Molykote
111
11
9 Nm 9
(80 lbfin) Molykote
111 Loctite
Loctite 243
243
20
13 Nm
1 (115 lbfin)
29
25 5 Nm 16 Loctite
(44 lbfin) 243
21
9 Nm
(80 lbfin)
Loctite
243
8
14
13
115 Nm
(85 lbfft) Loctite
243
F12D0SS
04-04-4 SMR2002-023_04_04A.FM
Section 04 ENGINE
DISASSEMBLY Using a suitable socket, unscrew retaining nut

no. 13 COUNTERCLOCKWISE when facing it.
717 Engine
NOTE: If socket is found too large to be inserted
NOTE: On 717 engine, the magneto system can in puller plate, machine or grind its outside diame-
be disassembled without removing the engine ter as necessary.
from the watercraft.
Magneto Cover 1
Remove screws no. 11 and wire support no. 12,
then withdraw magneto cover no. 1.
Magneto Flywheel and Ring Gear

Magneto flywheel no. 2 is locked with puller plate
(P/N 420 876 080), sleeves (P/N 290 847 220) and
extension handle (P/N 295 000 125).
1
F01D4BA
2 TYPICAL
1. Extension handle locking crankshaft
Remove nut no. 13 and lock washer no. 14 from

magneto flywheel.
3 Magneto flywheel is easily freed from crankshaft
with puller (P/N 529 035 547).
F01D47A 4
1. Screw
2. Extension handle
3. Puller plate
4. Sleeve
Using three M8 x 35 screws (P/N 420 841 591),

install screws through puller plate and slide
sleeves on screws then secure puller plate on
A00C1AA
magneto flywheel so that sleeves are against ring
gear no. 3. Fully thread on puller in puller plate.
Install extension handle on end of puller plate. Tighten puller bolt and at the same time, tap on
bolt head using a hammer to release magneto fly-
1 wheel from its taper.
F01D48A
TYPICAL
1. Sleeves on opposite side
SMR2002-023_04_04A.FM 04-04-5
Section 04 ENGINE
The following procedure is to find a common ref-

erence point on both crankcases (old and new) to
position armature plate.
1
Proceed as follows:
– Before removing the armature plate, find a
crankcase locating lug (the top one in this exam-
ple).
– Place a cold chisel at the end of chosen lug,
then punch a mark on armature plate at this
point.
2
1
3
F01D4CA 2
1. Puller plate
2. Puller
3. Extension handle
Lay magneto flywheel no. 2 on a steel plate. Tap

lightly on ring gear no. 3 using a hammer to re-
lease it from magneto flywheel.
F01D4DA
1
1. Crankcase locating lug
2. Mark armature plate at the end of lug
– At assembly, align armature plate mark (previ-

ously punched) with the end of the correspond-
ing locating lug on the new crankcase.
1
2
F01D3AA
1. Magneto flywheel
Armature Plate
Before removing, locate the manufacturer’s refer-
ence mark on the armature plate no. 4 and ensure F01D4EA
there is a corresponding indexing mark on the TYPICAL

crankcase housing. 1. Lug end of crankcase
2. Align mark and lug end here
NOTE: Since replacement crankcases do not have
timing mark for armature plate location, indexing Remove three retaining screws no. 15 and with-
marks should be made on armature plate and crank- draw armature plate.
case to ease reassembly and further ignition timing.
04-04-6 SMR2002-023_04_04A.FM
Section 04 ENGINE
Magneto Housing Battery Charging Coil

To remove magneto housing no. 5, starter has to To replace battery charging coil no. 7:
be removed. Refer to STARTING SYSTEM. – Heat the armature plate to 93°C (200°F) around the
Unscrew retaining screws, then withdraw housing. screw holes to break the threadlocker bond.
Generating Coil
To replace generating coil no. 6:
– Heat the armature plate to 93°C (200°F) around the
screw holes to break the threadlocker bond.
1
F00D09A
1. Heat the armature plate
CAUTION: Protect harness from flame.

1 – Remove screws.
F00D08A
– Uncrimp and unsolder YELLOW and YELLOW/
BLACK wires from coil.
1. Heat the armature plate
– Uncrimp and unsolder ground wire (BLACK) from
CAUTION: Protect harness from flame. coil core.
– Remove screws.
– Uncrimp and unsolder BLACK/RED wire from coil. 1
A25E0QA
1. Uncrimp and unsolder wire here A25E0SA 2

1. Uncrimp and unsolder ground wire (BLACK)
2. Uncrimp and unsolder YELLOW and YELLOW/BLACK wires
SMR2002-023_04_04A.FM 04-04-7
Section 04 ENGINE
787 RFI Engine Rotor and Ring Gear

Magneto Housing Cover Remove starter. Refer to STARTING SYSTEM.
Disconnect water hoses from heat exchanger cover. NOTE: Crankshaft can also be locked by using the
PTO flywheel extractor tool. For procedure, refer to
Loosen screws no. 11. Remove engine magneto
BOTTOM END.
cover no. 1.
Lock ring gear using special tool (P/N 529 035 846).
F15B01A
SPECIAL TOOL (P/N 529 035 846)

F07D0JA 1 2
787 RFI ENGINE
1. Disconnect water inlet hose
2. Heat exchanger cover
Remove oil pump shaft from magneto rotor nut.
F15D0AA 1
1. Special tool (P/N 529 035 846)
Remove crankshaft position sensor no. 18 before

F07D0IA 1
removing the ring gear.
1. Oil pump shaft
Alternatively, you can lock ring gear using special
tool assembly (P/N 295 000 155).
04-04-8 SMR2002-023_04_04A.FM
Section 04 ENGINE
Remove special tool locking ring gear.

1 2
Insert crankshaft protector to outer end of crank-
shaft and fully thread puller in magneto rotor.
1
F01B26A
1. Ring gear blocking tool (P/N 295 000 134)

2. Retaining plate (P/N 295 000 154)
F01D7YA
TYPICAL
1. Puller
Tighten puller screw and at the same time, tap on

screw head using a hammer to release magneto
rotor from its taper.
Magneto Housing
F01D85A 1
To remove magneto housing no. 5, starter has to
1. Ring gear blocking tool with retaining plate be removed. Refer to STARTING SYSTEM.
Unscrew retaining screws no. 19, then withdraw
1 housing.
F07D0KA
1. Crankshaft position sensor
Using a suitable socket, unscrew retaining nut F07D0LA 1

no. 13 of magneto rotor COUNTERCLOCKWISE REMOVE SCREWS
when facing it. 1. Magneto housing
Ring gear is easily freed from crankshaft with pull-

er (P/N 420 976 235) and crankshaft protective cap
(P/N 420 876 557).
SMR2002-023_04_04A.FM 04-04-9
Section 04 ENGINE
Stator Assembly Remove oil pump shaft from magneto rotor nut.
787 RFI Engine
Remove holding plate and withdraw plug from
cover.
Unscrew bolts no. 20 and remove stator no. 9
from magneto cover.
3 1
F06D23A 1
1. Remove oil pump shaft
Rotor and Ring Gear

To remove the rotor no. 8 or the ring gear no. 3,
the crankshaft must be locked. For procedure, re-
F07D0MA 2 fer to BOTTOM END.
787 RFI ENGINE
If necessary, the magneto rotor can be removed
1. Holding plate without removing the ring gear. Remove the six
2. Stator assembly screws no. 17.
3. Remove screws
947 Engines
Cover
cover no. 1.
F06D0LA 1
1. Screw
To remove the ring gear/rotor assembly, unscrew

nut no. 13 counterclockwise when facing it.
F06D1RA 1 2
TYPICAL
1. Cover
2. Screw
04-04-10 SMR2002-023_04_04A.FM
Section 04 ENGINE
DI Models
CAUTION: Be careful after ring gear removal
not to bend the encoder wheel teeth. Also pay
attention when putting away. If you suspect a
bent tooth, refer to ENGINE MANAGEMENT for
inspection procedure.
All 947 Engines

Stator and Trigger Coil/CPS
(Crankshaft Position Sensor)
Loosen screws no. 20 and no. 21 to remove the
stator no. 9 and trigger coil no. 10 from the engine
F06D0MA 1 magneto cover.
1. Nut
The magneto rotor is easily freed from crankshaft

Install protective cap (P/N 290 877 414) to crank-
shaft.
Fully thread puller in magneto rotor.
CAUTION: Ensure to completely screw the puller
until it bottoms. Otherwise, not enough threads
would be engaged and damage may occur.
F06D0NA 1
1. Remove screws
CLEANING
Clean all metal components in a solvent.
CAUTION: Clean coils and magnets using only
a clean cloth.
Clean crankshaft taper and threads using acetone.
Apply the acetone on a rag first then clean the
crankshaft.
F06D0PA 1
1. Puller

SMR2002-023_04_04A.FM 04-04-11
Section 04 ENGINE
ASSEMBLY Magneto Flywheel and Ring Gear

717 Engine Apply Loctite 648 (green) to magneto flywheel
mating surface. Lay ring gear on a steel plate, then
Generating Coil heat with a propane torch in order to install it on
Strip end of old wire then crimp and solder on new magneto flywheel.
coil. Pay particular attention to position ring gear teeth
Apply Loctite 243 (blue) to screws no. 22 and in- chamfer side as per following illustration.
stall the new coil on armature plate.
Use magneto coil centering tool (P/N 420 876 922)
and install so that it fits around armature plate be-
fore tightening screws.
F01D3BA 1
1. Teeth chamfer
NOTE: Ensure that ring gear contacts magneto

flywheel flange.
F00D0AA
Whenever replacing either ring gear or magneto
1. Magneto coil centering tool (P/N 420 876 922) flywheel, Gun Kote must be applied to prevent
CAUTION: Before reinstalling the magneto, re- possible corrosion.
move the loose epoxy from harness. CAUTION: Always assemble magneto flywheel
and ring gear prior to apply Gun Kote. If not done
Battery Charging Coil correctly, ring gear won’t contact magneto fly-
wheel flange.
Position new coil, crimp and solder all wires.
To apply Gun Kote proceed as follows:
Prior to assembly, apply Loctite 243 (blue).
1. Clean thoroughly and degrease replacement
part using a non oil base solvent.
and install it so that it fits around armature plate
before tightening screws no. 23. 2. Apply coating in light thin coats using a spray
gun.
NOTE: Do not spray Gun Kote into magneto fly-
1 wheel threaded holes.
3. Bake parts in oven at 175°C (350°F) for 1 hour
to cure Gun Kote.
CAUTION: Do not eliminate Gun Kote heat cur-
ing time because it will lose all its resistance
and it will not give any protection.
Magneto Housing
Install gasket no. 24 between magneto housing
F00D0AA no. 5 and engine crankcase.
1. Magneto coil centering tool (P/N 420 876 922) Install magneto housing and torque screws no. 16
to 9 N•m (80 lbf•in).
04-04-12 SMR2002-023_04_04A.FM
Section 04 ENGINE
Armature Plate Magneto Flywheel

Position the armature plate on the crankcase, Apply Loctite 243 (blue) on crankshaft taper.
aligning the marks on both parts. Position Woodruff key and magneto flywheel. Ap-
When reinstalling armature plate on a new crank- ply Loctite 243 (blue) on nut no. 13. Install nut with
case housing, proceed as follows. lock washer and torque to 145 N•m (107 lbf•ft).
Find manufacturer’s mark on armature plate. In CAUTION: Never use any type of impact wrench
line with this mark, punch another mark on adja- at magneto installation.
cent crankcase lug.
Ignition Timing
2 1
For ignition timing procedures of the 717 engine,
refer to IGNITION SYSTEM.
Magneto Housing Cover

Properly install O-ring no. 25 in magneto housing. Ap-
ply Loctite 767 anti-seize on screws no. 11, install
cover and wire support no. 12. Torque screws no. 11
in a criss-cross sequence to 9 N•m (80 lbf•in).
F01D4FA
TYPICAL 787 RFI Engine

1. Manufacturer’s mark on armature plate
2. Punch a mark on crankcase lug aligned with plate mark Stator
The new mark on crankcase will be used for fur- Install the stator no. 9 in magneto housing cover
ther assembly positioning as a pre-timing position. no. 1 and torque screws no. 20 to 9 N•m (80 lbf•in).
Install wiring harness bracket no. 26 of stator and
torque screws no. 27 to 4 N•m (35 lbf•in).
1 2
F01D4GA
F06D0CA
TYPICAL
1. Stator screws
1. For further assembly, use these marks 2. Bracket
Apply a drop of Loctite 243 (blue) on threads of
screws no. 15 and torque to 6 N•m (53 lbf•in).
SMR2002-023_04_04A.FM 04-04-13
Section 04 ENGINE
Magneto Housing Crankshaft Position Sensor

To install oil seal no. 28 of magneto housing no. 5, Install crankshaft position sensor no. 18 on mag-
use pusher (P/N 290 877 740) and handle (P/N 420 neto housing. Torque screw to 9 N•m (80 lbf•in).
877 650). NOTE: The crankshaft position sensor is not ad-
justable.
2 Cover
1
Before installing cover, make sure oil pump shaft
is properly positioned.
Before installation, properly install O-ring no. 25 in
engine magneto cover no. 1.
Apply Loctite 767 anti-seize compound on screws
no. 11. Torque screws in a criss-cross sequence
947 Engine
F01B2NA
1. Pusher
2. Handle Install the stator no. 9 and trigger no. 10 coil in
engine magneto cover. Torque screws to 9 N•m
(80 lbf•in).
Reinstall wiring harness bracket no. 29 using tap-
tite screws no. 16.
Torque trigger coil screws no. 21 to 9 N•m (80 lbf•in).
Torque stator screws no. 20 to 13 N•m (115 lbf•in).
NOTE: The trigger coil is not adjustable.
F04D0CA

and engine crankcase.
Install magneto housing and torque screws no. 19
Rotor and Ring Gear 1 2 3

F06D0NB
Apply Loctite 243 (blue) on crankshaft taper.

1. Torque to 9 N•m (80 lbf•in)
Install ring gear on crankshaft. 2. Taptite screws
Apply Loctite 243 (blue) on nut no. 13. Install nut
with lock washer no. 14 and torque to 120 N•m
(89 lbf•ft).
CAUTION: Never use any type of impact wrench
at magneto installation.
04-04-14 SMR2002-023_04_04A.FM
Section 04 ENGINE
Cover
Rotor and Ring Gear

Apply Loctite 648 (green) on mating surface of the
rotor no. 8.
When reinstalling rotor to ring gear no. 3, one of F06D24A 1
the protrusion end of rotor must be aligned with
1. Loctite 243 (blue) on crankshaft taper
hole in ring gear.
Install flywheel and make sure to align keyway
1 2 with the crankshaft Woodruff key.
with lock washer and torque to 115 N•m (85 lbf•ft).
CAUTION: Never use any type of impact wrench.
Unlock crankshaft. Reinstall pulse fitting with wash-
er and torque to 19 N•m (14 lbf•ft).
Cover
F15D01A
1. Protrusion
2. Hole DI Models
Apply Loctite 648 (green) on screws no. 17 retain- If heat exchanger cover has been removed, en-
ing rotor to ring gear and torque screws in a criss- sure to align its notch with the emboss in casing.
cross sequence to 13 N•m (115 lbf•in).
1
F12R0EA
1. Align notch with the emboss
SMR2002-023_04_04A.FM 04-04-15
Section 04 ENGINE
Subsection 05 (TOP END)
TOP END 0
717 Engine
24 Nm
(17 lbfft)
14 Loctite 243
Molykote 111
5
4
7
8
11
12 3
3
4
12 5
6
Engine
oil 6
24 Nm
(17 lbfft) 2
13 Engine
24 Nm oil
(17 lbfft)
Molykote 111 13
Loctite 243
Molykote 111
Loctite 243
10
F17D02S
SMR2002-024_04_05A.FM 04-05-1
Section 04 ENGINE
787 RFI Engine
Loctite
7 243 14 27 Nm
(17 lbfft)
8 Molykote
5 111
4
3
5 1
(34 rollers) 11
6
12
Engine oil 12
15
Molykote
111
Molykote
30 111
18
16 17 19
13
40 Nm
Loctite 243 (30 lbfft)
20 21
3 Nm
(27 lbfin)
Molykote 111
29 27 24 23 22 9
8
26 Molykote 111
25
10 Nm 10
(89 lbfin)
F07D0US
04-05-2 SMR2002-024_04_05A.FM
Section 04 ENGINE
34 Nm 14
7 (25 lbfft)
Loctite 243
8
Molykote
5 111 Molykote 111 34 Nm
(25 lbfft)
33
3 2
4 Loctite 243
5
6
Engine oil
34
31
15
Molykote 111 32
15 Nm
Molykote (133 lbfin)
30 111
18
16 17 19
20 21
3 Nm 9
(27 lbfin)
28 25
29 27 24 23 22
10
26 Loctite 243
10 Nm
(89 lbfin)
F08D0BS
SMR2002-024_04_05A.FM 04-05-3
Section 04 ENGINE
947 DI Engine
7
8 14 40 Nm
Loctite (30 lbfft)
243
Molykote 111
3
Engine oil
4
5
6
Engine oil
2
34
13
40 Nm
15 (30 lbfft) Molykote
111
3 Nm
18 (27 lbfin)
16 17 19 20 Loctite
243
9
Molykote 111 25
24 23 22
26 Loctite 243 10
10 Nm
(89 lbfin)
F12D0TS
04-05-4 SMR2002-024_04_05A.FM
Section 04 ENGINE
GENERAL 2 1 3
The 2-stroke ROTAX engine rotates counterclock-
wise seen from the rear (PTO flywheel).
The 717 and 787 RFI engines have a rotary valve
to control opening and closing of the intake. The
947 engine uses reed valves in the crankcase.
The 787 RFI and 947 engines are also equipped
with the RAVE system (Rotax Adjustable Variable
Exhaust).
CAUTION: No engine components can be inter-
changed between engines.
RAVE System
(Rotax Adjustable Variable Exhaust)
F06D3BA
BASIC OPERATION
1. Solenoid
The RAVE valves change the height of the exhaust 2. Pressure hose from crankcase
3. To atmospheric pressure
port. The RAVE valve solenoid, which is controlled
by the MPEM, allows either positive crankcase NOTE: A check valve on the pressure line elimi-
pressure (787 RFI and 947 with carburetor) or a nates the negative pressure from the crankcase.
pressure from the air compressor (947 DI) to in- To close the RAVE valves, the MPEM deactivates
flate the bellows and open the RAVE valves. the solenoid which blocks the crankcase positive
Carburetor-Equipped Engines pressure. The RAVE valves are opened to the at-
mosphere.
On top of the RAVE, there is a red plastic adjust-
ment knob. Turning the adjustment in or out 4
changes the preload on the return spring which, in
turn, will change the RPM at which the RAVE valve
opens and closes. On 947 engines, the spring pre-
load does not have a significant effect on the valve 3 5
operation. 2
787 RFI and 947 Carburetor-Equipped Engines
On these engines, the RAVE valves are controlled
by the Multi-Purpose Electronic Module (MPEM).
To open the RAVE valves, the MPEM activates a
solenoid which directs the positive pressure from
engine crankcase to the valves.
1
F06D16A
RAVE VALVE OPENED

1. Pulse from crankcase
2. Check valve
3. Positive pressure to solenoid
4. Solenoid activated
5. Positive crankcase pressure to RAVE valves
SMR2002-024_04_05A.FM 04-05-5
Section 04 ENGINE
4 4 5 6
3
2
1
F06D16B
F12D15A 1 2 3
RAVE VALVE CLOSED
1. Solenoid
1. Pulse from crankcase 2. Pressure from air compressor
2. Check valve 3. Pressure to RAVE valves
3. Positive pressure blocked by the solenoid 4. Vent to air intake silencer
4. Solenoid deactivated 5. Check valve
5. RAVE valves are opened to atmosphere 6. Vent from counterbalancing shaft oil cavity
947 DI Engine To close the RAVE valves, the MPEM deactivates the
To open the RAVE valves, the MPEM activates a solenoid which blocks the air compressor pressure.
solenoid which directs the pressure from air com- The RAVE valves are opened to the atmosphere.
pressor to the valves. The vent on couterbalancing shaft oil cavity is nec-
essary to prevent pressure buildup in the cavity by
1
the air compressor piston movement. The check
valve allows pressure to escape from the cavity
but does not allow liquid to enter into the cavity.
F12D02A
1. Pressure from solenoid
04-05-6 SMR2002-024_04_05A.FM
Section 04 ENGINE
MAINTENANCE
3 There are no wear parts anywhere in the system
2
and there are no adjustments to be periodically
checked. The only possible maintenance required
4 would be cleaning of carbon deposits from the
guillotine slide. Cleaning intervals would depend
upon the user’s riding style and the quality of the
oil used. We suggest annual cleaning of the valve.
If a customer uses a lower quality oil, than recom-
mended, 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 cyl-
1 inder. This is the minimum production clearance.
F12D04A
There is only a first oversize piston available for the
RAVE VALVE OPENED
787 RFI and 947 engines. That piston is 0.25 mm
1. Pressure from air compressor
2. Solenoid activated (.010 in) larger in diameter than the stock piston.
3. Pressure to solenoid When the oversize is installed, the guillotine will
4. Pressure to RAVE valves
have a minimum clearance of 0.375 mm (.015 in)
with the cylinder bore. This is the minimum oper-
3 ating clearance the guillotine should be used with.
2 Clearance less than 0.375 mm (.015 in) will require
reworking of the guillotine to achieve the proper
clearance and radius.
4
6 DISASSEMBLY
RAVE Valve
7 787 RFI and 947 Carburetor-Equipped Engines
Loosen Allen screws no. 26 each side of RAVE valve.
5
1
F12D05A
RAVE VALVE CLOSED

2. Solenoid deactivated
3. Pressure to solenoid
4. Pressure to RAVE valves blocked by the solenoid
5. Vent to air intake silencer
6. Check valve
7. Counterbalancing shaft oil cavity vent
F06D0QA 1
1. Remove screws
SMR2002-024_04_05A.FM 04-05-7
Section 04 ENGINE
Remove RAVE valve no. 15. NOTE: The following procedures relates the steps
Remove the cover no. 18 of the valve by releasing for the 787 RFI and 947 carburetor-equipped en-
the spring no. 16. gines. The DI engine is explained below.
Remove spring no. 30 retaining bellows no. 21 to
 WARNING valve piston no. 20.
Firmly hold cover to valve base. The com-
pression spring inside the valve is applying
pressure against the cover.
F06D0SA 1
1. Spring
Free bellows no. 21 from valve piston no. 20.

F06D0RA 1
1. Spring
Remove the compression spring no. 19.
F06D0TA 1
1. Bellows removed from piston
F06D25A 1
1. Remove spring
04-05-8 SMR2002-024_04_05A.FM
Section 04 ENGINE
Unscrew valve piston no. 20 from sliding valve Remove supporting ring no. 28.
no. 22.
1
NOTE: Hold the sliding valve to prevent it from
turning.
F06D27A
1. Remove supporting ring

F06D0TB 1 2
Remove O-ring no. 23.
1. Unscrew piston
2. Hold sliding valve
Remove compression spring no. 29.
F06D28A
1
1. Remove O-ring
A06D26A 1
1. Remove spring
SMR2002-024_04_05A.FM 04-05-9
Section 04 ENGINE
Remove sliding valve no. 22.
F06D0UA 1
F12D0UA 1 1
1. Remove sliding valve
1. Remove screws
Remove bellows no. 21.
Remove RAVE valve no. 15.
1 Remove the cover no. 18 of the valve by releasing
the spring no. 16.
 WARNING
F06D0VA
1. Remove bellows
947 DI Engine
F12D0VA 1
1. Spring
04-05-10 SMR2002-024_04_05A.FM
Section 04 ENGINE
Remove the compression spring no. 19. Remove sliding valve from valve housing.
F12D0YA 1 2 3
1. Valve piston
2. Valve housing
3. Sliding valve
Cylinder Head Cover and Cylinder Head

F12D0WA 1 Disconnect temperature sensor wire and spark
plug cables.
1. Remove spring
Connect spark plug cables on grounding device.
Unscrew valve piston no. 20 from sliding valve
no. 22. 717 Engine
NOTE: Hold the sliding valve to prevent it from Remove air intake silencer and support, refer to
turning. AIR INTAKE.
2 717 and 787 RFI Engines
Remove screws no. 14.
Remove cylinder head cover no. 1.
If shells, sand, salt or any other particles are present
in cylinder head, clean with a vacuum cleaner.
Remove cylinder head no. 2.
If shells, sand, salt water or any other particles are
present in cylinder cooling jacket, clean with a vac-
uum cleaner.
947 Engines
Disconnect hose of RAVE valves.
On DI engines, remove air/fuel rail. Refer to EN-
GINE MANAGEMENT.
F12D0XA 1
1. Unscrew piston
2. Hold sliding valve
SMR2002-024_04_05A.FM 04-05-11
Section 04 ENGINE
947 Carburetor-Equipped Engines Remove cylinder head no. 2.

NOTE: Due to the cylinder mounting studs, it is Remove cylinder head gasket no. 34.
recommended to remove the engine from the hull
to service the top end. However, one might unfas-
ten the engine support to allow leaning the engine
so that cylinder can be pulled out.
Loosen cylinder head bolts no. 14 following the
sequence shown in the next photo.
6 4 2
F06D0YA 1
1. Remove gasket
947 DI Engine
Use Snap-On Torx socket E12 and unscrew cylin-
der head screws no. 14 following the sequence
F06D0WA 5 1 3 7 shown in the next illustration.
UNTORQUING SEQUENCE FOR THE CYLINDER HEAD BOLTS 1
5
Loosen nuts no. 33 following the sequence shown 2 11
in the next photo.
6 9 10 8
5 2 4 7 12
4
7
3
F12D08B
Remove cylinder head no. 2 and gasket no. 34.
Cylinder
NOTE: When removing cylinder, be careful that
connecting rods do not hit crankcase edge.
F06D29A 6 3 1 8 787 RFI Engine
UNTORQUING SEQUENCE FOR THE NUTS Remove air intake silencer and support, refer to
AIR INTAKE.
Remove tuned pipe and exhaust manifold, refer to
EXHAUST SYSTEM.
Remove screws no. 13.
04-05-12 SMR2002-024_04_05A.FM
Section 04 ENGINE
Remove cylinders no. 9, being careful that con- NOTE: To ease removal, a plastic tip hammer can
necting rods do not hit crankcase edge. be used.
Remove cylinder base gasket no. 10.
 WARNING
If screws need to be heated for removal when 947 DI Engine
engine is in watercraft, fuel system pressuriza- Remove cylinders screws then cylinders no. 9.
tion must be done first. Do not use open flame;
use a heat gun. Piston
NOTE: All engines feature cageless piston pin
NOTE: Even if only 1 cylinder needs repair, both
bearings.
cylinders should be lifted to allow 1-piece cylinder
base gasket replacement. 717 and 787 RFI Engines
947 Carburetor-Equipped Engines Bring piston to Top Dead Center and install rubber
pad (P/N 295 000 101) over crankcase opening.
Remove studs no. 32. Take two head cover nuts.
Secure with screws. Lower piston until it sits on
Screw nuts onto stud. Lock both nuts together
pad.
and unscrew the stud. Repeat this operation for
the other studs. 1
NOTE: Studs must be removed prior cylinder block.
F01B0JA
1. Rubber pad (P/N 295 000 101)
If the other cylinder has been removed, complete-

ly cover its opening with a clean rag.
F06D2BA 1
1. Remove studs
Remove cylinder block no. 9.
F01D43A
1. Openings covered with rag and rubber pad
F06D0ZA 1
1. Remove cylinder block
SMR2002-024_04_05A.FM 04-05-13
Section 04 ENGINE
947 Engines To extract piston pin no. 4, use piston pin puller
Install rubber pad (P/N 290 877 032) to crankcase. (P/N 529 035 503) with the appropriate set of
Secure with screws. Lower piston to be removed sleeves.
until it sits on pad.
ENGINE SLEEVE SET
717/787 RFI P/N 529 035 542
947 P/N 529 035 543
1 2 3
F06B06B 1
1. Rubber pad (P/N 290 877 032)
All Engines
To remove circlip no. 5, insert a pointed tool in pis-
ton notch then pry it out and discard.
F00B0IA
 WARNING 1. Puller
2. Shoulder sleeve
Always wear safety glasses when removing 3. Sleeve
piston circlips.
– Fully thread on puller handle.
– Insert extractor spindle into the piston pin.
– Slide the sleeve and shoulder sleeve onto the
spindle.
– Screw in extracting nut with the movable ex-
tracting ring towards spindle.
1 2 3 4
F01D0PA
TYPICAL
1. Piston notch
F00B0JA
1. Puller
2. Sleeve
3. Shoulder sleeve
4. Extracting nut
04-05-14 SMR2002-024_04_05A.FM
Section 04 ENGINE
NOTE: The tool cutout must be positioned toward – Loosen the extracting nut and remove puller.
the bottom of the piston. – Remove the shoulder sleeve from piston.
1
F00B0KA 1
F00B0MA
1. Tool cut-out toward bottom of piston
1. Remove shoulder sleeve
– Firmly hold puller and rotate handle to pull pis-
ton pin no. 4. – Carefully remove the piston no. 3.
– Rotate spindle until the shoulder sleeve is – The needles, thrust washers and the sleeve re-
flushed with the piston recess. main in the connecting rod bore and may be
used again.
1
1 2
F00B0NA
F00B0LA 1. Needles and thrust washer

2. Sleeve
1. Shoulder sleeve flush with piston recess
SMR2002-024_04_05A.FM 04-05-15
Section 04 ENGINE
CLEANING The inspection of engine top end should include

the following measurements.
Discard all gaskets and O-rings.
TOLERANCES
Clean all metal components in a solvent. ENGINE
MEASUREMENT NEW PARTS WEAR
Clean water passages and make sure they are not (min.) (max.) LIMIT
clogged.
0.05 mm 0.1 mm
Remove carbon deposits from cylinder exhaust Cylinder taper N.A.
(.002 in) (.004 in)
port, RAVE valve (787 RFI and 947 engines), cyl-
inder head and piston dome. 0.008 mm 0.08 mm
Cylinder out of round N.A.
(.0003 in) (.003 in)
Clean piston ring grooves with a groove cleaner
tool, or a piece of broken ring. Piston/cylinder wall
0.10 mm 0.20 mm
clearance for the N.A.
(.0039 in) (.008 in)
717 engine
INSPECTION Piston/cylinder wall
0.13 mm 0.22 mm
Visually inspect all parts for corrosion damage. clearance for the N.A.
(.005 in) (.009 in)
787 RFI engine
Inspect piston for damage. Light scratches can be
sanded with a fine sand paper. Piston/cylinder wall
0.09 mm 0.20 mm
NOTE: When repairing a seized engine, connect- (.0035 in) (.008 in)
947 engine
ing rods should be checked for straightness and
crankshaft for deflection/misalignment. Refer to Piston/cylinder wall
0.12 mm 0.20 mm
BOTTOM END for procedures. 947 DI engine
(.0047 in) (.008 in)
Inspect plane surfaces for warpage. Small defor- Ring/piston groove
mation can be corrected by grinding surface with 0.025 mm 0.070 mm 0.20 mm
clearance for the
a fine sand paper. Install sand paper on a surface (.001 in) (.0027 in) (.008 in)
717 engine
plate and rub part against oiled sand paper.
Ring/piston groove
0.025 mm 0.070 mm 0.24 mm
clearance for the
(.001 in) (.0027 in) (.009 in)
787 RFI engine
Ring/piston groove
0.048 mm 0.075 mm 0.20 mm
clearance for the
(.002 in) (.0029 in) (.008 in)
947 engine
Ring/piston groove
0.044 mm 0.089 mm 0.20 mm
clearance for the
(.002 in) (.003 in) (.008 in)
947 DI engine
Ring end gap for the 0.25 mm 0.40 mm 1.0 mm
717 engine (.010 in) (.016 in) (.039 in)
787 RFI engine (.016 in) (.022 in) (.039 in)
947 engine (.018 in) (.024 in) (.039 in)
947 DI engine (.022 in) (.028 in) (.043 in)
N.A.: Not Applicable
04-05-16 SMR2002-024_04_05A.FM
Section 04 ENGINE
NOTE: Replacement cylinder sleeves are avail-

able if necessary. Also, oversize pistons of 0.25
mm (.010 in) are available for all engines and over-
size pistons of 0.5 mm (.020 in) are available for
the 717 engine.
Cylinder Taper
Using a cylinder bore gauge, measure cylinder diam-
eter at 16 mm (5/8 in) from top of cylinder just below
auxiliary transfer port, facing exhaust port and just be-
low the auxiliary transfer port facing the exhaust port. A A
Compare readings. If the difference between read- 2
ings exceed specification, cylinder should be rebored
and honed or replaced.
F01D8BA
1. Measuring in piston pin axis

2. Measuring perpendicularly (90°) to piston pin axis
A. 16 mm (5/8 in)
1 USED PISTON MEASUREMENT

Note the measurement on the piston dome.
A
F01D8AA 2
2. Auxiliary transfer port
A. 16 mm (5/8 in)
Cylinder Out of Round

Using a cylinder bore gauge, measure cylinder di-
ameter at 16 mm (5/8 in) from top of cylinder. Mea-
sure diameter in piston pin axis direction then per-
pendicularly (90°) to it. If the difference between F00D0EA 2 1
readings exceed specification, cylinder should be 1. Piston dome
rebored and honed or replaced. 2. Piston measurement
SMR2002-024_04_05A.FM 04-05-17
Section 04 ENGINE
Using a micrometer, measure piston skirt perpen-

dicularly (90°) to piston pin according to the follow-
ing table.
MAXIMUM A
ENGINE TYPE
mm (in)
717 29 (1.142)
787 RFI 28 (1.102)
947 28 (1.102)
947 DI 24 (0.945)
F00D0EA 2 1
1. Piston dome
2. Piston measurement
A Adjust and lock a micrometer to the specified val-

ue on the piston dome.
1
F01D0NA

A. See previous table
F00B08A
MAXIMUM PISTON SKIRT
ENGINE TYPE WEAR 1. Micrometer set to the piston dimension
mm (in)
With the micrometer set to the piston dimension,
All 0.12 (.005) adjust a cylinder bore gauge to the micrometer di-
mension and set the indicator to zero.
The measured dimension must not be less than
0.12 mm (.005 in) of the one scribed on piston
dome. Otherwise, install a new piston.
Piston/Cylinder Wall Clearance

Used and New Pistons 2 1
IMPORTANT: Make sure used piston is not worn
more than specified. See USED PISTON MEA-
SUREMENT above.
To determine the piston dimension, take the mea-
surement on the piston dome.
F00B09A
1. Use the micrometer to set the cylinder bore gauge

2. Dial bore gauge
04-05-18 SMR2002-024_04_05A.FM
Section 04 ENGINE
1 2
1 F01D0XA
1. Feeler gauge
F00B0AA 2. Rectangular ring (bottom)
1. Indicator set to zero 947 Engines

Position the dial bore gauge at 16 mm (5/8 in) be- Due to the semi-trapez rings, it is not possible to
low cylinder top edge. accurately measure ring/piston groove clearance.
Ring End Gap

Position ring halfway between exhaust port and
top of cylinder.
NOTE: In order to correctly position ring in cylin-
der, use piston as a pusher.
Using a feeler gauge, check ring end gap. If gap
1 exceeds specified tolerance, rings should be re-
placed.
A
F01D0KA

A. 16 mm (5/8 in)
Read the measurement on the cylinder bore gauge.

The result is the exact piston/cylinder wall clearance.
NOTE: Make sure the cylinder bore gauge indica-
tor is set exactly at the same position as with the 2
micrometer, otherwise the reading will be false.
Ring/Piston Groove Clearance F01D0OA 1

717 and 787 RFI Engines 1. Top of cylinder
2. Ring end gap
Using a feeler gauge, check clearance between
rectangular ring and groove. If clearance exceeds
specified tolerance, replace piston.
NOTE: Ring/piston groove clearance can be cor-
rectly measured only on rectangular ring which is
bottom ring.
SMR2002-024_04_05A.FM 04-05-19
Section 04 ENGINE
Cylinder Base Gasket RAVE Valve

NOTE: The general procedure is to install a new 787 RFI Engine
gasket of the same thickness. However, if you do Make sure to insert O-ring no. 23 onto rod of slid-
not know the gasket thickness that was installed ing valve no. 22.
or if a crank repair has involved replacement of
connecting rods, refer to the COMBUSTION CHAM- The TOP position of the sliding valve no. 22 is in-
BER VOLUME MEASUREMENT to properly deter- dicated on one side.
mine the required gasket thickness.
Different thicknesses of cylinder base gaskets are
used for a precise adjustment of the combustion
chamber volume.
To identify gasket thickness, refer to the identifi-
cation holes on the gasket.
3 2
F01D8KA
1
1. Sliding valve
2. O-ring
3. TOP
Install a new gasket no. 24. It must be installed at

the same time as the sliding valve no. 22.
F01D67A
Position the valve housing no. 25 onto the cylinder
TYPICAL so that its opening is toward the bottom.
1. Identification holes
All Engines
GASKET IDENTIFICATION
THICKNESS HOLES
0.3 mm (.012 in) 3
0.4 mm (.016 in) 4
0.5 mm (.020 in) 5
0.6 mm (.024 in) 6
0.8 mm (.031 in) 8
F01D8JB 1
RAVE Valve 1. Bottom of valve housing
787 RFI and 947 Engines When the valve is mounted onto the cylinder,
Check RAVE valve bellows no. 21 for cracks. move the valve piston no. 20 to ensure the sliding
valve no. 22 moves easily and doesn’t stick.
ASSEMBLY
Assembly is essentially the reverse of disassem-
bly procedures. However pay particular attention
to the following.
04-05-20 SMR2002-024_04_05A.FM
Section 04 ENGINE
Check the sliding valve O-ring. Replace if neces-

sary.
F01D8LA
F12D10A 1
1. Sliding valve O-ring
947 Carburetor-Equipped Engines Check the O-ring under valve housing. Replace if
Install the supporting ring no. 28 with the bevel necessary.
side facing the O-ring no. 27.
F06D11A
1. Bevel facing the O-ring
947 DI Engines F12D11A 1

Check the piston valve O-ring. Replace if neces- 1. Valve housing O-ring
sary. All RAVE-Equipped Engines
There is only one way to insert the sliding valve
no. 22 in valve housing no. 25.
F12D0ZA 1
1. Piston valve O-ring
SMR2002-024_04_05A.FM 04-05-21
Section 04 ENGINE
– Replace the inner halves by the appropriate

sleeve tool in the connecting rod bore.
– Insert piston pin into piston until it comes flush
with inward edge of piston hub.
– Warm piston to approximately 50 - 60°C (122 -
140°F) and install it over connecting rod.
NOTE: Make sure thrust washers are present each
1 side of needles.
– Install the shoulder sleeve tool on the opposite
side of the piston pin.
1 2
F06D12A
1. Sliding valve ridge toward housing groove
Piston
At assembly, place the pistons no. 3 with the let-
ters “AUS” (over an arrow on the piston dome)
facing in direction of the exhaust port.
F00B0OA
1
AUS 1. Piston pin
2. Shoulder sleeve
– Insert extractor spindle into the piston pin,

screw on extracting nut.
A01C01A
2 1
1. Exhaust side
NOTE: On the 787 RFI and 947 engines, the ex-

haust ports are located on the same side as the
intake.
Carefully cover crankcase opening as for disas-
sembly.
Piston Pin and Roller Bearing

To install roller bearing no. 4 and piston pin no. 6 F00B0PA
use, piston pin puller (P/N 529 035 503) with the
appropriate set of sleeves as for disassembly. 1. Puller installed on the opposite side of the piston pin
2. Tighten extracting nut
– Replacement bearings are held in place by a lo-
cating sleeve outside and 2 plastic cage halves – Rotate handle to pull piston pin carefully into the
inside. piston.
– Push needle bearing together with inner halves
out of the locating sleeve into the connecting
rod bore.
04-05-22 SMR2002-024_04_05A.FM
Section 04 ENGINE
Plastic Mounting Device Method – Insert piston pin into piston until it comes flush
This is an alternate method when no service tool with inward edge of piston hub.
is available.
Replacement roller bearings are delivered in a con-
venient plastic mounting device. For installation,
proceed as follows: 1
– Align replacement roller bearing with connect-
ing rod bore.
– Carefully push inner plastic sleeve into connect-
ing rod bore; outer plastic ring will release rollers.
2
1
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 oppo-
site side. Support piston from opposite side.
F01D0Q A
1. Outer ring removal after inner sleeve insertion into bore
– Make sure thrust washers are present each

side of rollers.
F01D0SA
1
– As necessary, pull halves of inner sleeve with
long nose pliers.
F01D0VA
1. Thrust washer each side
SMR2002-024_04_05A.FM 04-05-23
Section 04 ENGINE
947 Engines
Secure circlip in piston groove with its bent end in
piston notch as shown.
F01D0TA
1. Pulling inner sleeve half

1
Circlip F07D0AB
Always use new circlips. 1. Circlip end in piston notch
 WARNING All Engines

Always wear safety glasses when installing To easily insert circlip into piston, use circlip installer.
piston circlips. ENGINE TOOL P/N
CAUTION: Always use new circlips. At installa- 717 and 787 RFI 529 035 562
tion, take care not to deform them. Circlips 947 529 035 563
must not move freely after installation.
Secure circlip with its opening located at the bot-
tom of the piston.
CAUTION: To minimize the stress on the cir-
clips, it is important to install them as described.
F06B01A 1
1. Circlip installer
– Remove sleeve from pusher then insert circlip

into its bore.
– Reinstall sleeve onto pusher and push until cir-
clip comes in end of tool.
F06D18A 1
1. Circlip opening at 6 o’clock (at bottom)
F00B0QA
TYPICAL
1. Circlip near end of tool
04-05-24 SMR2002-024_04_05A.FM
Section 04 ENGINE
– Position end of tool against piston pin opening. NOTE: Ring compressor will not fit on oversize
– Firmly hold piston against tool and tap tool with parts.
a hammer to insert circlip into its groove. Make sure to align ring end gap with piston locat-
ing pin. Slide tool over rings.
1
F00B0RA F01D0ZA
1. Ring end gap aligned with piston locating pin

CAUTION: The hand retaining the piston should
absorb the energy to protect the connecting rod. Slide cylinder over piston.
Cylinder Base Gasket

Install new base gasket.
NOTE: The general procedure is to install a new
gasket of the same thickness. However, if you do
not know the gasket thickness that was installed
or if a crankshaft and/or crankcase repair or re-
placement was involved, refer to the COMBUS-
TION CHAMBER VOLUME MEASUREMENT to
properly determine the required gasket thickness.
Five thicknesses of cylinder base gaskets are
available for a precise adjustment of the squish
gap.
To identify gasket thickness, refer to the identifi- F01D10A

When reassembling cylinders to crankcase, it is
Cylinder important to have them properly aligned so that
exhaust flanges properly match up with exhaust
717 and 787 RFI Engines manifold.
To easily slide cylinder no. 9 over piston, install on
piston ring compressor (P/N 290 876 979).
A01B1TA 1
1. Slide this edge
SMR2002-024_04_05A.FM 04-05-25
Section 04 ENGINE
717 Engine
The aligning tool (P/N 420 876 904) or the exhaust
manifold can be used to align cylinders.
F00D0FA 1
787 RFI ENGINE
1. Aligning cylinders using exhaust manifold
F01D44A 1 Cylinder Block

717 ENGINE 947 Carburetor-Equipped Engine
1. Exhaust flange aligning tool
Install studs no. 32. Apply Molykote 111 to threads
and torque studs to 15 N•m (133 lbf•in). Refer to
1 exploded view to see what end to insert in crank-
case.
Remove O-rings from studs.
All 947 Engines
Install cylinder base gasket no. 10. There is only
one way to install gasket.
The cylinder block is positioned with locating dowels.
Line up dowels with corresponding holes in cylin-
der block.
1
F01D45A
717 ENGINE
1. Aligning cylinders using exhaust manifold
787 RFI Engine

The exhaust manifold is used to align cylinders.
F02D0UA 1
1. Dowels
04-05-26 SMR2002-024_04_05A.FM
Section 04 ENGINE
To easily slide cylinder block over pistons, use ring Torque screws in a criss-cross sequence for each
compressor (P/N 290 876 965). cylinder to 20 N•m (15 lbf•ft). Repeat the proce-
dure, retightening all cylinder screws to 40 N•m
(30 lbf•ft).
2 3 3 2
A01B1TA 1
1. Slide this edge
NOTE: For each ring, make sure to align ring end

gap with piston locating pin.
Install cylinder block.
Apply Molykote 111 on O-ring no. 31 and install it.
CAUTION: The O-rings must be installed and
properly positioned in the cylinder block. The
F01D7FA 4 1 1 4
O-rings are meant to dampen stud vibration.
Cylinder Screw 947 DI Engines

717 Engine Apply Molykote 111 below the screw head.
Apply Molykote 111 below the screw head. The blue coating underneath the cylinder screw
head can be only used once. Either replace with
Apply also Loctite 243 (blue) on screw threads. new bolts or remove blue coating and apply Loc-
Install and torque screws no. 13 in a criss-cross se- tite 243 (blue) below the screw heads.
quence for each cylinder to 24 N•m (17 lbf•ft). Refer Install and torque screws to 40 N•m (30 lbf•ft) in the
to the following illustration. indicated order. Refer to the following illustration.
1 4 1 4
7 2 3 5
6 4 1 8
3 2 3 2 F12D07A
F01D35A
All Engines
787 RFI Engine
Cylinder Head
Prior installation, apply Molykote 111 below screw
head and Loctite 243 (blue) on screw threads. Install cylinder head gasket.
Install M10 x 105 screws on exhaust side and the
M10 x 73.5 on opposite side.
SMR2002-024_04_05A.FM 04-05-27
Section 04 ENGINE
717 and 787 RFI Engines 947 DI Engine

Make sure to install O-rings no. 12 around spark Apply Loctite 243 (blue) below head of cylinder
plug holes and O-ring no. 11 of cylinder head as head bolts no. 14.
shown in the following illustration. Apply Molykote 111 on threads of cylinder head
bolts no. 14.
1
Torque bolts to 20 N•m (15 lbf•ft) as per following
sequence in the next picture. Repeat the torquing
sequence by retightening to 40 N•m (30 lbf•ft).
12
2 8
11 3
7 4
1 5
1 6 9
F01D5AA
10
1. O-rings
Apply Loctite 518 in O-ring groove of cylinder

sleeves. F12D08A
947 Carburetor-Equipped Engine

Apply Molykote 111 on the threads of the cylinder Cylinder Head Cover
block studs no. 32.
Apply Loctite 243 (blue) below head of cylinder
head bolts no. 14. Install cylinder head cover no. 1.
Apply Molykote 111 on threads of cylinder head Apply Loctite 243 (blue) below head of screws no. 14.
bolts no. 14. Apply also Molykote 111 on threads of screws no. 14.
Apply Loctite 243 under the head of the nuts Torque cylinder head screws no. 14 to 12 N•m
no. 33. (9 lbf•ft) as per following illustrated sequence. Re-
Torque bolts and nuts to 15 N•m (133 lbf•in) as peat the procedure, retightening all screws to 24
per following sequence in the next picture. Repeat N•m (17 lbf•ft).
the torquing sequence by retightening to 34 N•m
10 8 2 4 6 12
(25 lbf•ft).
7 12 1 10 8 3 14 6
F01D46A 9 7 3 1 5 11
F06D0WB 13 4 9 5 11 2 15 TORQUING SEQUENCE
TORQUING SEQUENCE
04-05-28 SMR2002-024_04_05A.FM
Section 04 ENGINE
ADJUSTMENT Combustion Chamber Volume

Measurement
RAVE Valve
All Engines
787 RFI Engine
NOTE: This procedure is required to determine
Turn the red plastic knob no. 17 until it is flush to the thickness of the cylinder base gasket to be in-
the valve cover. stalled if a crank repair has involved replacement
of connecting rods or if you are experiencing re-
1 petitive engine seizure.
The combustion chamber volume is the region in
the cylinder head above the piston at Top Dead
Center. It is measured with the cylinder head in-
stalled on the engine.
F00D0GA
1. Knob flush with the cover

F01D5VA
947 Carburetor-Equipped Engine
1. Combustion chamber
Turn the red plastic knob no. 17 until it is fully tight-
ened. NOTE: When checking the combustion chamber
volume, engine must be cold, piston must be free
1 of carbon deposit and cylinder head must be lev-
eled.
All Engines except 947 DI
1. Remove both spark plugs and bring one piston
to Top Dead Center a using a TDC gauge.
F00D0WA
1. Knob fully tightened
This will ensure the correct preload on the return

spring no. 19 in order to open and close the RAVE
valve at the proper RPM.
F01D2IA
1. Bring piston to TDC
SMR2002-024_04_05A.FM 04-05-29
Section 04 ENGINE
947 DI Engine NOTE: The liquid level in cylinder must not drop
1. Remove both direct injectors and bring one pis- for a few seconds after filling. If so, there is a leak
ton to Top Dead Center using a TDC gauge. between piston and cylinder. The recorded vol-
Keep spark plugs in their holes. ume would be false.
5. Let burette stand upward for about 10 minutes,
All Engines until liquid level is stabilized.
2. Obtain a graduated burette (capacity 0 - 50 cc) 6. Read the burette scale to obtain the quantity of
and fill with an equal part (50/50) of gasoline and liquid injected in the combustion chamber.
injection oil.
Compare the obtained value with the table below.
The volume should be within the allowable range.
If the volume of the combustion chamber is not
within specifications, change cylinder base gasket
thickness as follow.
A higher volume dictates a thinner gasket.
1 A lower volume dictates a thicker gasket.
All Engines except DI
NOTE: When the combustion chamber is filled to
top of spark plug hole, it includes an amount of
2.39 cc corresponding to the spark plug tip. The
following table of combustion chamber volume in-
cludes this value.
All Engines
F00B0BA
COMBUSTION CHAMBER
1. Graduated burette (0 - 50 cc) ENGINE
VOLUME
3. Open burette valve to fill its tip. Add liquid in
717 31.2 - 34.0 cc
burette until level reaches 0 cc.
4. Inject the burette content through the spark 787 RFI 34.7 - 37.9 cc
plug hole on all engines except 947 DI and
947 43.3 - 47.3 cc
through direct injector hole on DI engines until
liquid touches the top hole. 947 DI 45.7 - 48.4 cc
7. Repeat the procedure for the other cylinder(s).
F00D0HA 1
1. Top of spark plug hole
04-05-30 SMR2002-024_04_05A.FM
Section 04 ENGINE
Subsection 06 (BOTTOM END)
BOTTOM END 0
717 Engine
110 Nm Loctite 11

(81 lbfft) 518
1
Molykote
111
Anti-seize
lubricant
4
12
5
3
6 4
2
Loctite
6 642
Anti-seize
lubricant
12
4 Anti-seize
2 lubricant
5
Loctite
5910 Loctite
243
6
6
4
11
24 Nm 9
(17 lbfft) Molykote
111
Molykote Loctite
111 518
Loctite
518 Molykote
7 111
24 Nm
(17 lbfft) 10
10 Nm 8
(88 lbfin) 40 Nm
(30 lbfft)
F00D0YU
SMR2002-025_04_06A.FM 04-06-1
Section 04 ENGINE
787 RFI Engine
30 mL (1 oz)
SAE 30 Loctite 11
motor oil 518
110 Nm
(81 lbfft)
1 Anti-seize
lubricant
15 Molykote
111
5
4
6
18
2
13
Anti-seize 14 4
lubricant 6
12 16
Molykote 15
111 3
Anti-seize
lubricant Loctite
642
Anti-seize Anti-seize
lubricant lubricant
19 12
4
6
Molykote 2
111 4
Loctite Loctite
5910 243
6
Loctite
518
Molykote 11 Molykote
111 111
Anti-seize
40 Nm 8 Loctite Loctite lubricant
518 24 Nm
(30 lbfft) 518 7 (17 lbfft)
Molykote 111
7 Molykote 111
24 Nm
(17 lbfft) 8
9 Nm 40 Nm
(80 lbfin) (30 lbfft)
F07D0VS
Anti-seize lubricant
04-06-2 SMR2002-025_04_06A.FM
Section 04 ENGINE
20 Nm 40 mL
(15 lbfft) (1.35 oz)
Molykote SAE 30
111 motor oil
14
16 2
15 17
13
Molykote
111
4 6 Molykote
111 Loctite 243
1.5 Nm
6 (13 lbfin)
31
5 3 32
17 29
28
15
16 30
4 Loctite
Loctite 243 Molykote
243 4 111
6
Anti-seize
lubricant 9 Nm
6 Loctite (80 lbfin)
648 Loctite
Loctite Anti-seize 1 243
243 Molykote lubricant 115 Nm
111 Loctite (85 lbfft)
24 5910 23 Nm
9 4 22
(17 lbfft) Loctite
Molykote 5 648
7 Nm 111 2
(62 lbfin)
25 Loctite 20
243 21
27 21
23 20 XP
Loctite only
518 Synthetic
7 7 grease
7 7 Loctite 518 23 Nm
Molykote Molykote 111 (17 lbfft)
111 27 Nm Loctite Loctite
(20 lbfft) 518 518 8 27 Nm (20 lbfft)
Molykote 40 Nm (30 lbfft)
111 20 Nm 8
(15 lbfft) Molykote 111
27 Nm 40 Nm
F06D3IS (20 lbfft) (30 lbfft)
SMR2002-025_04_06A.FM 04-06-3
Section 04 ENGINE
947 DI Engines
1.5 Nm
(13 lbfin)
28 Loctite
243
29
Loctite 243
30 9 Nm
(80 lbfin) 2
Molykote
111
6 Molykote
Loctite 111
243 14
6
5 16
4 15 17 13
Anti-seize Molykote
4 lubricant 31 111
32
7 Nm Loctite 243 15 Engine
(62 lbfin) Anti-seize oil
6
lubricant Molykote
Loctite
243 3 111
6 13
9 2 1 Loctite
Molykote 648
24 111 4
Loctite Synthetic 6.5 Nm
5910 grease (58 lbfin)
25 4 22 20 Loctite
27 648
5
23
Loctite 21
Loctite 243
518 115 Nm 23 Nm
7 (17 lbfft)
7 (85 lbfft)
Molykote 7
111 27 Nm 27 Nm
8 (20 lbfft)
(20 lbfft) 20 Nm
(15 lbfft)
8 40 Nm
Anti-seize (30 lbfft)
lubricant
6.5 Nm
F12D12S
(58 lbfin)
04-06-4 SMR2002-025_04_06A.FM
Section 04 ENGINE
DISASSEMBLY 1
Engine has to be removed from watercraft and top
end has to be disassembled to open bottom end.
Refer to REMOVAL AND INSTALLATION and TOP
END.
PTO Flywheel
717 Engine F00D0ZA
To remove PTO flywheel no. 1, the crankshaft TYPICAL

must be locked. Refer to MAGNETO SYSTEM and 1. Extension handle locking crankshaft
follow the procedure to lock the magneto fly-
wheel. NOTE: When splines of PTO flywheel are worn
out and special tool cannot be used, proceed with
PTO flywheel is loosen using PTO flywheel remov-
the following alternate method.
er (P/N 295 000 001).
Use a pipe wrench and install it on PTO flywheel
as illustrated.
F01J0TA
Insert special tool in PTO flywheel splines.
1 F00D10A
TYPICAL
1. Extension handle locking crankshaft
787 RFI Engine

PTO flywheel is loosened using PTO flywheel ex-
tractor (P/N 295 000 156).
F01D1AA
TYPICAL
1. PTO flywheel remover (P/N 295 000 001)
Using a suitable wrench or socket with a breaker

bar, unscrew PTO flywheel COUNTERCLOCK-
WISE when facing it and hold extension handle
locking the magneto flywheel.
F00B04A
SMR2002-025_04_06A.FM 04-06-5
Section 04 ENGINE
Install special tool.

1
F06D37A 2 1
F06I02A 1. Loosen Allen screws
2. Breaker bar locking crankshaft
1. PTO flywheel extractor
Remove the coupler no. 20.
Install the extension handle (P/N 295 000 125) on
the PTO flywheel extractor. Loosen PTO flywheel XP Models
COUNTERCLOCKWISE when facing it.
Remove Allen screws no. 21.
947 Engines except XP
2 1 3
Use PTO flywheel remover (P/N 295 000 001) to
hold flywheel and remove Allen screws no. 21 re-
taining coupler no. 20 to PTO flywheel.
F01J0TA
PTO FLYWHEEL REMOVER TOOL F08D02A
1. PTO flywheel
2. Coupler
3. Loosen Allen screw
Remove coupler no. 20.
04-06-6 SMR2002-025_04_06A.FM
Section 04 ENGINE
All 947 Engines Starter Drive Assembly

Install puller plate (P/N 529 035 533) and extension 947 Engines Only
handle (P/N 295 000 125) to PTO flywheel.
Loosen 2 Allen screws no. 24 retaining starter
NOTE: Puller plate can be used without the exten- drive cover no. 25.
sion handle.
Loosen bolt no. 22 retaining the PTO flywheel to the
crankshaft using a suitable socket and breaker bar.
3
F06D1CA 2 1
1. Cover
2. Allen screw
F06D38A 2 1
Remove starter drive cover no. 25 and spring no. 9.
1. Puller plate
2. Extension handle Remove starter drive assembly no. 27.
3. Loosen bolt with socket and breaker bar
Remove the PTO flywheel using puller plate (P/N

529 035 533) and puller (P/N 529 035 547) and bolt
(P/N 529 035 549).
F06D1DA 1
947 ENGINE
1. Starter drive assembly
F06D39A 4 3 1 2
1. Puller plate
2. Puller
3. Bolt
4. Extension handle
SMR2002-025_04_06A.FM 04-06-7
Section 04 ENGINE
Reed Valve 717 and 787 RFI Engines

947 Engines Only Put engine on a stand. Loosen crankcase screws.
Remove both carburetor flanges. 3
F01D20C 3
717 ENGINE
1. M10 x 73.5 flanged screws
3. M8 x 45 socket head screws
F06D0JA 1
2
1. Carburetor flange
Remove reed valves no. 28 from crankcase.
Crankcase
Before opening the bottom end, remove the fol-
lowing parts: 1 1 1
– engine supports (717 engine)
– magneto flywheel, refer to MAGNETO SYSTEM
– magneto housing (except 947 engines)
– starter
– rotary valve cover and valve
(except 947 engines)
– starter drive assembly (947 engines) F15D05A 2
– reed valves (947 engines) 787 RFI ENGINE
– air compressor cover (947 DI engines). 2. M8 x 53.5 flanged screws
04-06-8 SMR2002-025_04_06A.FM
Section 04 ENGINE
947 Engines
Place engine upright on crankcase magneto side.
Loosen crankcase screws.
1 1
F01D1LA
1
TYPICAL
1. Separate halves by prying at provided lugs
Remove crankshaft and counterbalance shaft (787

RFI and 947 engines).
2
947 DI Engines
F07D09D
Open air compressor and disconnect the piston as
947 ENGINES described in ENGINE MANAGEMENT.
1. M8 x 45 flanged screws
Crankshaft Bearing and Seal
All Engines All Engines
Put engine back on a support. Insert a pry bar be- If a crankshaft end seal no. 5 has to be replaced,
tween crankcase lugs to separate halves. bottom end must be opened (except for the MAG
CAUTION: Be careful to precision machined sur- side seal on the 787 RFI engine, which is mount-
faces. ed on the magneto housing).
NOTE: Do not needlessly remove crankshaft bear-
ings.
Remove end seal(s).
1
F01D1KA
TYPICAL
F06D1GA 1
TYPICAL
1. End seal
SMR2002-025_04_06A.FM 04-06-9
Section 04 ENGINE
717 Engine 947 Engines

To remove end bearings no. 4 from crankshaft, To remove end bearings from crankshaft, use the
use the following tools. following tools.
1 2 3 4 5 6 6 1 3 4 5
2
8
F01B09A 7 F06B03A 6
717 ENGINE 947 ENGINES
1. Puller (P/N 420 877 635) 1. Puller (P/N 420 877 635)
2. Protective cap (P/N 420 876 557) 2. Protective cap (P/N 290 877 414)
3. Distance ring, MAG side only (P/N 420 876 569) 3. Distance ring (P/N 420 876 569)
4. Ring (both sides) (P/N 420 977 490) 4. Ring (P/N 420 977 480)
5. MAG side ring halves (P/N 420 276 025) 5. Ring halves (P/N 420 876 330)
6. PTO side ring halves (P/N 420 977 475) 6. Screw (P/N 420 940 755)
7. Screw M8 x 40 (P/N 420 840 681)
8. Screw M8 x 70 (P/N 420 841 201) All Engines
NOTE: To facilitate ring or distance ring installa-
tion, lubricate their inside diameters.
787 RFI Engine
1
To remove end bearings no. 4 from crankshaft,
use the following tools.
NOTE: The outer PTO bearing and crankshaft gear
can be removed in one step using another puller.
See Crankshaft Gear no. 18.
1 2 3 4 5
F01D1OA
TYPICAL
1. Removing crankshaft bearing
7
F01B2MA 6
787 RFI ENGINE
1. Puller (P/N 420 877 635)
2. Protective cap (P/N 420 876 557)
3. Distance ring (P/N 420 876 569)
4. Ring (P/N 420 977 490)
5. Ring halves (P/N 420 977 475)
6. Screw M8 x 40 (P/N 420 840 681)
7. Screw M8 x 70 (P/N 420 841 201)
NOTE: To facilitate ring or distance ring installa-

tion, lubricate their inside diameters.
04-06-10 SMR2002-025_04_06A.FM
Section 04 ENGINE
Or, use a bearing extractor such as Proto no. 4332 Install the puller as per following illustration.
and a press to remove two bearings at a time (ex-
cept on PTO side for the 787 RFI engine).
F00D0IA 2 1
1. Puller
2 2. Protective cap
F01D1PA
Secure puller in a vise and remove gear and bearing.
1. Press bearings out
2. Bearing extractor
Crankshaft Gear
787 RFI Engine
The crankshaft gear no. 18 and bearing no. 5 can
be removed in one step using the following puller.
F00D0JA
NOTE: If the inner PTO bearing needs to be re-

placed, remove the Woodruff key on the crank-
shaft.
F04B03A
1. Puller (P/N 290 877 665)
SMR2002-025_04_06A.FM 04-06-11
Section 04 ENGINE
Counterbalance Shaft
787 RFI Engine
Bearings no. 15 on counterbalance shaft no. 13
can be removed by using the following tools:
1 2 3 4
5 1
F00D0SA
F00B0CA
1. Index mark
1. Puller (P/N 420 877 635)
3. Ring (P/N 420 977 480)
Use a press to remove the gear no. 14 from the
4. Ring halves (P/N 420 876 330) counterbalance shaft.
5. Screw M8 x 40 (P/N 420 840 681)
F00D0KA 1
1. Tool installed
To remove gear no. 14, first trace an index mark F00D0TA
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.
04-06-12 SMR2002-025_04_06A.FM
Section 04 ENGINE
947 Engines
Use a press to remove counterweights no. 16 and
bearings no. 15.
CAUTION: There is no woodruff key to position
the counterweights. An index mark must be traced
to retain the proper position of the counterweight.
F00D2BA
F06D1HA 1
1. Trace an index mark
Remove seals no. 17.

Remove bearing no. 31 and washer no. 32.
Use a press to remove gear no. 14.
CLEANING
All Models
F00D2CA
Discard all oil seals, gaskets, O-rings and sealing
FIRST PASS
rings.
Clean oil passages and make sure they are not
clogged.
Crankcase mating surfaces are best cleaned using
a combination of the chisel gasket remover (P/N
413 708 500) and a brass brush. Brush a first pass
in one direction then make the final brushing per-
pendicularly (90°) to the first pass cross (hatch).
CAUTION: Do not wipe with rags. Use a new clean
hand towel only.
F00D2DA
SECOND PASS
SMR2002-025_04_06A.FM 04-06-13
Section 04 ENGINE
Finish the cleaning with acetone. – Install Bombardier degree wheel (P/N 529 035
CAUTION: Ensure to clean compressor lubrica- 607) on crankshaft end. Hand-tighten nut only.
tion nipple. – Remove both spark plugs.
CAUTION: Be careful not to spray cleaner on – Install a TDC gauge in spark plug hole on MAG
the painted surface of the engine. side.
CAUTION: Never use a sharp object to scrape – Bring MAG piston at Top Dead Center.
away old sealant as score marks incurred are – As a needle pointer, secure a wire with a cover
detrimental to crankcase sealing. screw and a washer.
– Rotate degree wheel (NOT crankshaft) so that
INSPECTION needle pointer reads 360°.
Assembled Engine
The following checks can be performed with en- 1
gine in watercraft without overhauling engine.
Crankshaft Alignment at Center Main

2
Journal
Since it is an assembled crankshaft it can become
misaligned or deflected. Crankshaft can be twist-
ed on center main journal, changing timing of one
cylinder in relation with the other.
3
F01D4IA
TYPICAL
1. TDC gauge
2. Degree wheel
F01D1NA 1 3. Hand tighten nut
4. Needle pointer
1. Main journal alignment here
– Remove TDC gauge and install on PTO side.
To accurately check if crankshaft is twisted on cen-
ter main journal, proceed as follows: – Bring PTO piston at Top Dead Center.
– Remove magneto housing cover. Interval between cylinders must be exactly 180°
therefore, needle pointer must indicate 180° on
– Remove flywheel nut (and magneto rotor for degree wheel (360° - 180° = 180°).
the 787 RFI and 947 engines). Refer to MAG-
NETO SYSTEM for procedures. Any other reading indicates a misaligned crank-
shaft.
04-06-14 SMR2002-025_04_06A.FM
Section 04 ENGINE
Crankshaft Alignment at Connecting Connecting Rod Straightness

Rod Journal Align a steel ruler on edge of small end connecting
Counterweights can also be twisted on connect- rod bore. Check if ruler is perfectly aligned with
ing rod journal on any or both cylinder(s). edge of big end.
F01D1Q A 2
F01D1NB 1 1. Ruler must be aligned with edge of connecting rod here
2. Align ruler here
1. Connecting rod journal alignment here
Crankshaft Deflection
Such misalignment may cause a crankshaft hard
to be manually turned. Verification can be done by All Models
measuring deflection each end of crankshaft.
MEASUREMENT MAG SIDE PTO SIDE
If deflection is found greater than specified toler-
ance, this indicates worn bearing(s), bent and/or Crankshaft 0.050 mm 0.030 mm
disaligned crankshaft. Proceed with the disassem- deflection (max.) (.002 in) (.001 in)
bly of the engine.
Crankshaft deflection is measured each end with
Disassembled Engine a dial indicator.
The following verifications can be performed with First, check deflection with crankshaft in crank-
the engine disassembled. case. If deflection exceeds the specified toler-
ance, it can be either ball bearings wear, bent or
Crankcase twisted crankshaft at connecting rod journal.
Inspect plane surfaces for warpage. Small defor- 1
mation can be corrected by grinding surface with
a fine sandpaper. Install sandpaper on a surface
Bearing
Inspect crankshaft bearings no. 4. Check for cor-
rosion, scoring, pitting, chipping or other evidence
of wear. Make sure plastic cage is not melted. Ro-
tate and make sure they turn smoothly.
Crankshaft F01D1SA
NOTE: If crankshaft and/or components are found 1. Measuring PTO side deflection in crankcase
defective, it must be repaired by a specialized
shop or replaced.
SMR2002-025_04_06A.FM 04-06-15
Section 04 ENGINE
NOTE: Crankshaft deflection cannot be correctly

1 measured between centers of a lathe.
Connecting Rod Big End Axial Play
CONNECTING ROD BIG END AXIAL PLAY

NEW PARTS WEAR
MODEL
(min.) (max.) LIMIT
0.390 mm 0.737 mm 1.2 mm

947 engine
(.015 in) (.029 in) (.047 in)
0.230 mm 0.617 mm 1.2 mm
F01D1TA 787 RFI engine
(.008 in) (.024 in) (.047 in)
1. Measuring MAG side deflection in crankcase
0.311 mm 0.677 mm 1.2 mm
717 engine
Remove crankshaft bearings and check deflection (.012 in) (.026 in) (.047 in)
again on V-shaped blocks as illustrated.
Using a feeler gauge, measure distance between
thrust washer and crankshaft counterweight.
1
1
F01D97A
2
F01D1WA
1. Measuring MAG side deflection on V-shaped blocks 1. Measuring big end axial play
2. Feeler gauge
F01D98A
1. Measuring PTO side deflection on V-shaped blocks
04-06-16 SMR2002-025_04_06A.FM
Section 04 ENGINE
Starter Drive Bearing Reed Valve

947 Engines Only 947 Engines Only
Check bearing no. 23 of starter drive assembly Check reed valve petals no. 29 for cracks or other
no. 27 in crankcase. defects. The reed petals must lie completely flat
against the reed valve body no. 30. To check, hold
against light.
F06D1IA 1
1. Bearing of starter drive assembly
Removal
Starter drive bearing can be easily removed from F06D1JA 1
lower crankcase half using the following suggest- 1. No play
ed tool or equivalent:
In case of a play, turn reed petals upside down and
– Snap-on hammer puller including: recheck. If there is still a play, replace petals.
– handle CJ93-1 Check perfect condition of rubber coating on reed
– hammer CJ125-6 valve body.
– claws CJ93-4. Check stopper distance from center of reed valve
block.
F01J0ZA
Close puller claws so that they can be inserted in A

end bearing. Holding claws, turn puller shaft clock-
wise so that claws open and become firmly tight
against bearing.
Slide puller hammer outwards and tap puller end.
Retighten claws as necessary to always maintain
them tight against bearing. Continue this way until
bearing completely comes out.
For installation, see below in this section. F06D1EA
A. 13 ± 0.25 mm (.512 ± .010 in)
SMR2002-025_04_06A.FM 04-06-17
Section 04 ENGINE
NOTE: Distance should be the same on both sides.

Bent stopper as required to obtain the proper dis-
tance. 1
Air Compressor
Refer to ENGINE MANAGEMENT for compo-
nents inspection. However, if you find aluminum
dust or debris in this area, they may have flowed F01B0HA
toward the injection oil reservoir. In this case, the
oil reservoir and lines must be flushed and the fil- 1. Distance gauge
ter replaced.
CAUTION: Failure to properly clean the oil sys- 1
tem will result in serious engine damage.
ASSEMBLY
to the following.
NOTE: It is recommended to spray BOMBARDIER-
ROTAX injection oil on all moving parts when re-
assembling the engine. 2
Crankshaft and Bearing

F01D1YA
Apply Loctite 767 anti-seize on part of crankshaft
where bearing fits. TYPICAL
1. Distance gauge
Prior to installation, place bearings no. 4 into a 2. Outer bearing
container filled with oil, previously heated to 75°C
(167°F). This will expand bearing and ease instal- Distance Ring
lation. When installing the distance ring no. 12, make
To properly position the outer bearing(s), a dis- sure to position it with its chamfer toward the
tance gauge must be temporarily installed against counterweight of the crankshaft.
the inner bearing. Slide the outer bearing until
stopped by the distance gauge, then remove it.
ENGINE DISTANCE GAUGE

717 P/N 529 034 800 (PTO)
787 RFI P/N 529 034 900 (MAG)
P/N 529 035 100 (MAG)
947
P/N 529 035 000 (PTO)
04-06-18 SMR2002-025_04_06A.FM
Section 04 ENGINE
Crankshaft Gear 787 RFI Engine

787 RFI Engine Position PTO seal against the retaining shim; the
gap between the seal no. 5 and bearing no. 4 will
Position the long flange of the gear no. 18 toward ensure proper lubrication of the bearing.
the counterweight of the crankshaft. Also, make
sure to align the gear keyway with the Woodruff 1
key on the crankshaft.
F00D0NA
1. Seal against the retaining shim
947 Engines
F00D0LA 1
Seals are positioned with the outer lip in the crank-
1. Woodruff key on the crankshaft case recess.
1 1
2
F00D0MA
1. Keyway
F06D1LA
2. Long flange toward the crankshaft counterweight
1. Seal lip in crankcase recess
Crankshaft Seal
All Models
When installing seal assembly no. 5, apply a light
coat of lithium grease on seal lips.
SMR2002-025_04_06A.FM 04-06-19
Section 04 ENGINE
Drive Pin
Make sure drive pins no. 6 of bearings are proper-
ly installed in crankcase recesses at assembly.
1
1
F00D0UA
F00D0OA
1. Gear notch aligned with the crankcase
1. Drive pins – The notch of the couterweight on the opposite

end of the counterbalance shaft must also be
Counterbalance Shaft aligned with the cranckcase.
787 RFI Engine 1
Press gear no. 14 onto counterbalance shaft no. 13
taking care to align both marks previously traced.
CAUTION: Counterbalance shaft must be prop-
erly assembled, otherwise engine will vibrate
and premature wear will occur.
Proceed as follows to check if the gear no. 14 is
properly positioned on the counterbalance shaft:
– Temporarily install the counterbalance shaft in
the crankcase.
– Rotate the counterbalance shaft to align the
notch of the gear with the crankcase.
F00D0VA
1. Counterweight notch aligned with the crankcase
If notches are not aligned with the crankcase, re-

move the gear and repeat the procedure until the
notches are properly aligned.
947 Engines
Install bearing no. 31 and washer no. 32.
When installing seals no. 17, apply a light coat of
Molykote 111 on seal lips.
Prior to installation, place bearings no. 15 into a
(167°F). This will expand bearings and ease their
installation.
04-06-20 SMR2002-025_04_06A.FM
Section 04 ENGINE
Reinstall counterweights no. 16 using a press and Turn by hand the crankshaft and counterbalance
take care to align index marks previously traced. shaft. Make sure they do not interfere with the
crankcase.
Crankshaft and Counterbalance Shaft
947 Engines
787 RFI and 947 Engines
Properly position bearing no. 31 and washer
Install crankshaft no. 3 first in crankcase. no. 32. Ensure to position lubrication hole on top
After crankshaft installation, install counterbal- (if so equipped).
ance shaft no. 13. Make sure to properly index
crankshaft and counterbalance shaft by aligning
marks of gears.
CAUTION: Marks on the crankshaft and coun-
terbalance shaft must be aligned, otherwise en-
gine will vibrate and premature wear will occur.
F12R16A 3 2 1
1. Bearing
2. Washer in crankcase groove
3. Lubrication hole on top (if so equipped)
Place seals no. 17 in their respective positions.
F00D0PA 1
787 RFI ENGINE
1. Marks must be aligned
F06D1OA 1
1. Seal in place
Air Compressor
F06D1MA 1 947 DI Engines
947 ENGINES Refer to ENGINE MANAGEMENT for procedures.
SMR2002-025_04_06A.FM 04-06-21
Section 04 ENGINE
Crankcase Use a plexyglass plate and apply some sealant on

it. Use a soft rubber roller (50 - 75 mm (2 - 3 in))
All Engines (available in arts products suppliers for printmak-
Crankcase halves are factory matched and there- ing) and roll the sealant to get a thin uniform coat
fore, are not interchangeable or available as single on the plate (spread as necessary). When ready,
halves. apply the sealant on crankcase mating surfaces.
Rotary valve shaft must be installed in crankcase
before closing halves.
CAUTION: Before joining crankcase halves, make
sure that crankshaft gear is well engaged with ro-
tary valve shaft gear.
717 Engine
Temporarily install armature plate to align crank-
case halves with each other.
947 DI Engines
Add 40 mL (1.35 oz) of Sea-Doo synthetic jet
pump oil (P/N 293 600 011) or standard gear oil in
the counterbalance shaft gear cavity. F12R17A
CAUTION: Using different type of oil may re-

duce engine component life.
All Models
IMPORTANT: When beginning the application of
the crankcase sealant, the assembly and the first
torquing should be done within 10 minutes. It is
suggested to have all you need on hand to save
time.
NOTE: It is recommended to apply this specific
sealant as described here to get an uniform appli-
cation without lumps. If you do not use the roller
method, you may use your finger to uniformly dis-
tribute the sealant (unlike the Drei Bond sealing F12R18A
compound, using a finger will not affect the adhe-
sion). Do not apply in excess as it will spread out inside
Use the silicone-based Loctite 5910 (P/N 293 800 crankcase.
081) on mating surfaces. CAUTION: If sealant spread out inside air com-
NOTE: The sealant curing time is similar to the pressor area, it could plug the compressor lu-
Loctite 518 without using the Primer N. brication nipple and serious compressor dam-
CAUTION: Do not use Loctite 515 or 518 to seal age may occur.
crankcase. Do not use Loctite Primer N with the NOTE: Do not use Loctite Primer N with this seal-
Loctite 5910. Using these products or non silicone- ant. The sealant curing time is similar to the Loc-
based sealant over a previously sealed crankcase tite 518 without using the Primer N, which is 4 to
with Loctite 5910 will lead to poor adhesion and 24 hours.
possibly a leaking crankcase. These products are
chemically incompatibles. Even after cleaning, the
Loctite 5910 would leave incompatible microscos-
pic particules.
04-06-22 SMR2002-025_04_06A.FM
Section 04 ENGINE
All 947 Engines

7 11 1 3 9 5 13
Make sure all locating dowels are in place.
F01D20D 8 12 4 2 10 6 14
Torque 2 M10 crankcase screws to 40 N•m (30

lbf•ft).
F06D1PA 1
1. Dowel
1
Counterbalance Shaft Bearing Cover
787 RFI Engine
Install the bearing cover no. 19 with its hollow
side toward the bearing.
F01D20B
787 RFI Engine

Apply Loctite 518 on screw threads and Molykote
111 below head screws.
1 Torque crankcase screws to 12 N•m (106 lbf•in)
as per following sequence. Repeat procedure, re-
tightening all screws to 24 N•m (17 lbf•ft).
11 7 21 1 3 22 5 9
F00D0QA
1. Hollow side facing bearing
Crankcase Screws
717 Engine
Apply Loctite 518 on screw threads and Molykote
111 below head screws.
Torque crankcase screws to 24 N•m (17 lbf•ft) as
per following illustrated sequence.
F15D05B 19 12 17 8 13 15 4 2 16 14 18 6 20 10
SMR2002-025_04_06A.FM 04-06-23
Section 04 ENGINE
As a final step, torque only M10 screws no. 8 of

crankcase to 40 N•m (30 lbf•ft) as per following se- 10
9
quence.
7 8
11 7 1 3 5 9
3 4
1 2
5 6
11
12
F07D09C
F15D05C 12 8 4 2 6 10
Oil Fittings
All 947 Engines
Apply Molykote 111 below head of screws and
Loctite 518 on threads. If inlet and outlet oil fittings no. 11 of rotary valve
shaft have been removed from crankcase, rein-
Torque crankcase screws to 12 N•m (106 lbf•in) stall them with their end pointing toward ignition
as per following sequence. Repeat procedure, re- housing. Apply Loctite 518 on threads of fittings.
Stud
10
9 24 717 Engine
8 At assembly in crankcase, apply Loctite 518 on
7
21 threads of studs no. 10. Torque to 10 N•m (89 lbf•in).
20
14 Starter Drive Bearing
4
3 15 947 Engines
To install bearing no. 23 of starter drive assembly,
1 13 use pusher (P/N 290 876 502) and handle (P/N 420
2 877 650).
16 17
18
5 6
19 1
11 23
22 12
F07D09E
As a final step, torque only the M10 x 73.5 bolts

to 40 N•m (30 lbf•ft) as per following sequence. 2
F06D32A
1. Handle
2. Pusher
04-06-24 SMR2002-025_04_06A.FM
Section 04 ENGINE
PTO Flywheel 787 RFI Engine

787 RFI Engine When engine assembly is completed, add 30 mL
(1 oz) of motor oil SAE 30 to the counterbalance
Install O-ring onto crankshaft. shaft gear through the crankcase filler plug.
1
F01D84A
F07D06A
1
1. O-ring
1. Remove plug and add SAE 30 motor oil
717 and 787 Engines 947 Carburetor-Equipped Engines
Apply Loctite anti-seize lubricant (P/N 293 800 070) When engine assembly is completed, add 40 mL
to crankshaft threads. (1.35 oz) of motor oil SAE 30 to the counterbalance
Using the same tools as for disassembly proce- shaft gear through the crankcase filler plug.
dure, torque PTO flywheel to 110 N•m (81 lbf•ft).
947 Engines
Apply Loctite 243 (blue) on bolt no. 22.
Using the same tools as for disassembly proce-
dure, torque bolt no. 22 to 115 N•m (85 lbf•ft).
Apply Loctite 648 on mating surface of PTO fly-
wheel and coupler.
Apply Loctite 243 (blue) to Allen screws no. 21 of
coupler and torque to 23 N•m (17 lbf•ft).
F06D2CA 1
Final Assembly 1. Remove plug and add SAE 30 motor oil
947 DI Engines
For rotary valve timing and assembly procedures,
refer to ROTARY VALVE. Add approximately 10 mL (.3 oz) of injection oil in
bottom of crankcase for each cylinder. This will
give an additional lubrication for the first engine
startup.
SMR2002-025_04_06A.FM 04-06-25
Section 04 ENGINE
Subsection 07 (ROTARY VALVE)
ROTARY VALVE 0
20 Nm
(15 lbfft) 2
Anti-seize 9
lubricant
5
6
10
9 Nm 14
(80 lbfin) 12
1 15 7
8
787 RFI engine 11
13
4
Molykote
12 111
1
Engine
oil
Loctite
243
717 engine
2
20 Nm
(15 lbfft)
F00D26T
SMR2002-026_04_07A.FM 04-07-1
Section 04 ENGINE
GENERAL 1
The following verification procedures such as clear-
ance of rotary valve cover or rotary valve shaft gear
backlash can be performed without removing en-
gine from watercraft.
However engine must be removed from water-
craft to work on rotary valve shaft/components.
Refer to REMOVAL AND INSTALLATION for en-
gine removal procedure.
Bottom end must be opened to remove rotary F01D53A
valve shaft. Refer to BOTTOM END.
1. 45° feeler gauge
INSPECTION ON WATERCRAFT If rotary valve cover clearance is out of specifica-

tions, machine rotary valve cover seating surface
Remove carburetor(s). Refer to CARBURETOR. or replace the cover.
Rotary Valve Cover SOLDERING WIRE METHOD
Unscrew 4 screws no. 2 and withdraw rotary valve Remove O-ring from rotary valve cover.
cover no. 1. Use the following type of solder:
Remove rotary valve no. 13. – resin core
– diameter: 0.8 mm (.032 in)
Rotary Valve/Cover Clearance
– electronic application (available at electronic
The clearance between the rotary valve and the stores).
cover must be 0.30 ± 0.05 mm (.012 ± .002 in).
Install 2 soldering wire pieces of 13 mm (1/2 in)
NOTE: If the clearance is below 0.25 mm (.010 in) long directly on rotary valve, one above and one
this could create an overheating situation and if below rotary valve gear. Apply grease to hold sol-
the clearance is over 0.35 mm (.014 in) this could der in position.
create a hard starting situation.
Refer to the following illustration for proper posi-
There are 2 methods to verify rotary valve/cover tion or rotary valve and pieces of soldering wire.
clearance:
– the 45° feeler gauge method
– the soldering wire method.
45° FEELER GAUGE METHOD
Remove O-ring no. 12 from rotary valve cover no. 1.
Remove intake manifold from rotary valve cover
(except 787 engine).
Reinstall cover no. 1 in place WITHOUT its O-ring
and torque screws to 20 N•m (15 lbf•ft).
Insert feeler gauge blade through cover inlet ports 1
to verify clearance. At least verify clearance at two
F01D3PA
different places in each port.
TYPICAL
Feeler gauge blade from 0.25 mm (.010 in) to
1. Soldering wire
0.35 mm (.014 in) thickness should fit between ro-
tary valve and cover. Reinstall cover in place WITHOUT its O-ring and
torque screws to 20 N•m (15 lbf•ft).
04-07-2 SMR2002-026_04_07A.FM
Section 04 ENGINE
Remove cover then clean and measure compressed Manually feel backlash at one position, then turn
soldering wire thickness, it must be within the spec- crankshaft about 1/8 turn and recheck. Continue
ified tolerance 0.30 ± 0.05 mm (.012 ± .002 in). this way to complete one revolution.
If rotary valve cover clearance is over specified tol- Backlash must be even at all positions. Otherwise
erances, machine rotary valve cover seating sur- overhaul engine to find which part is faulty (gear,
face or replace the cover. rotary valve shaft or crankshaft with excessive de-
flection).
MACHINING INFORMATION
The amount of material over tolerance must be DISASSEMBLY
removed from the rotary valve cover seating sur-
face. Rotary Valve Cover
Also cut the O-ring groove the same amount to
Unscrew 4 retaining screws and withdraw rotary
keep the 1.00 ± 0.03 mm (.039 ± .001 in) depth
valve cover no. 1 and rotary valve no. 13.
between the bottom of the groove and the seating
surface.
Rotary Valve Shaft
Remove burrs on the edges of the seating surface
and O-ring groove. To remove the rotary valve shaft assembly, the en-
gine must be removed from watercraft (refer to
1 ENGINE).
Open bottom end and remove crankshaft (refer to
BOTTOM END).
First remove snap ring no. 4 from crankcase.
A 1
F01D3OA
F01D22A
SAME AMOUNT REMOVED FROM COVER SEATING SURFACE
AND O-RING GROOVE BASE 1. Removing snap ring
1. Cover seating surface
A. O-ring groove depth must be 1.00 ± 0.03 mm (.039 ± .001 in) To remove rotary valve shaft assembly, use the
Reverify the clearance. appropriate puller (P/N 290 876 488).
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. F01D23B
Remove spark plugs, rotary valve cover and valve. PULLER (P/N 290 876 488)
SMR2002-026_04_07A.FM 04-07-3
Section 04 ENGINE
Place puller over rotary valve shaft end and screw Shaft Bearing
on puller bolt into shaft. While retaining bolt with
To remove bearing no. 8 use a bearing extractor
a wrench, turn puller nut CLOCKWISE until shaft
such as Snap-on no. CJ-950 (or equivalent) as illus-
comes out.
trated. Slide off distance sleeve no. 14, remove
snap ring no. 7 and washer no. 15 then press
shaft out.
F01D61A 1
1. Hold bolt
F01D4NA 2
1. Bearing
2. Bearing extractor Snap-on CJ-950
CAUTION: Ensure that rotary valve shaft is per-

fectly perpendicular with press tip.
End Bearing
CAUTION: Do not remove plug against bearing
in upper crankcase half.
F01D27A
Circlip and Spring Seat

If it is necessary to disassemble components of
rotary valve shaft assembly, use seat no. 6 to
compress spring and remove circlips no. 5.
1
1
F01D4OA
1. Do not remove this plug
F01D25A 2
1. Compress seat
2. Remove circlips
04-07-4 SMR2002-026_04_07A.FM
Section 04 ENGINE
End bearing no. 9 can be easily removed from up- INSPECTION

per crankcase half using the following suggested
tool (or equivalent): Rotary Valve Cover
– Snap-on hammer puller including: Inspect rotary valve cover no. 1 for warpage. Small
– handle CJ93-1 deformation can be corrected by surfacing with
– hammer CJ125-6 fine sand paper on a surface plate. Surface part
against oiled sand paper.
– claws CJ93-4.
Bearings
Inspect bearings no. 8 and no. 9. Check for scor-
ing, pitting, chipping or other evidence of wear.
F01J0ZA
Make sure plastic cage (on bigger bearing) is not
melted. Rotate them and make sure they turn
Close puller claws so that they can be inserted in smoothly.
wise so that claws open and become firmly tight Gear
against bearing. Visually check gear wear pattern. It should be even
Slide puller hammer outwards and tap puller end. on tooth length all around. Otherwise it could indi-
Retighten claws as necessary to always maintain cate a bent shaft, check deflection. Replace gear
them tight against bearing. Continue this way until if damaged.
bearing completely comes out. Check for presence of brass filings in gear housing.
1 Rotary Valve Shaft Deflection
Deflection is measured with a dial gauge. Install
rotary valve shaft in crankcase half, without its
gear.
NOTE: End bearing must be in crankcase half.
Measure shaft deflection next to gear splines.
F01D28A
1. End bearing
CLEANING
Discard all seals and O-rings.
Clean all metal components in a solvent. 1
clogged.
F01D2CA
Clean rotary valve shaft and inside of distance
sleeve no. 14. 1. Rotary valve shaft
2. End bearing in place
Deflection must not exceed 0.08 mm (.003 in). Re-

place shaft as necessary.
SMR2002-026_04_07A.FM 04-07-5
Section 04 ENGINE
ASSEMBLY Seal
Assembly is essentially the reverse of disassem- Apply Molykote 111 on seal lips. Position seal no. 11
bly procedures. However pay particular attention with shielded portion against shaft splines.
to the following.
Bearing
Bearing Install ball bearing as illustrated.
To install end bearing no. 9 in crankcase, use push-
er (P/N 420 876 501).
F00B07A 1 1
2 3
1. Pusher (P/N 420 876 501)
Position ball bearing shielded side towards rotary

valve.
A13C0FB
1. Seal
2. Ball bearing
3. Bearing extractor Snap-on CJ-950
Install washer no. 15, snap ring no. 7 and slide dis-
tance sleeve no. 14 on shaft.
1 2 3 4
F01D2DA 1
1. Shield side (toward gear)
Push bearing until it stops on its seat.
F01D2FA 5 6
1. Seal
2. Ball bearing
3. Snap ring
4. Distance sleeve
5. Washer 0.5 mm (.020 in)
6. Rotary valve shaft
Rotary Valve Shaft Assembly

CAUTION: Crankcase halves must be separat-
ed and crankshaft must not be present to install
rotary valve shaft assembly in crankcase.
F01D99A
04-07-6 SMR2002-026_04_07A.FM
Section 04 ENGINE
717 Engine Push shaft until it stops on bearing seat.

To install rotary valve shaft in crankcase, use a
pusher (P/N 420 876 605).
A00C0YA
1. Pusher
Push shaft until its stops on bearing seat.

F01D8OA

Snap Ring
Position snap ring no. 4 so that its sharp edge faces
outwards.
Rotary Valve
The rotary valve no. 13 controls the opening and
closing of the inlet ports. Therefore its efficiency
F01D34A 2 will depend on the precision of its installation.
1. Rotary valve shaft
2. Push shaft until it stops IDENTIFICATION OF THE ROTARY VALVE
787 RFI Engine ROTARY VALVE
ENGINE
To install rotary valve shaft in crankcase, use a VALVE P/N DURATION
pusher (P/N 290 876 609) and handle (P/N 420 877 717/787 RFI 420 924 502 159°
650).
F01B2FA
1. Pusher
2. Handle
SMR2002-026_04_07A.FM 04-07-7
Section 04 ENGINE
There is no identification code on the valve. To find out the duration, place an angle finder on the valve
and measure the valve cut-out angle or use the following template.
159°
F01D73W
04-07-8 SMR2002-026_04_07A.FM
Section 04 ENGINE
ROTARY VALVE TIMING Proceed as follows:

– Turning crankshaft, bring MAG side piston to
CAUTION: Never use the ridge molded in crank-
Top Dead Center using a TDC gauge.
case as a timing mark.
The following tools are required to measure rotary
valve opening and closing angles in relation with 1
MAG side piston.
350 360 10
340 20
0 10 360 350 3 30
33 20 40
0 30 33 40
32 40 0
32
50 0
50
0
31
60
31
60
0
0
30
70
300
70
80
290
290
110 100 90
80
529 035 607
270 280
280 270 26
90 100 11
260
120
0
0
250
130
250
120
0
24
24
14
13
0
2
30
0
0
15
23
0 22 40
16 0 0
210 0 22 15
200 190 180 17 0 0
160 21
170 1 2 0 0
80 190
F01D2IA
295 000 143 1. Bring piston to TDC

F00B0DB
– For opening mark, first align 360° line of degree

Rotary valve must be set so that timing occurs as wheel with BOTTOM of MAG side inlet port.
follows: Then, find 147° line on inner scale of degree
wheel and mark crankcase at this point.
TIMING
ENGINE OPENING CLOSING
BTDC ATDC 2
717 147° ± 5 65.5° ± 5 147°

787 RFI 147° ± 5 63.5° ± 5
Timing Procedure
The following specifications are used in this pro-
cedure:
OPENING: 147° BTDC
CLOSING: 65° ATDC F01D3DC
1
OPENING MARK
Step 1 : Bottom of MAG inlet port.
Align 360° line of degree wheel
Step 2 : Find 147° on inner scale of degree wheel and mark here
NOTE: Do not rotate the crankshaft.
SMR2002-026_04_07A.FM 04-07-9
Section 04 ENGINE
– For closing mark, first align 360° line of degree

wheel with TOP of MAG side inlet port. Then,
find 65° line on outer scale of degree wheel and
mark crankcase at this point.
65°
F01D3EB
2
CLOSING MARK
Step 1 : Top of MAG inlet port.
Align 360° line of degree wheel
Step 2 : Find 65° on outer scale of degree wheel and mark here
– Remove degree wheel.

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

Install O-ring no. 12 and rotary valve cover no. 1 then
torque screws no. 2 to 20 N•m (15 lbf•ft) in a criss-
cross sequence.
04-07-10 SMR2002-026_04_07A.FM
Section 04 ENGINE
Subsection 08 (EXHAUST SYSTEM)
EXHAUST SYSTEM 0
717 Engine Model GTI and GTI LE
4 Nm
(35 lbfin)
4 Nm
(35 lbfin)
4 Nm
25 Nm (35 lbfin)
(18 lbfft)
10 7-9
4 Nm
(35 lbfin)
4 Nm
4 (35 lbfin)
1 2
6-19 15 5 3 11
25 Nm
(18 lbfft)
F17D01S
SMR2002-027_04_08A.FM 04-08-1
Section 04 ENGINE
787 RFI Engine
25 Nm
(18 lbfft)
Loctite
243 Loctite 243
10 19
48 Nm 16
(35 lbfft) 25 Nm
18 (18 lbfft)
7 19
20 22
9 14 1
3
Loctite 518 19
1
18 1
19 Loctite
12 82046
Loctite 6 4 Nm
13 243 21
(35 lbfin)
40 Nm 2
(30 lbfft) 25 Nm
(18 lbfft) 1
26
1
27
Loctite
82046 1
11
2
Loctite
82046 1 28
24
4 Nm
(35 lbfin)
1
Silicone
25 sealant
24
1
Loctite
82046
F15D02U
04-08-2 SMR2002-027_04_08A.FM
Section 04 ENGINE
947 Carburetor-Equipped Engines (XP Model)
5 2
25 Nm
(18 lbfft) 4 Nm
(35 lbfin)
18
6
40 Nm
19 (30 lbfft) 3 1
11
1
Loctite 82046
23 Nm
(17 lbfft)
14 Nm 15
(124 lbfin) Silicone
sealant
4
7 9 Loctite 82046
48 Nm Loctite
(35 lbfft) 14 12-13
243
10
Loctite 243 16 22 21
47 Nm
48 Nm (35 lbfft)
(35 lbfft) 8 9
18
25 Nm
(18 lbfft) 40 Nm
20 (30 lbfft)
19
F07D0PU
SMR2002-027_04_08A.FM 04-08-3
Section 04 ENGINE
947 Carburetor-Equipped Engines (GTX Model)
Loctite 5
82046
14 Nm 15
(125 lbfin) 4 25 Nm 19
(18 lbfft)
7 9 10
Loctite 243 18
48 Nm 14
(35 lbfft) 6
12-13 40 Nm
(30 lbfft)
16
9
Loctite 243 21 22
47 Nm
(35 lbfft)
48 Nm 25 Nm
(35 lbfft) (18 lbfft)
18
20 40 Nm
(32 lbfft)
3 19
2
4 Nm
(35 lbfin)
1
1
4 Nm 1
(35 lbfin) 4 Nm
(35 lbfin)
11
2
Loctite
82046
Loctite
296
F07D0TT
04-08-4 SMR2002-027_04_08A.FM
Section 04 ENGINE
947 Carburetor-Equipped Engines (RX Model)
5 1
4 Nm
25 Nm (35 lbfin)
2
(18 lbfft)
18 1
Loctite 243
6 1
19
3
Loctite 40 Nm 1
243 (30 lbfft)
Loctite
82046 11
14 Nm 15
(124 lbfin)
4
7 9
Loctite Silicone
82046 sealant
48 Nm
(35 lbfft) Loctite 14 12-13
243
10
Loctite 243 16 22 21
47 Nm
48 Nm (35 lbfft)
(35 lbfft) 8 9
18
25 Nm
(18 lbfft) 40 Nm
20 (30 lbfft)
19
F16D05S
SMR2002-027_04_08A.FM 04-08-5
Section 04 ENGINE
947 DI Engines
14 Nm 25 Nm
9 15 (18 lbfft)
(124 lbfin)
48 Nm 4 19
(35 lbfft)
7 18 6
10 Loctite
82046 5 40 Nm
16 22 12-13 (30 lbfft)
14
48 Nm 25 Nm
(35 lbfft) (18 lbfft) 21
19
8 9
18 Loctite 243
Loctite 243
1 4 Nm 20
(35 lbfin)
40 Nm
(30 lbfft)
3
2 1 1
Loctite
82046
11
Silicone
sealant
Body

F12D0RT
04-08-6 SMR2002-027_04_08A.FM
Section 04 ENGINE
REMOVAL XP Model
Open engine compartment cover.
All Models except XP
Remove storage basket.
Remove seat(s).
Remove rear vent hose support from body opening. Tuned Pipe
717 Engine
Disconnect water supply hose and water injection
hose.
Disconnect tuned pipe bleed hose.
1 3
F06L0WA 1
GS SHOWN
1. Rear vent hose support
Remove seat support (all models except RX and

XP).
2 F01D8NA 2
TYPICAL
1. Bleed hose removed
2. Injection hose removed
3. Supply hose removed
Loosen exhaust hose collar no. 1 at tuned pipe

outlet.
Disconnect strap no. 2 retaining muffler no. 11.
Remove exhaust hose no. 3 from tuned pipe by
pulling muffler.
Remove clamp no. 4 from tuned pipe.
Remove tuned pipe cone no. 5.
Remove tuned pipe retaining screw no. 6 from ex-
F07L1KA 2 1 haust manifold side.
TYPICAL Remove screws no. 7, nut no. 8 and flat washers
1. Seat support no. 9 from tuned pipe flange.
2. Remove screws
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.
SMR2002-027_04_08A.FM 04-08-7
Section 04 ENGINE
787 RFI Engine

Remove air intake silencer.
Disconnect water supply hose and water injection
hose at tuned pipe.
Loosen hose clamp no. 1 retaining exhaust hose
no. 3 to tuned pipe cone.
1
F06E08A 1
1. Water return hose
2. Disconnect small hose from water outlet fitting

at the tuned pipe head no. 10.
F06D14A
1. Loosen clamp
Remove screws no. 7 and washers no. 9 at tuned

pipe head flange.
Remove screw no. 6 and screw no. 20 retaining
tuned pipe to engine.
Remove tuned pipe from watercraft.
947 Engine
To remove this tuned pipe, there are 2 possible
ways to proceed. F06E09A 1
The first procedure separates the tuned pipe head 1. Disconnect hose from outlet fitting
from the tuned pipe cone, using the following pro-
cedure. The second procedure removes the tuned 3. Disconnect the water injection hose at tuned
pipe without tuned pipe head and tuned pipe cone pipe head no. 10.
separation. This procedure is explained further.
Tuned Pipe Removal with Separation from
Tuned Pipe Head and Tuned Pipe Cone
1. Disconnect water return hose at tuned pipe
head no. 10.
04-08-8 SMR2002-027_04_08A.FM
Section 04 ENGINE
6. Loosen and remove clamp no. 4 retaining tuned

pipe head no. 10 to tuned pipe cone no. 5.
F06E0AA 1
1. Water injection hose
F06D1SA
1
4. Disconnect the water bleed hose.
1. Loosen and remove clamp
7. Loosen Allen screw retaining carburetor brack-

et to tuned pipe head.
F06E0BA 1
1. Water bleed hose
5. Loosen clamp no. 1 retaining exhaust hose no. 3 F06D3JA 1

to tuned pipe cone no. 5.
1 8. Remove external seal.
F06D14A
TYPICAL
1. Loosen clamp
SMR2002-027_04_08A.FM 04-08-9
Section 04 ENGINE
9. Loosen Allen screws no. 7 and nut no. 8 at tuned 11. Remove tuned pipe head no. 10.
pipe flange. 12. Loosen bolt no. 6 of tuned pipe cone beside
NOTE: To loosen nut, use polygonal wrench (P/N the engine water return hose.
529 035 505).
F06D1VA 1
F06D1TA 1
1. Loosen bolt
1. Tuned pipe flange
13. Remove tuned pipe cone no. 5.
10. Loosen bolt no. 20 of tuned pipe head above 14. Block exhaust opening in the manifold to keep
the engine magneto then remove bolts retain- debris from entering cylinder during threads
ing bracket to engine. cleaning procedure.
15. Remove the stud no. 21 from “Y” manifold.
16. Use a M10 x 1.5 screw/tap to clean the 4
threaded holes on the “Y” manifold and the 2
threaded holes on tuned pipe. Clean out the
debris with a spray cleaner and air pressure.
CAUTION: It is very important that the threads
are free of debris before installing new self-
locking fasteners.
Tuned Pipe Removal without Separation from
Execute the above procedures 1 through 5.
Later, use the following procedure:
F06D1UA 1
Remove the strap no. 2 retaining the muffler then
1. Remove bolt remove the exhaust hose no. 3 from tuned pipe
cone no. 5.
04-08-10 SMR2002-027_04_08A.FM
Section 04 ENGINE
Loosen Allen screw retaining carburetor bracket

to tuned pipe head.
F06D1UA 1
1. Remove bolt
F06D2DA 1
Remove tuned pipe assembly.
Block exhaust opening in the manifold to keep de-
Loosen Allen screws no. 7 and nut no. 8 at tuned bris from entering cylinder during threads cleaning
pipe flange. procedure.
NOTE: To loosen nut, use polygonal wrench (P/N Remove the stud no. 21 from “Y” manifold.
529 035 505). Use a M10 x 1.5 screw/tap to clean the 4 threaded
holes on the “Y” manifold and the 2 threaded
holes on tuned pipe. Clean out the debris with a
spray cleaner and air pressure.
locking fasteners.
Exhaust Manifold
Remove 8 Allen screws no. 12 and lock washers
no. 13 then withdraw exhaust manifold.
Resonators
1 GTI, GTI LE and RX Models
F06D1TA
Remove vent tube support.

Upper Type Resonators
Loosen bolt no. 20 of tuned pipe head above the
engine magneto then remove bolts retaining Detach resonator from body.
bracket to engine. Loosen clamps and disconnect hoses. Withdraw
resonator from watercraft.
SMR2002-027_04_08A.FM 04-08-11
Section 04 ENGINE
Detach holding strap retaining resonator inside

2
bilge.
Pull resonator out of bilge.
Muffler
On DI models, disconnect the EGT (exhaust gas
temperature) sensor.
Disconnect hoses from muffler no. 11.
Disconnect hoses of the water flow regulator
valve (except 717 engine).
F07L1DA 1 3
TYPICAL
1. Loosen hose clamps
2. Upper type resonator
3. Muffler holding strap
Footwell Type Resonators

NOTE: Some models are equipped with both types
of resonators (GTX RFI and GTX).
F01E1FD 1 2
TYPICAL
1. Water supply hose
2. To injection fitting on tuned pipe
2 Disconnect retaining strap no. 2 of muffler.

Pull muffler no. 11 out of bilge.
NOTE: On RX and XP models, remove the VTS
motor. Refer to VARIABLE TRIM SYSTEM.
TUNED PIPE REPAIR

1 This procedure is given to repair tuned pipe cracks
using T.I.G. welding process.
Procedure
F07L1EA
– Sand the cracked area to obtain bare metal.
TYPICAL – Perform a 1.50 mm (1/16 in) depth chamfer over
1. Footwell type resonator crack.
2. Upper type resonator
– Use pure argon gas with 5.55 mm (3/32 in) tungsten
Loosen clamps retaining exhaust hose going from electrode (puretung “green”, zirtung “brown”) and
resonator to muffler. AC current.
Loosen clamps retaining exhaust hose to exhaust – Use a 5.55 mm (3/32 in) aluminum welding rod
outlet. (no. 4043), to fill crack.
– Sand welding slightly to remove material sur-
plus.
04-08-12 SMR2002-027_04_08A.FM
Section 04 ENGINE
Test 787 RFI Engine

– Use compressed air at 124 kPa (18 PSI) to pres- Apply Loctite 518 on 2 screws no. 12. On the oth-
surize tuned pipe. er screws no. 12, apply Molykote 111 on threads.
Install screws. Refer to the following illustration
CAUTION: Always ensure water passages are
for proper position of screws.
not blocked partially or completely while weld-
ing tuned pipe. 1 2 1 2
NOTE: Prior to verify leaks, plug all holes and pres-
surize tuned pipe while immerging it in water.
INSTALLATION
Installation is essentially the reverse of removal
procedures. However, pay particular attention to
the following.
Exhaust Manifold
Make sure gasket(s) no. 17 are properly posi-
tioned prior to finalizing manifold installation.
717 Engine
F01D82B 2 2
Apply Molykote 111 on threads of screws no. 12.
1. Screw with Loctite 518
Install exhaust manifold no. 14 and torque screws 2. Screw with Molykote 111
no. 12 to 24 N•m (17 lbf•ft) as per following illus-
trated sequence. Torque exhaust manifold screws to 24 N•m
(17 lbf•ft) as per following illustrated sequence. Re-
peat the procedure, retightening screws to 40 N•m
(30 lbf•ft).
1 3 1 7 6
7 5
6 4 2 8
3
5 8 2
F01D82A
F01D59A
SMR2002-027_04_08A.FM 04-08-13
Section 04 ENGINE
947 Engine Tuned Pipe

Apply Molykote 111 on threads of Allen screws 717 Engine
no. 12.
CAUTION: Torque wrench tightening specifica-
Install and hand tighten Allen screws no. 12 as per tions must be strictly adhered to. Locking de-
following picture. vices (ex.: locking tabs, elastic stop nuts, self-
locking fasteners, etc.) must be installed or re-
placed with new ones where specified. If the
effiency of a locking device is impaired, it must
be renewed.
Ensure rubber bushings no. 19 and sleeve no. 18
are not damaged and are properly installed into
tune pipe support(s).
CAUTION: Damage to bushings and/or sleeve
will eventually cause stress to tune pipe and may
cause cracking.
Make sure that gasket no. 16 is properly located
on exhaust manifold prior to finalizing pipe instal-
lation.
F06D1YA 1 2 1
Apply Loctite 243 (blue) on nut no. 8 and screws
1. M10 x 60 Allen screws no. 6 and no. 7.
2. M10 x 110 Allen screws
NOTE: Hand tighten all fasteners before torquing
Torque Allen screws to 24 N•m (17 lbf•ft) as per fol- any of them. For torquing sequence, see the fol-
lowing illustrated sequence. Repeat the procedure, lowing illustrations.
retightening Allen screws to 40 N•m (30 lbf•ft).
5 2
8 2 3 6 25 Nm 25 Nm
(18 lbfft) (18 lbfft)
1 3
F06D1YB 7 4 1 5 F00D29A
Install tuned pipe cone no. 5 with collar no. 15 and

clamp no. 4.
04-08-14 SMR2002-027_04_08A.FM
Section 04 ENGINE
Position clamp no. 4 as illustrated. Do not tighten 787 RFI

clamp yet. CAUTION: Torque wrench tightening specifica-
tions must be strictly adhered to. Locking de-
vices (ex.: locking tabs, elastic stop nuts, self-
locking fasteners, etc.) must be installed or re-
placed with new ones where specified. If the
effiency of a locking device is impaired, it must
be renewed.
1 NOTE: Loosen all pipe supports from engine be-
fore install tuned pipe.
Ensure rubber bushings no. 19 and sleeve no. 18
are not damaged and are properly installed into
tune pipe support(s).
CAUTION: Damage to bushings and/or sleeve
will eventually cause stress to tuned pipe and
F01D41A 2 may cause cracking.
1. Clamp Make sure that gasket no. 16 is properly located
2. Exhaust collar on exhaust manifold prior to finalizing pipe instal-
With hose removed, align cone outlet with muffler lation.
inlet. Install the tuned pipe end into exhaust hose no. 3.
NOTE: Due to exhaust cone angle, it may have to Do not toque yet.
be rotated to obtain alignment. Torquing Sequence:
Push cone no. 5 until it touches tuned pipe, then CAUTION: Torque the tuned pipe in accordance
tighten exhaust clamp no. 4 and torque to 4 N•m with the following sequence, otherwise serious
(35 lbf•in). engine damage may occur.
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.
SMR2002-027_04_08A.FM 04-08-15
Section 04 ENGINE
NOTE: Press the pipe support on the engine

before torquing the pipe support bolt.
25 Nm (18 lbfft) 10
25 Nm
11 (18 lbfft)
25 Nm
(18 lbfft) 13 1 Nm
1 (9 lbfin)
25 Nm
(18 lbfft) 12 40 Nm
15 (30 lbfft)
6 Nm
9 (53 lbfin) 7
40 Nm
14 (30 lbfft)
48 Nm
5 (35 lbfft) 3
6 Nm
2 (53 lbfin) 4
48 Nm
6 (35 lbfft) 8
F15D06S
04-08-16 SMR2002-027_04_08A.FM
Section 04 ENGINE
947 Engine Apply a thin layer of Loctite 30542 heat resistant

CAUTION: Torque wrench tightening specifica- sealant (P/N 293 800 090) all around sealing ring
tions must be strictly adhered to. Locking de- no. 15.
vices (ex.: locking tabs, elastic stop nuts, self- CAUTION: Damage to bushings and/or sleeve
locking fasteners, etc.) must be installed or re- will eventually cause stress to tuned pipe and
placed with new ones where specified. If the may cause cracking.
effiency of a locking device is impaired, it must CAUTION: It is very important that the threads
be renewed. are free of debris before installing new self-
NOTE: Loosen all pipe supports from engine be- locking fasteners. Refer to removal procedure
fore install tuned pipe. for the proper thread cleaning procedure.
Make sure to install the sealing ring no. 15 on Clean the “Y” manifold and tuned pipe surfaces.
tuned pipe cone if it was removed. Screw stud no. 21 into the “Y” manifold. Torque
to 47 N•m (35 lbf•ft).
Install the new bushing no. 18.
Torquing Sequence:
CAUTION: Torque the tuned pipe in accordance
with the following sequence, otherwise serious
engine damage may occur.
NOTE: Apply Loctite 243 (P/N 293 800 060) on
stud nut before tightening to 2.5 N•m (22 lbf•in).
Use special tool (P/N 529 035 505).
Install external seal no. 22 and secure with a lock-
ing tie.
F07D0RA
1
TYPICAL
1. Sealing ring
SMR2002-027_04_08A.FM 04-08-17
Section 04 ENGINE
40 Nm 40 Nm
6 (30 lbfft) 7 (30 lbfft)
6 Nm
(53 lbfin) 5
14 Nm 6 Nm
(124 lbfin) 16 9 (53 lbfin)
25 Nm
15 (18 lbfft)
6 Nm
(53 lbfin) 8
25 Nm
(18 lbfft) 14
6 Nm
6 Nm 3 (53 lbfin)
(53 lbfin) 2
48 Nm
48 Nm 12 (35 lbfft)
(35 lbfft) 11
2.5 Nm
(22 lbfin) 4 6 Nm
1 (53 lbfin)
48 Nm
(35 lbfft) 13 48 Nm
10 (35 lbfft)
F07D0SS
04-08-18 SMR2002-027_04_08A.FM
Section 04 ENGINE
Install exhaust hose.

1
F06D14A
1. Torque clamp to 4 N•m (35 lbf•in)
SMR2002-027_04_08A.FM 04-08-19
Section 05 ENGINE MANAGEMENT (RFI)
TABLE OF CONTENTS 0
OVERVIEW............................................................................................................................. 05-02-1
AIR INDUCTION................................................................................................................. 05-02-2
FUEL DELIVERY................................................................................................................. 05-02-2
FUEL PUMP ....................................................................................................................... 05-02-2
FUEL PRESSURE REGULATOR ........................................................................................ 05-02-2
FUEL FILTERS .................................................................................................................... 05-02-3
FUEL PUMP MODULE....................................................................................................... 05-02-3
FUEL INJECTORS .............................................................................................................. 05-02-3
ELECTRONIC MANAGEMENT.......................................................................................... 05-02-4
ELECTRONIC CONTROL UNIT (ECU)............................................................................... 05-02-4
MPEM (MULTI-PURPOSE ELECTRONIC MODULE)........................................................ 05-02-4
DIAGNOSTIC PROCEDURES ................................................................................................ 05-03-1

DIAGNOSTIC OPTION EXAMPLE..................................................................................... 05-03-1
FAULT CODE TABLES....................................................................................................... 05-03-2
ECU FAULTS...................................................................................................................... 05-03-2
INPUT SIGNAL FAULTS ................................................................................................... 05-03-2
OUTPUT SIGNAL FAULTS ............................................................................................... 05-03-3
COMPONENT INSPECTION.................................................................................................. 05-04-1

GENERAL ........................................................................................................................... 05-04-1
AIR INDUCTION SYSTEM................................................................................................. 05-04-3
THROTTLE BODY .............................................................................................................. 05-04-3
FUEL DELIVERY................................................................................................................. 05-04-3
FUEL FILTER ...................................................................................................................... 05-04-3
FUEL PUMP ....................................................................................................................... 05-04-3
REGULATOR ...................................................................................................................... 05-04-3
FUEL INJECTOR ................................................................................................................ 05-04-4
LEAK TEST (SUPPLY AND VENTILATION CIRCUITS) .................................................... 05-04-5
HIGH PRESSURE TEST (FUEL PUMP CIRCUIT) .............................................................. 05-04-5
THROTTLE POSITION SENSOR (TPS) ............................................................................. 05-04-6
CRANKSHAFT POSITION SENSOR (CPS) ....................................................................... 05-04-7
AIR TEMPERATURE SENSOR (ATS) ................................................................................ 05-04-8
WATER TEMPERATURE SENSOR (WTS) ........................................................................ 05-04-8
AIR PRESSURE SENSOR (APS) ....................................................................................... 05-04-9
RAVE SOLENOID ............................................................................................................... 05-04-10
RFI SENSORS RESISTANCE VALUES .............................................................................. 05-04-11
SMR2002-052_05_01ATOC.FM 05-01-1
TROUBLESHOOTING SUMMARY ........................................................................................ 05-05-1

ENGINE DOES NOT START .............................................................................................. 05-05-1
FLOODED ENGINE FEATURE............................................................................................ 05-05-1
SPARK PLUG INSPECTION ............................................................................................... 05-05-1
ECU FAULT CODES ........................................................................................................... 05-05-1
ENGINE STARTS BUT RUNS POORLY ............................................................................ 05-05-1
ENGINE STARTS BUT STALLS AFTER APPROXIMATELY 30 SECONDS ..................... 05-05-1
ENGINE CANNOT REACH MAXIMUM REVOLUTIONS .................................................. 05-05-1
ADJUSTMENT ....................................................................................................................... 05-06-1

THROTTLE CABLE ADJUSTMENT ................................................................................... 05-06-1
THROTTLE POSITION SENSOR (TPS).............................................................................. 05-06-1
CLOSED TPS....................................................................................................................... 05-06-1
IDLE SPEED ........................................................................................................................ 05-06-1
REMOVAL AND INSTALLATION .......................................................................................... 05-07-1

MPEM.................................................................................................................................. 05-07-1
THROTTLE POSITION SENSOR (TPS).............................................................................. 05-07-1
AIR TEMPERATURE SENSOR (ATS) ................................................................................ 05-07-1
AIR PRESSURE SENSOR (APS) ........................................................................................ 05-07-1
CRANKSHAFT POSITION SENSOR (CPS)........................................................................ 05-07-1
FUEL PUMP ASSEMBLY ................................................................................................... 05-07-1
REGULATOR....................................................................................................................... 05-07-2
FUEL FILTER ....................................................................................................................... 05-07-2
FUEL INJECTOR ................................................................................................................. 05-07-2
05-01-2 SMR2002-052_05_01ATOC.FM
Subsection 02 (OVERVIEW)
OVERVIEW 0
15
3
7
2
8 14
6
10
16
11 13
9
12
F07F18S
DESCRIPTION OF THE FUEL INJECTION SYSTEM

1. Fuel tank 9. Throttle plate
2. Fuel filter 10. Throttle Position Sensor (TPS)
3. Fuel pump 11. Air Pressure Sensor (APS)
4. Regulator 12. Air Temperature Sensor (ATS)
5. Fuel rail 13. Crankshaft Position Sensor (CPS)
6. Fuel injector 14. Water Temperature Sensor (WTS)
7. Electronic Control Unit (ECU) 15. Battery
8. Multi-Purpose Electronic Module (MPEM) 16. Ignition coil
SMR2002-028_05_02A.FM 05-02-1
The Rotax Fuel Injection (RFI) is a semi-direct elec- FUEL DELIVERY

tronic fuel injection system.
Fuel is injected into each cylinder through the rear FUEL PUMP
transfer port. With this design, the injector is not
exposed to high combustion pressure, tempera- An electric fuel pump provides fuel pressure and
ture and contaminants. flow rate to the system.
This system delivers the following benefits:
– easier cold engine starting (no choke)
– easier hot engine starting
– improved idling
– better throttle response
– better fuel economy
F07F0JA
– no fuel valve.
FUEL PUMP
This system has the advantage of optimizing the
engine power, fuel economy and emission con- FUEL PRESSURE REGULATOR
trols under all engine operating conditions by man-
aging both the fuel injection duration and ignition A regulator maintains a constant fuel pressure of
timing. 386 - 414 kPa (56 - 60 PSI).
The Rotax Fuel Injection (RFI) is composed of the
3 following basic systems:
1. air induction
2. fuel delivery
3. electronic management.
AIR INDUCTION
A single throttle body (56 mm) breath through the
air intake silencer to provide a sufficient amount
of air for the engine operation.
F07F0IA
REGULATOR
F07F08A
THROTTLE BODY
05-02-2 SMR2002-028_05_02A.FM
FUEL FILTERS FUEL PUMP MODULE

A dual piece fuel filter protects the fuel pump, reg- All these components are comprised in a single
ulator and injectors. module mounted in the fuel tank. The fuel gauge
sender is also mounted on this module.
F07F0KA
1. Fuel pump assembly

2. External fuel filter
F07F09A
FUEL PUMP ASSEMBLY
FUEL INJECTORS
1 2 The injectors inject a metered quantity of fuel from
the fuel rail into the cylinder rear transfer port in
accordance with the signal from the Electronic
Control Unit (ECU).
F07F0LA
1. End cap of fuel pump assembly removed

2. Internal fuel filter
F07F0AA
INJECTOR
SMR2002-028_05_02A.FM 05-02-3
ELECTRONIC MANAGEMENT Fail-Safe Function

In the event of a sensor malfunction, the ECU will
ELECTRONIC CONTROL UNIT use a default operating mode to ensure driveability
(ECU) to shore. A message may be displayed on the Info
Center to inform the operator.
The electronic fuel injection is equipped with a
Diagnostic Mode
Bosch Electronic Control Unit (ECU).
The ECU is able to detect malfunctions in the sen-
sor network. The malfunction is recorded in the
memory of the ECU. The memory of the ECU can
be checked using the MPEM programmer tool.
MPEM
(multi-purpose electronic module)
The MPEM is also used with the Rotax Fuel Injec-
tion system.
F07F0BA
ELECTRONIC CONTROL UNIT (ECU)
The ECU is mounted behind the MPEM in the

front of the watercraft, in a watertight box.
The ECU controls the following functions:
Basic Operating Function

Electronic Fuel Injection
The ECU receives the signals from 5 sensors which
indicate engine operating conditions at millisecond F07H0BA
intervals. MPEM
– Throttle Position Sensor (TPS)
It is responsible of the following electrical func-
– Crankshaft Position Sensor (CPS) tions:
– Air Temperature Sensor (ATS) – interpreting information
– Water Temperature Sensor (WTS) – distributing information
– Air Pressure Sensor (APS). – start/stop function
These signals are used by the ECU to determine – timer
the injection duration required for optimum air-fuel
– vehicle hours
ratio.
– Digitally Encoded Security System (DESS).
Ignition Timing
The MPEM has a special safety feature to limit
The ECU is programmed with data for optimum engine revolutions when the battery voltage is too
ignition timing under all operating conditions. Us- low.
ing data provided by the sensors, the ECU controls
the ignition timing for optimum engine operation. For example, when the battery voltage reaches
8.9 volts for at least 30 seconds, engine revolu-
Maximum Engine Speed tions are limited to 4480 RPM.
The ECU limits the maximum allowable engine When voltage reaches 7 volts for at least 30 sec-
speed. The RPM rev limiter is set at 7200 ± 50 onds, the engine is automatically shut off by the
RPM. MPEM.
05-02-4 SMR2002-028_05_02A.FM
PARAMETERS SENSORS FUEL

DELIVERY
Air Pressure
Intake air Sensor
pressure Fuel tank
(APS)
Crankshaft Crankshaft
position and Position Fuel filter
engine speed Sensor (CPS)
Throttle valve Throttle

position (Idle to Position Fuel pump
wide open throttle) Sensor (TPS)
Water
Engine Temperature
temperature Regulator
Sensor (WTS)
Air
Intake air Temperature
temperature Injectors
Sensor (ATS)
Battery To engine
voltage
Start/stop
signal Multi-Purpose Electronic Module
(MPEM)
Electronic Control Unit

(ECU)
F07F0NS
SIGNAL MANAGEMENT
SMR2002-028_05_02A.FM 05-02-5
Subsection 03 (DIAGNOSTIC PROCEDURES)
DIAGNOSTIC PROCEDURES 0
The MPEM programmer is the primary tool to di- By selecting DIAGNOSIS the following message
agnose fuel injection related problems. “INITIALIZING IN PROCESS” will be displayed a
The latest software designed for the RFI model few seconds, then a new menu will appear on the
allows sensor inspection, diagnostic options and screen.
adjustment such as the Throttle Position Sensor Select READ FAULT and press ENTER.
(TPS). 1. BOSCH INFO
NOTE: Make sure your MPEM programmer is up- 2. READ FAULT
dated with the latest software version. For a com-
plete overview of the programmer, refer to the 3. ERASE FAULT
MPEM Programmer Guide (P/N 219 700 090). 4. ADJUSTMENT
5. REAL TIME
DIAGNOSTIC OPTION EXAMPLE 6. END DIAGNOSIS
Turn on the programmer and enter your password. NOTE: Line no. 1 BOSCH INFO will display the iden-
Select VEHICLE INFO from the main menu and tification of the watercraft and the MPEM/ECU.
press ENTER. By selecting READ FAULT, the MPEM program-
1. CHECK KEYS mer will display the number of faults in the ECU
memory and the codes related with the fault(s).
2. PROGRAM KEY
The programmer will offer PRESS ANY KEY. If
3. VEHICLE INFO
there is more than 1 fault in the ECU memory, the
4. START VEH. next fault code will be displayed.
5. OTHERS NOTE: On this model, there is always at least the
By selecting the VEHICLE INFO you will access a 04 FC fault code. Ignore this fault code. Also,
9-line sub-menu. Select BOSCH SYSTEM from when the engine is NOT operating, the fault code
the sub-menu and press ENTER. 02 01 03 will be displayed for the CPS (crankshaft
position sensor). It should not be considered as a
1. CUSTOMER NAME
fault in the static mode.
2. DELIVERY DATE
Refer to the tables on next page for the explana-
3. VEH. SERIAL # tion of the fault codes.
4. ENGINE PARAM. After reading the fault codes in the memory of the
5. PROGRAM KEY ECU, PRESS ANY KEY will return the program-
mer to the latest menu.
6. HOUR INFO
By selecting ERASE FAULT in the menu, it will
7. MPEM INFO
allows you to erase the faults in the ECU memory.
8. BOSCH SYSTEM
NOTE: The programmer will not allow fault code
9. SAVE + QUIT erasing without first viewing in the READ FAULT.
By selecting BOSCH MENU you will enter a sec-
ond sub-menu. Select DIAGNOSIS and press EN-
TER.
1. DIAGNOSIS
2. START VEHICLE
SMR2002-028_05_03A.FM 05-03-1
FAULT CODE TABLES

ECU FAULTS
FAULT CODE
FAULT DETECTION MPEM TYPE OF FAULT
B.U.D.S.
programmer
No fault detected FF FF 88 N.A. • No defect
Electronic Control Unit Internal FF FF 00 P 0604 • Internal defect
memory FF FF 1B P 0605 • Not plausible = EEPROM defect
Electronic Control Unit FF FE 2B P 1600 • EEPROM not programmed
EEPROM
FF FD 10 P 1601 • Data in EEPROM out of range (1 of 3 bytes)
EEPROM Data Setting FF FD 25 P 1602 • Data in EEPROM out of range
(all 3 bytes different)
INPUT SIGNAL FAULTS

FAULT CODE
B.U.D.S.
programmer
02 14 07 P 0562 • Voltage from the battery too low
Supply voltage to ECU
02 14 06 P 0563 • Voltage from the battery too high
02 0A 1D P 0117 • Sensor circuit shorted to ground
Engine Water Temperature
02 0A 1E P 0118 • Signal interruption or short circuit to battery
Sensor (WTS)
02 0A 1B P 0116 • Non plausible signal
02 06 1F P 0122 • Sensor circuit shorted to ground
Throttle Position Sensor (TPS)
02 06 1C P 0123 • Sensor circuit shorted to battery
Crankshaft Position Sensor 02 1F 06 P 0219 • Signal exceeding RPM limits
(CPS) 02 1F 23
02 01 03 P 0335 • No signal detected (fault code active when
Crankshaft Position Sensor engine is not running and ignition is on)
(CPS)
02 01 1B P 0336 • Synchronization error (sensor/toothed wheel)
Air Intake Temperature Sensor 02 0F 1D P 0112 • Sensor circuit shorted to ground
(ATS) 02 0F 1E P 0113 • Signal interruption or short circuit to battery
02 10 1D P 0107 • Sensor circuit shorted to ground
Air Pressure Sensor (APS)
02 10 1E P 0108 • Signal interruption or short circuit to battery
05-03-2 SMR2002-028_05_03A.FM
OUTPUT SIGNAL FAULTS

FAULT CODE
B.U.D.S.
programmer
04 E1 1C P 0262 • Short circuit to battery
Injector 1 04 E1 1D P 0261 • Short circuit to ground
04 E1 1E P 1200 • Interruption or open circuit
04 E2 1C P 0265 • Short circuit to battery
Injector 2 04 E2 1D P 0264 • Short circuit to ground
04 E2 1E P 1201 • Interruption or open circuit
Fuel pump 04 EB 1C P 0230 • Short circuit to battery
Not applicable 04 FC N.A. • Not applicable
04 DB 1C P 0478 • Short circuit to battery
RAVE vacuum solenoid 04 DB 1D P 0477 • Short circuit to ground
04 DB 1E P 0479 • Interruption or open circuit
SMR2002-028_05_03A.FM 05-03-3
Subsection 04 (COMPONENT INSPECTION)
COMPONENT INSPECTION 0
GENERAL CAUTION: Never use injector cleaning products.
They may contain additive that could damage in-
 WARNING jector components. A copper wire brush may be
used to clean the tip of the direct injectors if nec-
The fuel system of a fuel injection system holds essary.
much more pressure than on a carbureted wa-
tercraft. Prior to disconnecting a hose or to re- Engine problems are not necessarily related to the
moving a component from the fuel system, fol- electronic fuel injection system.
low the recommendation described here. It is important to check that the electrical system
is functioning properly:
– Always disconnect battery properly prior to – battery
working on the fuel system.
– fuses
 WARNING – DESS
Fuel lines remain under pressure at all times. – ignition (spark)
Always proceed with care and use appropriate – ground connections
safety equipment when working on pressur-
ized fuel system. Wear safety glasses and work – wiring connectors.
in a well ventilated area. Do not allow fuel to If all of the above mentioned items are functioning
spill on hot engine parts and/or on electrical correctly, the following verifications can be per-
connectors. Proceed with care when removing/ formed to detect any faulty components.
installing high pressure test equipment or dis- NOTE: Troubleshooting should be performed us-
connecting fuel line connections. Cover the fuel ing the MPEM programmer tool. See TROUBLE-
line connection with an absorbent shop rag. SHOOTING in this subsection.
Slowly disconnect the fuel hose to minimize
spilling. Wipe off any fuel spillage in the bilge. It is possible that a component seems to operate
Fuel is flammable and explosive under certain in static condition but in fact, it is defective. In this
conditions. Always work in a well ventilated ar- case, the best way to solve this problem is to re-
ea. Always disconnect battery prior to work on move the original part and replace it with one
the fuel system. After performing a pressure which is in good condition.
test, use the valve on the fuel pressure gauge to Never use a battery charger to replace temporarily
release the pressure (if so equipped). the battery, as it may cause the MPEM to work
erratically or not to work at all. Check related-circuit
When the job is done, ensure that hoses from fuel fuse solidity and condition with an ohmmeter. Vi-
rail going to fuel pump are properly secured in their sual inspection could lead to false results.
support. Then, pressurize the fuel system. Per-
form the high pressure test as explained in this
section and pressurize the fuel tank and fuel lines
 WARNING
All electrical actuators (injectors, fuel pump,
as explained in FUEL SYSTEM section.
RAVE solenoid, ignition coil and starter sole-
Properly reconnect the battery. noid) are permanently connected to the bat-
tery positive terminal, even when the safety
 WARNING lanyard is removed. Always disconnect the
Ensure to verify fuel line connections for dam- battery prior to disconnecting any electric or
age and that NO fuel line is disconnected prior electronic parts.
to installing the safety lanyard on the DESS
post. A pressure test must be done before con- To perform verifications, a good quality multimeter
necting the safety lanyard. The fuel pump is such as Fluke 111 (P/N 529 035 868) should be
started each time the safety lanyard is installed used.
and it builds pressure very quickly.
SMR2002-028_05_04A.FM 05-04-1
Pay particular attention to ensure that pins are not Resistance Measurement
out of their connectors or out of shape. The trou-
When measuring the resistance with an ohmmeter,
bleshooting procedures cover problems not re-
all values are given for a temperature of 20°C
sulting from one of these causes.
(69°F). The resistance value of a resistance varies
 WARNING with the temperature. The resistance value for
usual resistor or windings (such as injectors) in-
Ensure all terminals are properly crimped on creases as the temperature increases. However,
wires and connector housings are properly our temperature sensors are NTC types (Negative
fastened. Temperature Coefficient) and work the opposite
which means that the resistance value decreases
Before replacing a MPEM, always check electrical as the temperature increases. Take it into account
connections. Make sure that they are very tight and when measuring at temperatures different from
they make good contact and that they are corrosion- 20°C (69°F). Use this table for resistance variation
free. A “defective module” could possibly be re- relative to temperature for temperature sensors.
paired simply by unplugging and replugging the
MPEM. The voltage and current might be too TEMPERATURE RESISTANCE (ohms)
weak to go through dirty wire pins. Check carefully °C °F NOMINAL LOW HIGH
if posts show signs of moisture, corrosion or if
they look dull. Clean pins properly and then coat - 30 - 22 12600 11800 13400
them with silicon-based dielectric grease or other - 20 -4 11400 11000 11800
appropriate lubricant (except if otherwise speci- - 10 14 9500 8000 11000
fied) when reassembling them. If the newly re-
placed MPEM is working, try the old one and re- 0 32 5900 4900 6900
check if it works. 10 50 3800 3100 4500
Ensure that all electronic components are genuine 20 68 2500 2200 2800
— particularly in the ignition system. Installing re- 30 86 1700 1500 1900
sistive caps, non-resistive spark plug cables (or
modified length) or non-resistive spark plugs may 40 104 1200 1080 1320
lead to generate fault codes or bad operation. 50 122 840 750 930
NOTE: Diagnostics Communication Kit. See DI- 60 140 630 510 750
AGNOSTICS section. 70 158 440 370 510
After a problem has been solved, ensure to clear 80 176 325 280 370
the fault(s) in the MPEM using the VCK. Refer to
DIAGNOSTIC PROCEDURES. 90 194 245 210 280
100 212 195 160 210
110 230 145 125 160
120 248 115 100 125
CONVERSION CHART FOR TEMPERATURE SENSORS
The resistance value of a temperature sensor may

test good at a certain temperature but it might be
defective at other temperatures. If in doubt, try a
new sensor.
05-04-2 SMR2002-028_05_04A.FM
Also remember this validates the operation of the REGULATOR

sensor at ambient temperature. It does not vali-
date the over temperature functionality. To test it, The regulator is mounted on top of the fuel pump
the sensor could be removed from the engine/ assembly.
muffler and heated with a heat gun while it is still
connected to the harness to see if the MPEM will 1
detect the high temperature condition and gener-
ate a fault code.
When working with injectors, the resistance value
might test good while the complete current would
not flow through the wire when pulsating current
is supplied to the injector in its normal operation.
A solution would be to use a jumper wire to direct-
ly supply the injector from the MPEM. If it now
works, replace the defective wire. A Noid light
(available from after-market tool/equipment sup-
pliers) may also be used to validate the injector
operation.
F07F0DA
AIR INDUCTION SYSTEM 1. Regulator
To inspect the regulator, a fuel pressure test must

THROTTLE BODY be done.
Check that the throttle plate moves freely and Check that battery voltage is above 12 volts.
smoothly when depressing throttle lever. Place a suitable container below the quick connect
fitting of the fuel rail.
FUEL DELIVERY Cover the quick connect fitting with a shop towel.
Press on both tabs and disconnect the quick con-
FUEL FILTER nect fitting.
To inspect the fuel filter, the fuel pump assembly has
to be removed from the fuel tank. See REMOVAL in
this subsection for the procedure.
FUEL PUMP
The fuel pump operation can be checked as fol-
lows.
Install the safety lanyard cap on the switch. The
fuel pump should run for approximately 1 second
and then shut off.
If not, check the electrical circuit and the 10 A fuse
on the MPEM module.
F07F11A 1
1. Fuel rail
 WARNING
Fuel is under pressure. Wipe off any fuel spillage
in the bilge.
SMR2002-028_05_04A.FM 05-04-3
Install a fuel pressure gauge (P/N 529 035 591) to FUEL INJECTOR
the quick connect fitting of the fuel hose.
1
F02B0BA
6
FUEL PRESSURE GAUGE (P/N 529 035 591)
Install the safety lanyard cap on the switch to ac- F07F0CA 7

tivate the fuel pump. The fuel pressure should be 1. Inlet side
between 386 - 414 kPa (56 - 60 PSI). 2. Filter
3. Wiring terminal
If the pressure is too high, replace the fuel pump 4. Coil
5. Plunger
module. 6. Needle valve
7. Injection side
If the pressure is too low, check the following com-
ponents: Touch the injector while cranking the engine to
– fuel hoses and connections feel the operation of the injector.
– fuel filter If there is no signal detected from the injector, dis-
connect the plug connector from the injector and
– fuel pump check the signal from the MPEM.
– regulator To check the signal, verify voltage at the plug con-
– voltage at fuel pump (minimum 8 Vdc). nector. There should be at least 6 Vdc while crank-
ing engine.
05-04-4 SMR2002-028_05_04A.FM
Check the resistance of the fuel injector circuits. Install the safety lanyard cap on the switch to ac-
Disconnect the AMP plug connector no. 4 on the tivate the fuel pump.
MPEM. Check for fuel leakage from the injector nozzle.
Using a multimeter, check resistance value be- There should be less than 1 drop of fuel per minute.
tween terminal as follows.
CONTACT LOCATION
Injector no. 1 18 and 20
Injector no. 2 19 and 21
3
18 19 20 21
F07F16A 1 2
1. Fuel injectors
2. Fuel rail
3. Injector nozzles
If not within specification, replace the fuel injector(s).
LEAK TEST
(supply and ventilation circuits)
F07F15A
Refer to FUEL SYSTEM.
The resistance should be between 2.3 Ω and
2.5 Ω at temperature of 20°C (68°F). HIGH PRESSURE TEST
If resistance value is incorrect, check wiring har- (fuel pump circuit)
ness between AMP plug connector and fuel injec-
tors for damaged wires or bad connections. Repair Before proceeding to the pressure test ensure the
if necessary. battery is fully charged. Battery voltage must be
over 12 volts.
Recheck resistance value at AMP plug connector
no. 4.  WARNING
If not within specification, replace the fuel injector. The fuel hose may be under pressure. Cover
the fuel line connection with an absorbent
Leakage Test (fuel injector) shop rag. Slowly disconnect the fuel hose to
To perform a leakage test, the injectors and fuel rail release the pressure. Wipe off any fuel spill-
have to be removed from engine. See REMOVAL age inside bilge.
in this subsection for the procedure.
NOTE: Do not detach injectors from fuel rail.
Reconnect the wire connector of the injector.
Place each injector in a clean bowl.
SMR2002-028_05_04A.FM 05-04-5
Press on both tabs and pull quick connect fitting ELECTRONIC MANAGEMENT
to disconnect the fuel hose from fuel rail.
THROTTLE POSITION SENSOR
(TPS)
Check the resistance value of the throttle position
sensor.
F02F1XA 2 1
1. Quick connect fitting
2. Fuel rail
Install fuel pressure gauge (P/N 529 035 591) be-

tween fuel rail and fuel hose from fuel tank. F07F0EA 1
1. Throttle position sensor (TPS)
Disconnect the AMP plug connector no. 4 on the

MPEM.
Using a multimeter, check the resistance between
terminal 3 (PURPLE/BROWN wire) and terminal 4
(BLACK/BROWN wire) on the AMP plug connec-
tor.
The resistance should be between 1.6 kΩ and
2.4 kΩ.
Check also the resistance between terminal 4
(BLACK/BROWN wire) and terminal 11 (WHITE/
BROWN wire) with the throttle plate in idle posi-
tion.
F02B0BA
Install the safety lanyard cap on the switch to activate

the fuel pump.
The fuel pump should run for approximately 1 sec-
ond and the fuel pressure should be between 386 -
414 kPa (56 - 60 PSI).
Check hose connections at fuel pump and at fuel
rail.
05-04-6 SMR2002-028_05_04A.FM
The resistance should be between 710 Ω and CRANKSHAFT POSITION

1380 Ω.
SENSOR (CPS)
Check the resistance of the crankshaft position
sensor.
1
3 4 11
F07F15B
F07H0CA
If resistance is below specifications, replace the
throttle position sensor (TPS). 1. Crankshaft position sensor (CPS)
If resistance is above specifications, disconnect Disconnect the AMP plug connector no. 4 from
the connector of the throttle position sensor and the MPEM module.
check resistance of wiring harness and terminals
between AMP plug connector and TPS sensor
terminal 7 (GREY/YELLOW wire) and terminal 14
connector.
(GREY/RED wire) on the plug connector.
If there is an open circuit, repair or replace the defec-
The resistance should be between 774 Ω and
tive wire or terminal.
946 Ω at temperature above 20°C (68°F).
Reconnect the throttle position sensor connector
and recheck resistance values at AMP plug con-
nector no. 4.
If not within specification, replace the throttle po-
sition sensor.
NOTE: Whenever the TPS is replaced, removed
or adjusted, the TPS closed position must be re-
adjusted.
Voltage Test
If the sensor resistance value is good, check the volt-
age output from MPEM to throttle position sensor.
Disconnect plug connector from throttle position
sensor and connect a voltmeter between the
PURPLE/BROWN wire and the BLACK/BROWN 14 7
F07F15C
wire in the wiring harness.
Depress the start/stop button with the safety lan- If not within specification, replace the crankshaft
yard removed to activate the timer. There should position sensor.
be 5 Vdc.
SMR2002-028_05_04A.FM 05-04-7
AIR TEMPERATURE SENSOR If resistance is below specifications, replace air

temperature sensor (ATS).
(ATS)
If resistance is above specifications, disconnect
NOTE: When testing the resistance of the air tem- the connector of the air temperature sensor and
perature sensor (ATS), it is important to check the check resistance of wiring harness and terminals
ambient temperature. The resistance values for between AMP plug connector and ATS sensor
the sensor will be different according to the tem- connector.
perature.
If there is an open circuit, repair or replace the de-
Check the air temperature sensor resistance. fective wire or terminal.
Reconnect the air temperature sensor connector
and recheck the resistance between terminal 6
and terminal 13 in the AMP plug connector no. 4.
If not within specification, replace the air temper-
ature sensor.
WATER TEMPERATURE SENSOR

(WTS)
Resistance Test
Check the water temperature sensor resistance.
1
F07F0FA 1
1. Air temperature sensor (ATS)
Disconnect the AMP plug connector no. 4 from

the MPEM module.
terminal 6 (BLACK/WHITE wire) and terminal 13
(WHITE/GREY wire) on the plug connector.
2.736 kΩ at temperature of 19°C to 21°C (66°F to
70°F).
F07F0GA
1. Water temperature sensor (WTS)
Disconnect the AMP plug connector no. 4 from

the MPEM module.
terminal 5 (BLACK/ORANGE wire) and terminal 12
(TAN/ORANGE wire) on the plug connector.
13 6
F07F15D
05-04-8 SMR2002-028_05_04A.FM
The resistance should be between 2.280 kΩ and If there is not 5 V, check the wiring harness and
2.736 kΩ at temperature of 19°C to 21°C (66°F to pin #12 on the #4 AMP plug connector.
70°F). Remove the TAN/ORANGE wire from the #12 po-
sition on the AMP plug connector, install a test
connector (a female connector with about 25 mm
(1 in) of wire) then reconnect the AMP plug con-
nector. Press the start/stop button, and check for
5V on the test wire. If none is present, replace the
MPEM.
On the WTS connector, check for continuity to
ground on the BLACK/ORANGE wire when the
system is not powered up, and within 5 - 12 ohms
when the system is powered up. Otherwise,
check the wiring harness and pin #5 on the #4 AMP
plug connector. Remove the BLACK/ORANGE
wire from the #5 position on the AMP plug connec-
tor, install a test connector (as described above)
then reconnect the AMP plug connector. Repeat
F07F15E
12 5 the same tests as above, if the tests are not within
specs, replace the MPEM.
If not within specification, continue with the fol-
lowing tests. AIR PRESSURE SENSOR (APS)
Operation Test 1
Remove WTS from engine and keep it connected.
Place the WTS in a metal container filled with wa-
ter and heat with a heat gun. Use a thermometer
to monitor the temperature. Keep the container
outside and away from bilge as much as possible.
 WARNING
Do not use an open flame in the bilge area.
Fuel vapors may be present and this may lead
to an explosion.
Heat up above 94°C (201°F) then start engine.

CAUTION: Do not run the engine longer than 1 F07F0HA
minute. If so, plug the WTS hole and use the flush 1. Air pressure sensor (APS)
kit to cool the engine.
Check the air pressure sensor resistance.
At this temperature, the overheat beeper should
sound. Otherwise, check the following. Disconnect the AMP plug connector no. 4 from
the MPEM module.
Stop engine.
Disconnect the WTS.
Remove safety lanyard and press the start/stop
button to power up the system and check for 5 V
on the TAN/ORANGE wire.
SMR2002-028_05_04A.FM 05-04-9
Using a multimeter, check the resistance between RAVE SOLENOID

terminal 9 (WHITE/BLUE wire) and terminal 2
(BLACK/BLUE wire) on the plug connector.
9 1 2
F07F15F
F07D0GA
The resistance should be between 3.4 kΩ and RAVE SOLENOID

8.2 kΩ. Disconnect the AMP plug connector no. 4 from the
Check also the resistance between terminal 2 MPEM module.
(BLACK/BLUE wire) and terminal 1 (PURPLE/ Check resistance value between terminal 16 and
BLUE wire) of the plug connector. terminal 23 on the plug connector.
8.2 kΩ.
If not within specification, disconnect the connec-
tor of the water temperature sensor and check re-
sistance of wiring harness and terminals between
AMP plug connector and APS sensor connector.
Reconnect the air pressure sensor connector and
recheck the resistance value between terminals in
the AMP plug connector no. 4.
If not within specification, replace the air temper-
ature sensor.
Voltage Test
If the sensor resistance value is within specifications,
disconnect the plug connector from the APS sensor 16 23
F07F15G
and check the voltage between the PURPLE/BLUE
wire and the BLACK/BLUE wire in the wiring harness
The resistance value should be 30 Ω.
from the MPEM.
Depress the start/stop button with the safety lan-
yard removed to activate the timer. There should
be 5 Vdc.
05-04-10 SMR2002-028_05_04A.FM
RFI SENSORS RESISTANCE VALUES

TERMINAL RESISTANCE
COMPONENT WIRE COLOR VOLTS
NUMBER VALUE
1 and 2 PU/BL and BK/BL 2.4 k - 8.2 k ohms 5 Vdc between

Air pressure sensor
9 and 2 WH/BL and BK/BL 3.4 k - 8.2 k ohms PU/BL and BK/BL
3 and 4 PU/BW and BK/BW 1.6 k - 2.4 k ohms 5 Vdc between

Throttle position sensor PU/BW and
4 and 11 BK/BW and WH/BW 710 - 1380 ohms BK/BW
Water temperature sensor 5 and 12 BK/OR and TA/OR 2280 - 2736 ohms N.A.
Air temperature sensor 6 and 13 BK/WH and WH/GY 2280 - 2736 ohms N.A.
Crankshaft position sensor 7 and 14 GY/YL and GY/RE 774 - 946 ohms N.A.
Rave solenoid 16 and 23 PU/GY and BK/GY 30 ohms N.A.
Injector no. 1 18 and 20 BL/PU and BL/BK 2.3 - 2.5 ohms 6 Vdc at the plug
Injector no. 2 19 and 21 GR/PU and BK/GR 2.3 - 2.5 ohms connector
SMR2002-028_05_04A.FM 05-04-11
Subsection 05 (TROUBLESHOOTING SUMMARY)
TROUBLESHOOTING SUMMARY 0
ENGINE DOES NOT START ECU FAULT CODES
If the engine does not start, the following items Fault codes in the ECU memory will identify poten-
should be verified in this order: tial problems with the RFI system. When checking
– fuses fault codes without engine in operation, the CPS
fault code will always appear. Also, the 04 FC fault
– ignition (spark) code will always appear.
– fuel pump Disconnecting the battery will erase the fault codes
– check fault codes in the ECU memory. in the ECU memory.
FLOODED ENGINE FEATURE ENGINE STARTS BUT RUNS

If the engine does not start and it is flooded, pro- POORLY
ceed as follows: If the engine starts but runs poorly, the following
Remove spark plug cables and connect them on items should be verified in this order:
the grounding device. – Check spark plug condition.
Remove spark plugs and dry them using a rag. – Check fault codes in the ECU memory.
Cover spark plug holes with a rag. – Check fuel pressure.
Depress and hold the throttle lever at full throttle – Check TPS adjustment.
position.
If some work has been performed on the unit,
Install the safety lanyard cap on the switch. Press make sure injector wire connectors were not
the start/stop button wait 2 seconds then crank mixed. It is also possible that the RAVE solenoid
the engine for approximately 10 seconds. connector be mixed with one of the injector con-
NOTE: Proceeding in this order, no fuel is injected nector. Refer to the wiring diagram for wire colors
and the accumulated fuel in the engine will be ex- and positions.
pelled.
Reinstall spark plugs and connect cables. ENGINE STARTS BUT STALLS
Start engine normally without applying the throt- AFTER APPROXIMATELY
tle. 30 SECONDS
The RPM signal (GREY wire) is short circuit to the
SPARK PLUG INSPECTION ground. Check wire condition. If the wire test
Whenever replacing the spark plugs, always use good, either the tachometer or Info Center is de-
NGK BR8ES with the resistor feature. The spark fective.
plug gap is set at 0.5 - 0.6 mm (.02 - .024 in).
To check for ignition, attach an inductive timing ENGINE CANNOT REACH
light to the high tension lead while turning the en- MAXIMUM REVOLUTIONS
gine with the starter.
Check battery voltage. When voltage is too low,
Reversed high tension cables will not allow the RFI the MPEM limits the engine revolutions.
to run. Unlike other Sea-Doo models, the spark plugs
Recharge or replace battery.
spark independently on each piston stroke. Re-
versed high tension cables will cause backfires. The RAVE system is not functioning properly. The
sliding valves do not open. Check pressure hoses
and check valve from crankcase to RAVE solenoid.
Check RAVE solenoid.
SMR2002-028_05_05A.FM 05-05-1
Subsection 06 (ADJUSTMENT)
ADJUSTMENT 0
THROTTLE CABLE CAUTION: Do not select “YES” until the idle
speed screw is loosened to allow the throttle
ADJUSTMENT plate to close.
Fully depress throttle lever. Lever must touch han- Loosen the lock nut of the idle speed screw.
dlebar grip.
Loosen the idle speed screw until it does not con-
tact the throttle plate stopper.
Loosen the adjustment of the throttle cable.
1
F01K08A
1. Must touch handlebar grip
Ensure throttle plate is fully open.

Adjust cable to obtain a gap of 0.75 mm (.030 in)
between throttle lever stopper and bracket on
throttle body.
THROTTLE POSITION SENSOR F07F17A

(TPS) 1. Idle speed screw
This adjustment is very important. The setting of
Depress throttle lever a few times and ensure
the TPS will determine the basic parameters for all
throttle plate is completely closed.
fuel mapping.
Selecting “YES” will instantly readjust the close
NOTE: Adjustment must be done each time the
throttle position adjustment to the new setting.
throttle position sensor (TPS) is loosened or re-
moved. NOTE: If the ECU is replaced, the TPS closed po-
sition must be readjusted.
CAUTION: An improperly adjusted TPS may
lead to serious engine damage.
The adjustment of the TPS is performed using the
IDLE SPEED
MPEM programmer. Access the BOSCH SYSTEM in the MPEM pro-
grammer. Then, select REAL TIME in the sub-menu.
CLOSED TPS Turn idle speed screw approximately 3 turns from
the point when the screw end touches the lever,
To perform this adjustment, proceed as follows:
or until the TPS idle position reads 6 - 7.
Access the BOSCH SYSTEM in the MPEM pro-
For a precise adjustment of the idle speed, it should
grammer. Then, select ADJUSTMENT in the sub-
be finalized in water.
menu.
Idle speed in water is 1500 ± 100 RPM.
Choose CLOSE TPS in the ADJUSTMENT menu.
The screen will display the actual adjustment of
the TPS in degrees and it will also offer to adjust it.
SMR2002-028_05_06A.FM 05-06-1

MPEM CRANKSHAFT POSITION
IMPORTANT: When MPEM is replaced, the safe- SENSOR (CPS)
ty lanyard(s), the TPS closed position and the TDC Disconnect the connector of the CPS.
setting must be reprogrammed/reset. Refer to
their specific section for adjustment. Loosen Allen screw retaining the CPS.
Remove the CPS.
THROTTLE POSITION SENSOR At installation, apply Loctite 243 (blue) on the Allen
(TPS) screw.
NOTE: Clean threads prior installing screw.
Remove the air intake silencer.
Remove the flame arrester. FUEL PUMP ASSEMBLY
Remove the air temperature sensor to ease removal
of the TPS. Open the front storage compartment cover.
Disconnect the connector of the TPS. Remove the storage basket.
Loosen 2 Allen screws retaining the TPS. Remove the glove box.
Remove TPS. Disconnect the wire connector from the fuel pump
assembly.
AIR TEMPERATURE SENSOR Disconnect fuel vent hose from fuel pump assem-
bly.
(ATS)
Cover the quick connect fitting with a shop towel.
Press on both tabs and disconnect the quick con-
Remove the flame arrester. nect fitting.
Disconnect the connector of the ATS.
Pull the ATS from the grommet retaining it.  WARNING
Fuel is under pressure. Wipe off any fuel spill-
AIR PRESSURE SENSOR (APS) age in the bilge. Fuel is flammable and explo-
sive under certain conditions. Always work in
Remove the air intake silencer. a well ventilated area.
Disconnect the connector of the APS.
Loosen nuts retaining the fuel pump assembly to
Loosen Allen screw retaining the APS. the fuel tank.
Remove the APS.
1
At installation, apply Loctite 243 (blue) on screw
threads.
WATER TEMPERATURE
SENSOR (WTS)
Disconnect the connector of the WTS.
Loosen the WTS from the cylinder head.
At installation, apply Loctite 518 on threads of the
WTS.
F07F0DB
1. Loosen nuts
SMR2002-028_05_07A.FM 05-07-1
Remove fuel pump assembly from fuel tank.
REGULATOR
The regulator is not serviceable. Replace the fuel
pump assembly if the regulator is defective.
FUEL FILTER
The fuel filter is not serviceable. Replace the fuel
pump assembly if the fuel filter must be replaced.
FUEL INJECTOR
Place a suitable container below the quick connect
fitting of the fuel rail. F07F0SA 1
1. Loosen screws retaining the fuel rail
Cover the quick connect fitting of the fuel rail with
a shop towel. Remove the fuel rail with both fuel injectors.
Press on both tabs and disconnect the quick con- To remove the fuel injector from the fuel rail, pry
nect fitting. off the retaining clip.
Disconnect the wire connectors of both fuel injec-
tors.
1
F07F0TA 1
1. Pry the clip
F07F0RA
When reinstalling the fuel injector, install the re-
taining clip to the injector, then insert the injector
1. Press retaining clip to unlock the connector to the fuel rail.
Loosen both screws retaining the fuel rail to the Apply a thin layer of injection oil to O-rings of fuel
cylinders. injectors to ease fuel rail installation.
CAUTION: Whenever removing fuel injector,
always replace both injector O-rings with new
ones.
05-07-2 SMR2002-028_05_07A.FM
Section 06 ENGINE MANAGEMENT (DI)
TABLE OF CONTENTS 0
OVERVIEW............................................................................................................................. 06-02-1
OPERATING PRINCIPLE .................................................................................................... 06-02-2
AIR INDUCTION................................................................................................................. 06-02-2
AIR COMPRESSOR SYSTEM............................................................................................ 06-02-2
FUEL DELIVERY SYSTEM................................................................................................. 06-02-2
BASIC OPERATION ........................................................................................................... 06-02-2
AIR/FUEL RAIL ASSEMBLY .............................................................................................. 06-02-2
FUEL PUMP MODULE....................................................................................................... 06-02-3
MPEM (multi-purpose electronic module) ...................................................................... 06-02-4
IGNITION SYSTEM............................................................................................................ 06-02-8
COMPONENT INSPECTION AND ADJUSTMENT .............................................................. 06-03-1

GENERAL ........................................................................................................................... 06-03-1
FUEL SYSTEM ................................................................................................................... 06-03-1
ELECTRICAL SYSTEM....................................................................................................... 06-03-2
AMP CONNECTOR PIN-OUT ............................................................................................ 06-03-3
QUICK FUEL PRESSURE TEST ........................................................................................ 06-03-4
THROTTLE BODY .............................................................................................................. 06-03-5
AIR COMPRESSOR............................................................................................................ 06-03-8
PRESSURE TEST ............................................................................................................... 06-03-8
REPAIR ............................................................................................................................... 06-03-9
FUEL DELIVERY................................................................................................................. 06-03-12
FUEL INJECTOR ................................................................................................................ 06-03-14
AIR/FUEL RAIL ................................................................................................................... 06-03-15
DIRECT INJECTOR ............................................................................................................ 06-03-16
FUEL PUMP ....................................................................................................................... 06-03-17
MPEM REPLACEMENT ..................................................................................................... 06-03-21
MANIFOLD AIR TEMPERATURE SENSOR (MATS)......................................................... 06-03-26
MANIFOLD AIR PRESSURE SENSOR (MAPS) ................................................................ 06-03-27
EXHAUST GAS TEMPERATURE SENSOR (EGT) ............................................................ 06-03-28
KNOCK SENSOR (KS) ....................................................................................................... 06-03-28
RAVE SOLENOID ............................................................................................................... 06-03-29
IGNITION COIL .................................................................................................................. 06-03-30
TDC SETTING .................................................................................................................... 06-03-32
SMR2002-052_06_01ATOC.FM 06-01-1
SPARK PLUGS.................................................................................................................... 06-03-35

CRANKING SYSTEM.......................................................................................................... 06-03-36
DI SYSTEM TEST SUMMARY........................................................................................... 06-03-36
DIAGNOSTIC PROCEDURES................................................................................................. 06-04-1

GENERAL............................................................................................................................ 06-04-1
DESS SYSTEM ................................................................................................................... 06-04-2
FAULT DETECTION AND COMPENSATORY ACTIONS .................................................. 06-04-4
COMPONENT FAILURE WARNING SYSTEM .................................................................. 06-04-4
VCK (VEHICLE COMMUNICATION KIT) ........................................................................... 06-04-6
DI SYSTEM FAULT CODES ............................................................................................... 06-04-7
06-01-2 SMR2002-052_06_01ATOC.FM
OVERVIEW 0
F12F03T
SMR2002-029_06_02A.FM 06-02-1
OPERATING PRINCIPLE
The Orbital Combustion Process (OCP) provides a
stratified combustion process resulting from the
direct injection of a finely atomized fuel spray (less
than 10 microns). This is achieved by using a pneu-
matically assisted direct injection system, a
unique combustion chamber geometry and a pre-
cise control of the combustion process by the
MPEM (Multi-Purpose Electronic Module).
AIR INDUCTION
Air for combustion is drawn directly at the base of
F12D01A
the engine through two 46 mm throttle bodies.
The air flow is controlled by two throttle plates.
The air continues through the reed valves into the FUEL DELIVERY SYSTEM
crankcase.
BASIC OPERATION
When the piston reaches the correct position, the
MPEM opens the fuel injector and fuel is dis-
charged into a cavity inside the direct injector.
Next, the direct injector opens and the fuel is dis-
charged into the combustion chamber by the com-
pressed air which breaks the fuel up into a very
fine mist in the process. This air/fuel mixture is
then ignited by the spark plug.
AIR/FUEL RAIL ASSEMBLY

F12F05A 1 1 2 4 3 2 6
TWIN 46 mm THROTTLE BODIES
AIR COMPRESSOR SYSTEM

The air compressor supplies the compressed air
required for fuel atomization in the air injector. It is
integrated with the engine and mechanically driv-
en by the counterbalance shaft. It also supplies the
air pressure required to operate the RAVE valves.
F12F06A 5 7 1 8
TYPICAL
1. Air/fuel rail
2. Fuel injector
3. Fuel pressure regulator
4. Air pressure regulator
5. Air inlet hose
6. Fuel inlet
7. Air return
8. Fuel return
06-02-2 SMR2002-029_06_02A.FM
The air/fuel rail assembly is mounted on top of the FUEL PUMP MODULE
cylinder head. It provides support for the air/fuel
injectors and both air and fuel regulators. It also
contains passages for the air and the fuel. The rail
is a small reservoir for the injectors that keeps
enough fluid at the proper pressure to supply the
injectors demand.
Fuel Injector
Fuel injectors are used to provide fuel from the
fuel rail to the to the direct injector.
Fuel Pressure Regulator

A fuel pressure regulator controls the pressure in-
side the fuel rail, and allows the excess of fuel to
return to the fuel tank. The fuel pressure regulator
regulates the fuel pressure at approximately
185 kPa (27 PSI) higher than the air pressure in the
fuel rail. The back side of the diaphragm is ex- F12D0AA
posed to the air rail pressure. As the air pressure

increases in the fuel rail, the fuel pressure needed The fuel pump module is located inside the fuel
to open the regulator will increase equally. tank. The module includes the fuel pump and the
fuel level sensor.
The differential pressure regulation utilizes the air
pressure reference signal to maintain constant Fuel Pump
pressure drop across fuel injector orifice.
It operates at a nominal pressure of approximately
The initial operating pressure of the regulator is 735 kPa (107 PSI).
preset by the manufacturer and is not adjustable.
Fuel Filter
Direct Injector
A mesh filter is located at the bottom of the fuel
Also called air injector, two direct injectors (one pump module inside the fuel tank. An inline fuel
per cylinder) are used to inject air/fuel mixture into filter is also installed on the fuel line going to the
the combustion chamber. fuel rail.
Air Pressure Regulator
An air pressure regulator regulates the pressure of
air delivered by the air compressor.
It regulates the pressure developed inside the air
passage to approximately 550 kPa (80 PSI).
The initial operating pressure of the regulator is
SMR2002-029_06_02A.FM 06-02-3
ELECTRONIC MANAGEMENT The MPEM is directly powered by the battery. It is

responsible for the following engine management/
MPEM electrical functions:
(multi-purpose electronic module) – interpreting information
The electronic fuel injection is equipped with a – distributing information
MPEM. It is also called ECU (Electronic Control – start/stop function
Unit). It is the brain of the electrical system/fuel – timer
injection system.
– DESS (Digitally Encoded Security System)
1 – ignition timing maps
– injection maps (fuel injector and direct injector)
– MPEM contains a total of 34 maps (injection
and ignition) for optimum engine operation in all
conditions
– engine RPM limiter
– etc.
The MPEM features a permanent memory that
will keep the programmed safety lanyard(s) active,
fault codes and other vehicle information, even
when the battery is removed from the watercraft.
MPEM — General Functions

F12D0EA Automatic Power Shut-Down
TYPICAL The MPEM is equipped with an automatic power
1. Multi-purpose electronic module (MPEM) shut-down. This feature prevents the battery from
The MPEM is mounted in the front of the water- losing its charge if the safety lanyard cap is left on
craft. the post when the engine is not running.
After connecting the safety lanyard cap, the
MPEM will remain in standby mode during the
next 10 minutes, waiting for a starting. If the start/
stop button is not depressed, then the MPEM will
be automatically powered down.
Antistart Feature
This system allows starting the vehicle only with
safety lanyard(s) that has been programmed to op-
erate a specific watercraft. This functionality is the
DESS system. See below for details.
Digitally Encoded Security System (DESS)
The following components are specially designed
for this system: Multi-Purpose Electronic Module
(MPEM), safety lanyard cap and safety lanyard
post.
06-02-4 SMR2002-029_06_02A.FM
The safety lanyard cap contains a magnet and a Gauges Current Supply
ROM chip. The magnet actually closes the reed The purpose of this function is to allow reading of
switch inside the post which is the equivalent of a gauges without the engine running. It will give ac-
mechanical ON/OFF switch. The chip has a unique cess to most functions of the information center
digital code. gauge without starting the engine.
The DESS circuitry in the watercraft MPEM is ac- Gauges are supplied with current for 33 seconds
tivated at the factory. Therefore, a safety lanyard when connecting the safety lanyard cap on its post
must be programmed to start the engine. or when pressing the start/stop switch without
NOTE: Actually, it is the memory of the MPEM the safety lanyard on the DESS post.
which is programmed to recognize the digital code NOTE: The fuel pump will be activated for 2 sec-
of the safety lanyard cap. This is achieved with the onds to build up pressure in the fuel injection sys-
MPEM programmer (P/N 529 035 878) or the VCK tem, only when connecting the safety lanyard cap
(Vehicle Communication Kit) (P/N 529 035 844). to the post.
Refer to their operation manual or help system to
program a safety lanyard. Engine Starting
The system is quite flexible. Up to 8 safety lan- If the MPEM recognizes a valid safety lanyard, it
yards may be programmed in the memory of the allows engine to start when the start/stop switch
watercraft MPEM. They can also be erased indi- is pressed.
vidually. If the safety lanyard is left on the DESS post for
The MPEM also offers a special safety lanyard — the more than 10 minutes after stopping the engine,
Sea-Doo LK™ (learning key) — which can be pro- the MPEM may send out 1 long beep when press-
grammed so that the vehicle can be run only at a ing the start/stop switch. The current supply to
limited speed — approximately 48 km/h (30 MPH). gauges will be stopped as explained in the ANTI-
Such feature is ideal for first time riders or renters. START FEATURE section. A light pressure on the
safety lanyard or removing and reinstalling the
 WARNING safety lanyard is required to allow the MPEM to
read and validate the safety lanyard, the engine
When programming a Sea-Doo LK™ (learning
can then be started.
key), use only a lanyard that is identified for
that purpose. Otherwise, a customer could use If start/stop button is held after engine has started,
a vehicle with a greater speed than he was ex- the MPEM automatically stops the starter when
pecting. the engine speed reaches 1000 RPM.
If start button is activated while the throttle lever
NOTE: If desired, a safety lanyard can be used on is depressed more than 70%, the engine will not
other watercraft equipped with the DESS. It only be allowed to start.
needs to be programmed for that watercraft.
Engine RPM Limiter
When connecting a safety lanyard cap on the post,
the DESS is activated and will emit audible signals: The MPEM will limit the maximum engine speed.
– 2 short beeps indicate a working safety lanyard. Engine Stopping
Engine starting can take place. There are 2 ways to stop the engine.
– 1 long beep indicates a wrong safety lanyard is Press and hold start/stop switch or remove the
being used or that something is defective. En- safety lanyard cap from its post.
gine starting is not allowed.
If the engine is stopped by removing the safety lan-
The memory of the MPEM features two self- yard, it is possible to restart the engine as explained
diagnostic modes for the DESS operation. Refer in the ENGINE STARTING section.
to DIAGNOSTIC PROCEDURES subsection for
more information. If safety lanyard cap is reconnected within 6 sec-
onds, the current supply to gauges is cut for a brief
The memory of the MPEM is permanent. If the moment and comes back on with the audible sig-
battery is disconnected, no information is lost. nal of safety lanyard validation.
When ordering a new MPEM from the regular
parts channel, the DESS circuitry will be activated.
SMR2002-029_06_02A.FM 06-02-5
Low-Fuel and Low-Oil Level Warning Device Power Distribution

When the fuel level in the reservoir is low, the fuel The MPEM distributes power from battery to all
level sensor transmits a signal to the MPEM. The accessories. Accessories are protected by fuses
MPEM sends out signals for the beeper and to the integrated in the MPEM. Fuses are identified be-
information center gauge. sides their holder.
When the oil level is low in the reservoir, the IMPORTANT: The sensors and injectors are con-
MPEM sends out a signal to the information center tinuously powered with the supply from the bat-
gauge and the pilot lamp on the gauge will turn on. tery. The MPEM switches the ground to com-
plete the electrical circuits it controls. Take this
into account when troubleshooting the electrical
system.
MPEM — Engine Management Functions
F12D0CS
06-02-6 SMR2002-029_06_02A.FM
This engine management system controls both Flooded Engine (drowned mode)
the fuel injection and the ignition timing. If the engine does not start and it is flooded, pro-
As shown in the DI CONTROL SYSTEM illustra- ceed as follows:
tion, the MPEM is the central point of the fuel in- Remove spark plug cables and connect them on
jection system. It reads the inputs, makes compu- the grounding device.
tations, uses pre-determined parameters and
sends the proper signals to the outputs for proper Remove spark plugs and dry them using a rag.
engine management. Cover spark plug holes with a rag.
The MPEM also stores the fault codes and general While engine is stopped, depress and HOLD the
information such as: operating conditions, vehicle throttle lever at full throttle position for cranking.
hours, serial numbers, customer and maintenance Crank the engine several times.
information.
A 1 second beep every second indicates the drowned
Electronic Fuel Injection mode is active.
The MPEM receives the signals from different sen- NOTE: Proceeding in this order, no fuel is injected,
sors which indicate engine operating conditions at no ignition occurs and the accumulated fuel in the
milli-second intervals. engine will be expelled.
Signals from sensors are used by the MPEM to In case of water-flooded engine, if water does not
determine the injection parameters (fuel maps) re- completely go out, it may be necessary to remove
quired for optimum air-fuel ratio. the air intake silencer then to lean the vehicle so
The CPS and both TPS are the primary sensors that water can flow out from throttle bodies.
used to control the injection and ignition timing. Reinstall spark plugs and connect cables.
Other sensors are used for secondary input.
Start engine normally without applying the throttle.
NOTE: The EGT sensor does not provide control
inputs to the MPEM. Its sole purpose is to protect Monitoring System
the exhaust system components by emitting a The MPEM monitors the electronic components
warning signal in the event of overheating. of the fuel injection system and some compo-
nents of the electrical system. When a fault oc-
Ignition Timing
curs, it sends visual messages through the infor-
The MPEM is programmed with data (it contains mation center and/or audible signals through a
ignition mappings) for optimum ignition timing un- beeper to inform you of a particular condition. Re-
der all operating conditions. Using engine operat- fer to the DIAGNOSTIC PROCEDURES subsec-
ing conditions provided by the sensors, the MPEM tion for the displayed messages and the beeper
controls the ignition timing for optimum engine coded signals chart.
operation.
Limp Home Modes
Knock Sensor
Besides the signals as seen above, the MPEM
A knock sensor is mounted on top of the cylinder may automatically set default parameters to the
head. It detects specific vibration that would be engine management to ensure the adequate op-
typically generated by engine detonation. If deto- eration of the watercraft if a component of the fuel
nation occurs, the knock sensor detects it and the injection system is not operating properly.
MPEM retards the ignition advance temporarily (it
Depending on the severity of the malfunction, the
goes in a specific mode) until detonation stops.
watercraft speed may be reduced and not allowed
Engine Modes of Operation to reach its usual top speed as usual.
The MPEM controls different operation modes of The engine RPM may be limited to idle if some
the engine to allow proper operation for all possi- critical components fail. In this case, removing and
ble conditions: Cranking, flare, idle, warm up, nor- reinstalling the safety lanyard on its post may al-
mal operation, Sea-Doo LK™ (learning key) (limit- low retrieving normal operation.
ed vehicle speed), engine speed limiter, drowned
engine and limp home (see below).
SMR2002-029_06_02A.FM 06-02-7
These performance-reduced modes allow the rid- Ignition Coil

er to go back home which would not be possible
Ignition coil induces voltage to a high level in the
without this advanced system. Refer to the DIAG-
secondary windings to produce a spark at the
NOSTIC PROCEDURES for a complete chart.
spark plug.
If a fault occurs and involves a limp home mode
Two separate ignition coils receive input from the
operation, the DI system will reduce engine RPM
MPEM. Each coil provides high voltage to its cor-
gradually to the proper level.
responding spark plug.
Diagnostic Mode This ignition system allows spark plugs to spark
The malfunctions are recorded in the memory of independently.
the MPEM. The memory of the MPEM can be CAUTION: Do not interchange spark plug ca-
checked using the VCK (Vehicle Communication bles. The white tape on the ignition coil should
Kit) (P/N 529 035 844) to see the fault codes. Refer match the white tape on the high tension cable.
to the DIAGNOSTIC PROCEDURES subsection.
Both coils are located inside the electrical box.
IGNITION SYSTEM 2 1
The ignition system consist of different sub-systems
where some are interrelated.
Unregulated AC current is produced by the mag-
neto. Part of the AC current is rectified and regu-
lated for the charging system.
A 12 volts battery supplies the Multi-Purpose Elec-
tronic Module (MPEM) with DC current.
Refer to CHARGING SYSTEM.
The following type of ignition system is used:
– Digital Inductive System.
Magneto System F12R0UC
The magneto is the primary source of electrical TYPICAL

energy. It transforms magnetic field into electric 1. PTO side ignition coil
2. MAG side ignition coil
current (AC).
The magneto has a 3 phases, delta wound stator
on 18 poles. Capacity is 270 watts.
06-02-8 SMR2002-029_06_02A.FM
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)
COMPONENT INSPECTION AND

ADJUSTMENT 0
GENERAL  WARNING
Engine problems are not necessarily related to the Fuel lines remain under pressure at all times. Al-
electronic fuel injection system. ways proceed with care and use appropriate
It is important to ensure that the mechanical integ- safety equipment when working on pressurized
rity of the engine/propulsion system is present: fuel system. Wear safety glasses and work in a
well ventilated area. Do not allow fuel to spill on
– good jet pump/drive system operation hot engine parts and/or on electrical connectors.
– good engine compression and properly operat- Proceed with care when removing/installing
ing mechanical components, no leaks etc. high pressure test equipment or disconnecting
– fuel pump connection and fuel lines without leaks. fuel line connections. Use the VCK (Vehicle Com-
munication Kit) to release fuel pressure prior to
Check the chart in TROUBLESHOOTING section removing a hose. Cover the fuel line connection
to have an overview of problems and suggested with an absorbent shop rag. Slowly disconnect
solutions. the fuel hose to minimize spilling. Wipe off any
When replacing a component, always check its fuel spillage in the bilge. Fuel is flammable and
operation after installation. explosive under certain conditions. Always work
in a well ventilated area. Always disconnect bat-
 WARNING tery prior to working on the fuel system. After
Air compressor hose may be hot. Use a rag performing a pressure test, use the valve on the
or gloves or let hose cool down. fuel pressure gauge to release the pressure (if so
equipped).
FUEL SYSTEM – Always disconnect battery properly prior to

 WARNING When the job is done, ensure that hoses from fuel
The fuel system of a fuel injection system holds rail going to fuel pump are properly secured in their
much more pressure than on a carbureted wa- support. Then, pressurize the fuel system. Per-
tercraft. Prior to disconnecting a hose or to re- form the high pressure test as explained in this
moving a component from the fuel system, fol- section and pressurize the fuel tank and fuel lines
low the recommendation described here. Pay as explained in FUEL SYSTEM section.
attention that some hoses may have more than Properly reconnect the battery.
one clamp at their ends. Ensure to reinstall the
same quantity of clamps at assembly.  WARNING
Ensure to verify fuel line connections for dam-
– Use the VCK (Vehicle Communication Kit) (P/N 529
age and that NO fuel line is disconnected prior
035 844) to release the fuel pressure in the system.
to installing the safety lanyard on the DESS
Look in the Activation section of the software
post. Always perform the high pressure test if
B.U.D.S.
any component has been removed. A pressure
test must be done before connecting the safety
lanyard. The fuel pump is started each time the
safety lanyard is installed and it builds pressure
very quickly.
SMR2002-030 _06_03A.FM 06-03-1

CAUTION: Never use injector cleaning products. Pay particular attention to ensure that pins are not
They may contain additive that could damage in- out of their connectors or out of shape. The trou-
jector components. A copper wire brush may be bleshooting procedures cover problems not re-
used to clean the tip of the direct injectors if nec- sulting from one of these causes.
essary.
To check air/fuel rail for leaks, first pressurize the  WARNING
system then spray soapy water on all hose con- Ensure all terminals are properly crimped on
nections, regulators and injectors. Air bubbles will wires and connector housings are properly
show the leaking area. Check also for leaking fuel fastened.
or fuel odor.
Before replacing a MPEM, always check electrical
 WARNING connections. Make sure that they are very tight and
Never use a hose pincher on high pressure they make good contact and that they are corrosion-
hoses. free. A “defective module” could possibly be re-
MPEM. The voltage and current might be too
ELECTRICAL SYSTEM weak to go through dirty wire pins. Check carefully
It is important to check that the electrical system they look dull. Clean pins properly and then coat
is functioning properly: them with silicon-based dielectric grease or other
– battery appropriate lubricant (except if otherwise speci-
– fuses fied) when reassembling them. If the newly re-
placed MPEM is working, try the old one and re-
– DESS check if it works.
– ignition (spark) Ensure that all electronic components are genu-
– ground connections ine — particularly in the ignition system. Installing
– wiring connectors. resistive caps, non-resistive spark plug cables (or
modified length) or non-resistive spark plugs may
It is possible that a component seems to operate lead to generate fault codes or bad operation.
in static condition but in fact, it is defective. In this
case, the best way to solve this problem is to re- NOTE: Diagnostics Communication Kit. See DI-
move the original part and replace it with one AGNOSTICS section.
which is in good condition. After a problem has been solved, ensure to clear
Never use a battery charger to replace temporarily the fault(s) in the MPEM using the VCK. Refer to
the battery, as it may cause the MPEM to work DIAGNOSTIC PROCEDURES.
fuse solidity and condition with an ohmmeter. Vi- Communication Errors Between
sual inspection could lead to false results. B.U.D.S. and the MPEM
Remember that if there has not been active com-
 WARNING munication between B.U.D.S. and the MPEM for
All electrical actuators (injectors, fuel pump, more than 10 minutes, the MPEM automatically
RAVE solenoid, ignition coil and starter sole- shuts down. This causes false “communication
noid) are permanently connected to the bat- errors”. This occurs quite frequently and confuses
tery positive terminal, even when the safety many technicians. Whenever this occurs, simply
lanyard is removed. Always disconnect the remove and replace the lanyard to restart the
battery prior to disconnecting any electric or MPEM. In fact, one should get into the habit of
electronic parts. resetting the MPEM with the lanyard whenever
the MPEM does not seem to respond. It must be
To perform verifications, a good quality multimeter kept “awake”.
such as Fluke 111 (P/N 529 035 868) should be used.
06-03-2 SMR2002-030 _06_03A.FM

Resistance Measurement Also remember this validates the operation of the

date the over temperature functionality. To test it,
the sensor could be removed from the engine/
with the temperature. The resistance value for
connected to the harness to see if the MPEM will
creases as the temperature increases. However,
ate a fault code.
our temperature sensors are NTC types (Negative
Temperature Coefficient) and work the opposite When working with injectors, the resistance value
which means that the resistance value decreases might test good while the complete current would
as the temperature increases. Take it into account not flow through the wire when pulsating current
when measuring at temperatures different from is supplied to the injector in its normal operation.
20°C (69°F). Use this table for resistance variation A solution would be to use a jumper wire to direct-
relative to temperature for temperature sensors. ly supply the injector from the MPEM. If it now
works, replace the defective wire. A noid light
TEMPERATURE RESISTANCE (ohms) (available from after-market tool/equipment sup-
°C °F NOMINAL LOW HIGH pliers) may also be used to validate the injector
operation.
- 30 - 22 12600 11800 13400
- 20 -4 11400 11000 11800 AMP CONNECTOR PIN-OUT
- 10 14 9500 8000 11,000
Use this diagram to locate the pin numbers on the
0 32 5900 4900 6900 AMP connector no. 3 and no. 4 of the wiring har-
10 50 3800 3100 4500 ness when performing tests.
20 68 2500 2200 2800
18 19 20 21
30 86 1700 1500 1900
40 104 1200 1080 1320
50 122 840 750 930
60 140 630 510 750
70 158 440 370 510
80 176 325 280 370
90 194 245 210 280
100 212 195 160 210
110 230 145 125 160
120 248 115 100 125
F07F15A
AMP CONNECTOR PIN-OUT (WIRING HARNESS SIDE)
new sensor.
SMR2002-030 _06_03A.FM 06-03-3

QUICK FUEL PRESSURE TEST

 WARNING
Read PRESSURE TEST under AIR/FUEL RAIL
farther in this section for precautions and
setup to take care of, before performing this
test. The procedure here is a quick summary.
Disconnect outlet hose (the one with the fuel fil-

ter) from fuel pump using tool (P/N 529 035 714).
Connect adapter to pressure gauge as shown.
3
1
1 F12R09A
1. Fuel filter
2. Fuel line going to air/fuel rail
3. Pressure gauge between disconnected hose (inline installation)
Install safety lanyard and observe fuel pressure.

Do not crank engine.
FUEL REGULATOR PRESSURE
(when installing safety lanyard)
2
185 ± 14 kPa (27 ± 2 PSI)
If pressure is within limits, air/fuel rail is working

F12R08A
adequately. Proceed with the fuel pressure test
1. Pressure gauge (P/N 529 035 709) below.
2. T-adapter (P/N 529 035 710)
If pressure is out of limits, go to FUEL DELIVERY
Install pressure gauge between disconnected hose part and proceed with the tests described there.
(inline installation).
Crank or start engine and observe fuel pressure.
FUEL PRESSURE
(when cranking engine
or when engine is running)
738 ± 14 kPa (107 ± 2 PSI)
If pressure is within limits, fuel and air systems are

working adequately. No subsequent tests are nec-
essary for the air/fuel system.
Remove pressure gauge and reinstall fuel hose. At
installation apply engine oil on O-ring.
If pressure is out of limits, proceed with all the
tests.
06-03-4 SMR2002-030 _06_03A.FM

AIR INDUCTION SYSTEM Remove TPS, throttle lever, spring and guide from
the old throttle body.
THROTTLE BODY Installation
Mechanical Inspection Reinstall removed parts on the new throttle body. For
Check that the throttle plates moves freely and TPS replacement procedures, refer to THROTTLE
smoothly when depressing throttle lever. Take this POSITION SENSOR (TPS) in ELECTRONIC MAN-
opportunity to lubricate the throttle cable. AGEMENT below.
IMPORTANT: The throttle bodies are designed to Properly attach throttle bodies together if previ-
be tamper proof. Changing the idle stop or modi- ously detached.
fying them in any way will not increase perfor-
mance or change the idle speed. Adjustment
Before replacing any parts, check the following as Throttle Body Synchronization
these could be causing the fault. Perform the test NOTE: If both throttle bodies are replaced togeth-
while the engine is not running. er with new ones, no synchronization is required
– Throttle cable adjustment too tight. Not return- as it has already been set at the factory. However,
ing fully to idle stop. proceed with throttle cable and closed TPS adjust-
ments as described below. If only one throttle body
– Throttle body idle set screw is loose or worn.
is replaced, proceed with the complete following
– Throttle linkage between the two throttles has adjustments. Ensure to perform all the adjust-
moved. ments prior to starting the engine. Otherwise, en-
– TPS is loose. gine may run at a limited RPM in limp home mode.
– Corroded or damaged wiring or connectors. IMPORTANT: The throttle body synchronization
is required only when replacing one throttle body.
– Throttle body has been replaced and the closed
Otherwise, do not tamper with it as this is NOT a
TPS reset has not been performed.
regular maintenance procedure.
– MPEM has been replaced and the closed TPS
The master throttle body is the one driven by the
reset has not been performed.
throttle cable. The slave throttle body follows the
master and must me synchronized with the master.
Electrical Inspection
Refer to THROTTLE POSITION SENSOR (TPS) in 1 7
ELECTRONIC MANAGEMENT below.
Replacement
Removal
To remove throttle bodies from engine, proceed
as follows:
– Remove air intake silencer. Refer to AIR INTAKE
section.
– Disconnect TPS connectors.
– Disconnect throttle cable and oil injection pump
cable.
– Detach hoses and remove fasteners retaining 4 5 8 6 2 3
F12R0XA
throttle bodies and pull out together.
1. Throttle cable attachment
If only one throttle body replacement is required, 2. Master throttle body
detach them and remove the sealant on idle set 3. Master throttle plate
4. Slave throttle body
screw head. Gently remove the plastic cap from 5. Slave throttle plate
the synchronization screw. 6. Idle set screw
7. Lock nut
8. Synchronizing screw with its tamper proof cap
SMR2002-030 _06_03A.FM 06-03-5

NOTE: In the following illustrations, the lower link

plate has been removed for clarity purposes only.
It does not have to be removed to perform the
adjustment.
Loosen lock nut of idle set screw.
Unscrew idle set screw so that master throttle
plate completely closes in the throttle body. En-
sure screw end clears the lever stopper.
F12R1BA 2 1
1. Measure resistance between pins 2 and 3
2. Turn screw clockwise to increase resistance
Tighten lock nut.
 WARNING
Do not apply any threadlocker to the screw
F12R0YA 2 1 threads. The threadlocker may leak off the
1. Unscrew until master throttle plate is fully closed in throttle body screw and onto the throttle mechanism and
2. Unscrew here cause the throttle to stick.
3. Gap here
Remove synchronizing screw and spring between Recheck reading and readjust as necessary.
levers. Slave TPS
NOTE: The 175 Ω below is used to open the throt- Install a new synchronizing screw. Screw in and
tle plates the same amount on each throttle body ensure screw end clears the lever stopper. Ensure
to obtain the proper synchronization. It is the also to keep slave throttle plate completely closed
equivalent of using a drill bit in the throttle bore to in the throttle body.
open throttle plate on carburetors.
Master TPS  WARNING
Snap throttle plate a few times to ensure it is com- Ensure to use a new screw which is coated
pletely closed. with the proper threadlocker to avoid further
loosening. Do not use the removed screw
Using an ohmmeter, measure resistance between
even if you were applying any threadlocker.
pins 2 and 3. Note the resistance value. Add
The threadlocker may leak off the screw and
175 Ω to that value.
flow onto the throttle mechanism and cause
Turn idle set screw clockwise until ohmmeter the throttle to stick.
reading reaches the computed value above ± 20 Ω.
06-03-6 SMR2002-030 _06_03A.FM

Ensure spring is still well positioned on stoppers.

2
Properly reinstall the plastic cap to the synchroni-
zation screw.
Apply Loctite 5900 (P/N 293 800 066) flange seal-
ant on idle set screw head.
1
F12R1DA
1. Gap here
2. Spring removed
Snap throttle plate a few times to ensure it is com-

pletely closed.
Measure resistance between pins 2 and 3. Note
the resistance value. Substract 175 Ω from that
value.
Properly reinstall the spring. Ensure that master
throttle plate is still closed.
Turn synchronizing screw clockwise until read- F12R10A 2
ing reaches the computed value above ± 20 Ω. 1. Plastic cap
2. Wider spaced tabs here
1 3. Loctite 5910 flange sealant
 WARNING
Ensure no Loctite product protrudes screw head.
F12R1CA 2
2. Turn screw clockwise to decrease resistance
SMR2002-030 _06_03A.FM 06-03-7

Throttle Cable Adjustment Injection Oil Pump Cable Adjustment

Mechanically adjust the throttle cable using the ad- As oil injection cable is throttle dependent, always
justing device underneath body, below steering. proceed with the oil injection pump cable adjust-
Slacken lock nut to allow adjuster rotation. Free- ment after throttle cable adjustment. Refer to OIL
play on lever should be between 2 and 3.5 mm INJECTION PUMP.
(1/16 and 1/8 in). When done, tighten lock nut. CAUTION: Improper oil injection pump synchro-
nization with throttle bodies can cause serious
1 engine damage.
2
AIR COMPRESSOR
PRESSURE TEST
The pressure test will show the available pressure
from the air compressor.
First ensure there is no leak from compressor gas-
kets, hoses and fittings. Soapy water can be sprayed
on components. Repair any leak.
Disconnect hose outlet from air compressor.
F12R1GB
1. Slacken nut
2. Turn adjuster
NOTE: On LRV DI models, vent tube removal in

front storage compartment may be necessary to
reach the adjusting device. F12R02A
CAUTION: Improper cable adjustment will cause

strain on cable and/or damage cable bracket or Connect adapters and pressure relief valve to pres-
throttle lever at handlebar. sure gauge as shown.
Use the vehicle communication kit (VCK) with the
B.U.D.S. software to perform this adjustment.
Choose the Monitoring tab.
Press throttle lever to reach full throttle.
Turn cable adjustment until Throttle Opening
meter indicates between 95% and 99%.
Closed TPS Adjustment
Perform the CLOSED TPS ADJUSTMENT as de-
scribed in THROTTLE POSITION SENSOR (TPS)
in ELECTRONIC MANAGEMENT below.
06-03-8 SMR2002-030 _06_03A.FM

If pressure is below limits, ensure inlet hose is not

1
obstructed, bent or kinked. Otherwise, repair the
air compressor.
Remove pressure gauge and reinstall air compres-
sor hose.
REPAIR
Top End
Remove retaining screws.
Lift cover then remove compressor head.
Clean all parts in a solvent and visually inspect for
corrosion damage.
Check reed valve plates for cracks, deformation,
dirt or other defects. The reed plates must lie com-
pletely flat against the reed valve body.
F12R03A 4 3 2 Inspect plane surfaces for warpage.
1. Pressure gauge (P/N 529 035 709)
If reed valve is found defective, it is suggested to
2. Adapter for air compressor (P/N 529 035 712) replace it then to temporarily reassemble the com-
3. T-adapter (P/N 529 035 710) pressor to then make a pressure test. If it fails,
4. Pressure relief valve (P/N 529 035 711)
check bottom end.
CAUTION: Ensure to install the pressure relief When changing reed valve, ensure to position ring
valve to allow excess pressure to go out. Note plate opening so that 2 holes align inside the open-
the arrow on the valve. Otherwise, air compres- ing. Holes must not be obstructed by the opening
sor components might be damaged. edges.
Install pressure gauge to air compressor.
NOTE: To prevent fuel to be injected and thus go-
ing out the disconnected hose, use the drowned
engine mode to crank engine. While engine is
stopped, depress and HOLD the throttle lever at
full throttle position for cranking.
Ensure the battery is in good condition to get the
normal cranking speed.
Crank engine and observe air pressure.
 WARNING 1 2
F12R04A
Be careful of pressure relief valve outlet. Com-
pressed air may flow out there. 1. Reed valve opening
2. Rotate opening to align 2 holes inside without obstructing the
holes
MINIMUM AIR PRESSURE (at cranking)
Ensure to position O-ring, around top of cylinder
621 ± 14 kPa (90 ± 2 PSI) sleeve.
If pressure is within limits, air compressor is work-

ing adequately.
SMR2002-030 _06_03A.FM 06-03-9

Remove engine support and slightly lift engine to

allow access. Block engine in this position.
Remove top end as explained above.
Remove access plug of air compressor connect-
ing rod.
Remove connecting rod retaining screw.
As a puller, use a M7 x 1.0 x 50 mm screw to re-
lease connecting rod “crankpin”.
IMPORTANT: Trace a mark on “crankpin” (bush-
ing) outer end. This is needed for reinstallation.
F12R05A 1
1. O-ring on top of cylinder sleeve
Ensure to position screw from the bottom up as

show. Torque nut to 2.7 N•m (24 lbf•in).
2.7 Nm
(24 lbfin)
F12R06A 1
1. Use a M7 x 1.0 x 50 mm screw as a puller
Push piston upward with or without the cylinder

sleeve.
Remove rubber plug then push piston pin end to
remove from connecting rod.
Inspection
1 corrosion damage.
F12D0BA
1. Screw from bottom up Clean piston ring grooves with a groove cleaner
tool, or a piece of broken ring.
CAUTION: Failure to properly position screw
Check bearings and pins for wear and heat discol-
head will lead piston to hit it.
oration. Check connecting rod for straightness.
If pressure is still low then continue with BOTTOM Replace damaged components.
END. Otherwise, remove components again. In-
stall a new gasket, new O-ring, compressor head
sanded with a fine sand paper.
and cover. Apply synthetic grease below screw
head and Loctite 243 on threads. Install screws If you find aluminum dust or debris in this area,
then torque to 5 N•m (44 lbf•in) to then finalize to they may have flowed toward the injection oil res-
11 N•m (97 lbf•in). ervoir. In this case, the oil reservoir and lines must
be flushed and the filter replaced.
Bottom End CAUTION: Failure to properly clean the oil sys-
To gain access to piston, rings and connecting rod, tem will result in serious engine damage.
engine PTO flywheel must be removed. Refer to
ENGINE section.
06-03-10 SMR2002-030 _06_03A.FM

The inspection of top end should include the fol- Install the oil ring with the “TOP” marking on top.
lowing measurements. Identify the correct position by looking at beveled
edge of oil ring and while installation, make sure
TOLERANCES that the beveled edge should be towards the top
ENGINE of the piston.
MEASUREMENT NEW PARTS WEAR
(min.) (max.) LIMIT
1
Piston/cylinder wall 0.12 mm 0.2 mm
N.A.
clearance (.005 in) (.008 in)
0.1 mm 0.25 mm 0.5 mm

Ring end gap
(.004 in) (.010 in) (.020 in)
N.A.: Not applicable

Clearance can be quickly checked with a feeler 1
gauge. Insert feeler gauge in cylinder then slide
piston (without piston rings installed). If clearance
exceeds tolerance, check cylinder top area with
your finger to feel if there is a ridge. If so, the cyl-
inder sleeve is worn and needs replacement. Oth-
erwise, replace piston.
F12R1OA
Ring End Gap 1. Beveled edge

Position ring close to top of cylinder top.
Position ring openings 180° apart.
der, use piston as a pusher. 1
exceeds specified tolerance, rings should be re-
placed.
F12R15A 2
1. Ring openings 180° apart
2. TOP marking on this side
F12R07A 2 1 Use ring compressor (P/N 529 035 713) and insert
piston in cylinder.
1. Top of cylinder
2. Ring end gap NOTE: Cylinder may be removed from crankcase
Assembly to install piston more easily on the bench from the
bottom if desired.
Apply injection oil in cylinder and on rings prior to
installing.
SMR2002-030 _06_03A.FM 06-03-11

When attaching connecting rod to “crankpin”, strict-

ly follow this procedure:
1. Block counterbalance shaft to prevent any rota-
tion.
2. Install the “crankpin” (bushing) with the previ-
ously marked end outside. If the mark is not
present anymore, place a straight edge against
bushing end to find the tapered end (concave).
A very small gap between the edge and the
bushing will identify the tapered end to be in- 1
stalled against the counterweight.
3. Install a NEW screw and torque to 6.5 N•m
(58 lbf•in). Do not apply any thread locker product.
4. Turn the screw clockwise an additional 80 de-
grees ± 5 degrees.
CAUTION: Failure to strictly follow this proce-
dure may cause screw to loosen and lead to 2
engine damage. The bushing tapered end must
be against the counterweight. Besides, as the
“crankpin” screw has been stretched from the
previous installation, it is very important to use F12R08A
a new screw at assembly. Also, the new screw

will have the proper threadlocking coating. 2. T-adapter (P/N 529 035 710)
Ensure to correctly position O-ring on access cov- Install pressure gauge between disconnected hose
er and install cover. (inline installation).
Reinstall remaining removed parts. Ensure to
check engine alignment.
FUEL DELIVERY
FUEL PRESSURE REGULATOR
Pressure Test
at the air/fuel rail. It validates the pressure regula-
tor and leaks in the system.
IMPORTANT: Before checking air/fuel rail pres-
sure, make sure the fuel pressure from the fuel
pump and the air pressure from the air compres- 2
sor are within specifications. See the procedures
elsewhere in this section.
Also ensure there is no leak from hoses and fit-
tings. Repair any leak.
3
Ensure there is enough gas in fuel tank. 1
Release the fuel pressure in the system.
Disconnect outlet hose (the one with the fuel fil- F12R09A
1. Fuel filter
Connect adapter to pressure gauge as shown. 2. Fuel line going to air/fuel rail
06-03-12 SMR2002-030 _06_03A.FM


Do not crank engine. 1

185 ± 14 kPa (27 ± 2 PSI)
If pressure is within limits, fuel pressure regulator

is working adequately.
A rapid pressure drop indicates leakage either
from the air/fuel rail or from the fuel pump check
valve. Check air/fuel rail for leaks. If it is not leaking
then replace fuel pump.
A slow pressure drop indicates leakage either from
the fuel injector or from the fuel pressure regulator.
Check fuel injector for leaks (see below). If it is not
leaking then replace fuel pressure regulator.
NOTE: Fuel in air compressor outlet line is an indica-
tion of a leaking fuel pressure regulator diaphragm.
F12R0DA
installation apply engine oil on O-ring. 1. Push clip toward injector to release connector
Unscrew rail retaining screws.

 WARNING
Wipe off any fuel spillage in the bilge. Fuel is 1 1
flammable and explosive under certain con-
ditions. Always work in a well ventilated area.
Fuel Pressure Regulator Replacement

Removal
Disconnect spark plug cables from spark plugs.
Disconnect the fuel injector wires, if necessary. F12R19A
1. Retaining screws
Gently pull rail up by hand, working each side slight-

ly at a time.
Pull rail out.
Unscrew retaining plate screws.
SMR2002-030 _06_03A.FM 06-03-13

4 2 5
Electrical Test
Safety lanyard must be on DESS post.
Using the vehicle communication kit (VCK) with
the B.U.D.S. software, energize the fuel injector
from the Activation section.
If the injector does not work, disconnect the plug
connector from the injector.
Install a temporary connector to the injector with
wires long enough to make the connection out-
side the bilge and apply voltage (12 V) to this test
F12R1AA 2 3 1 3 2 harness.
1. Retaining plate This will validate the injector mechanical and elec-
2. Screws
3. Fuel injector trical operation.
4. Fuel pressure regulator and cover
5. Air pressure regulator If it does not work, replace it.
NOTE: If needed, use a small screwdriver to lift Otherwise, check the resistance of the fuel injec-
the fuel pressure regulator. tor circuit.
To remove fuel pressure regulator, pull the fuel Reconnect the injector and disconnect the AMP
regulator and the cover out of rail. plug connector number 4 on the MPEM.
Using a multimeter, check resistance value be-
Installation
tween terminals as follows.
For the installation, reverse the removal procedure
but pay attention to the following. COMPONENT CONTACT LOCATION
If the same regulator is reinstalled, it is recommend- Fuel injector MAG 7 and 13
ed to change the O-rings.
Fuel injector PTO 8 and 14
Insert the fuel pressure regulator into the cover
then install both regulators together in place with
The resistance should be between 1.7 and 1.9 Ω.
your hand. Do not use any tool.
If resistance value is correct, try a new MPEM.
NOTE: A thin film of injection oil may be applied
Refer to MPEM REPLACEMENT procedures else-
to O-ring to ease insertion in rail.
where in this section.
Apply Loctite 243 on rail retaining screws then
If resistance value is incorrect, repair the wiring
harness/connectors between AMP plug connec-
tor and fuel injector.
FUEL INJECTOR
Fuel Injector Replacement
Leakage Test
When one fuel injector is defective, both have to
Testing the fuel injector operation can be per- be replaced at the same time. Be sure to check
formed with the air/fuel rail installed. the other one. Also replace direct injectors.
The leakage test is validated when performing the Removal
FUEL DELIVERY SYSTEM DIAGNOSTIC FLOW
CHART elsewhere in this section. See FUEL PRESSURE REGULATOR REPLACE-
MENT above for procedure. However, do not re-
move any regulator.
To remove fuel injector, pull it out of rail.
06-03-14 SMR2002-030 _06_03A.FM

Installation Air/Fuel Rail Replacement

For the installation, reverse the removal proce- Removal
dure. Paying attention to the following details.
If the same injector is reinstalled, it is recommend-
Disconnect air compressor supply hose from rail.
Disconnect fuel hoses (supply and return) at their
Insert the fuel injector in place with your hand. Do
inline connectors.
not use any tool.
Temporarily connect those hose ends together to
NOTE: A thin film of injection oil may be applied prevent rail draining.
Disconnect spark plug cables from spark plugs
Apply Loctite 243 on rail retaining screws then torque and fuel injector wires. Cut locking ties of wiring.
AIR/FUEL RAIL 3 1 4 2
Pressure Test
FUEL PRESSURE
(when cranking engine or when engine is running)
738 ± 14 kPa (107 ± 2 PSI)

Remove pressure gauge and reinstall fuel hose. At F12R0CA
1. Air/fuel rail
If pressure is out of limits, check air/fuel rail for 2. Air supply hose
3. Fuel supply hose
leaks. If it is not leaking then replace air regulator 4. Retaining screws
A higher pressure may be an indication of a
pinched or clogged air regulator outlet line. 1
Air Pressure Regulator Replacement

Removal
See FUEL PRESSURE REGULATOR REMOVAL
above for procedure.
Remove the fuel regulator then the air regulator.
Installation
but pay attention to the following.
F12R0DA
1. Push clip toward injector to release connector

SMR2002-030 _06_03A.FM 06-03-15
Gently pull rail up by hand, working each side slight- Leakage Test
ly at a time.
If direct injector leaks through its large top O-ring,
Pull rail out. there will be an air/fuel leak between the injector
Disconnect hose ends at their inline connectors and the air/fuel rail. Replace O-ring of both injectors.
and drain fuel rail. If there is an injector internal leak, the high tempera-
Disconnect air and fuel hoses from rail. ture from the combustion chamber will make visible
overheated area. Replace damaged components.
2 Electrical Test
1 the B.U.D.S. software, energize the direct injector
in the Activation section.
harness.
This will validate its mechanical and electrical op-
eration.
If it does not work, replace the direct injector.
Otherwise, check the resistance of the direct in-
jector circuit.
Reconnect the injector and disconnect the AMP
F12R0FA
plug connector number 4 on the MPEM.
1. Air and fuel return hoses
2. Fuel supply hose Using a multimeter, check resistance value be-
NOTE: When lifting/removing air/fuel rail, we rec-
ommend replacing carbon dams on direct injec- COMPONENT CONTACT LOCATION
tors that have been running for 50 hours or more.
Direct injector MAG 5 and 15
Remove fuel injector, fuel pressure regulator and
air pressure regulator. Direct injector PTO 6 and 21
Installation The resistance should be between 1 and 1.6 Ω.
For installation, reverse the removal process but If resistance value is correct, try a new MPEM.
pay attention to the following. Refer to MPEM REPLACEMENT procedures else-
A thin film of injection oil may be applied to O-rings where in this section.
of fuel injectors to ease rail installation. If resistance value is incorrect, repair the wiring
Apply Loctite 243 on rail retaining screws then torque harness/connectors between AMP plug connec-
to 25 N•m (18 lbf•ft). tor and direct injector.
When installing fuel or air hoses fitting to the air/
fuel rail, use Loctite Krylox (no. 29-719). Direct Injector Replacement
IMPORTANT: Do not remove direct injector need-
DIRECT INJECTOR lessly. They are sealed with a carbon dam that may
expand when pulled out. A special tool is required
When one direct injector is defective, both have to compress it prior to reinstalling. Otherwise,
to be replaced at the same time. Be sure to check sealing efficiency might be affected.
the other one. Also replace fuel injectors.
Remove air/fuel rail retaining screws. Partially lift
The direct injectors can be replaced by lifting the rail to allow direct injector removal.
air/fuel rail.
06-03-16 SMR2002-030 _06_03A.FM
Disconnect direct injector connector then pull in- Carbon Dam Replacement
jector out of cylinder head. Remove direct injector. See procedure above.
1 NOTE: When replacing a carbon dam, it is recom-
mended to replace it on both injectors. It is also
recommended to replace all O-rings. When servic-
ing air/fuel rail or direct injectors, we recommend
replacing carbon dams that have been running for
50 hours or more.
CAUTION: Never reuse a carbon dam after it has
been removed from the injector. Always install
a new one.
Remove carbon dam and O-ring using a small pick.
Install seal guide (P/N 529 035 715) on end of injec-
tor. Carefully slide carbon dam in injector groove.
Use carbon dam compressor (P/N 529 035 716) to
compress carbon dam evenly.
2
F12R0GA
FUEL PUMP
1. Air/fuel rail
2. Disconnect and pull injector out
Pressure Test
Compress the carbon dam using tool (P/N 529 035 The pressure test will show the available pressure
716).
from the fuel pump.
Carefully install direct injector in cylinder head pay-
ing attention to carbon dam insertion. Ensure to Ensure there is no leak from hoses and fittings.
position connector pointing toward bottom of cyl- Repair any leak.
inder head. Ensure there is enough gas in fuel tank.
NOTE: A thin film of injection oil may be applied Use the VCK (Vehicle Communication Kit) to re-
to carbon dam if necessary to ease insertion in cyl- lease the fuel pressure in the system. Look in the
inder head. Activation section of the software B.U.D.S.
Reconnect electrical connector. Disconnect inlet and outlet hoses from fuel pump
using tool (P/N 529 035 714).
2
Connect adapters and pressure relief valve to
pressure gauge as shown.
F12R0HA 1
1. Carefully insert direct injector
2. Connector pointing toward bottom of cylinder head
Reinstall air/fuel rail.
SMR2002-030 _06_03A.FM 06-03-17

1
2
1
3
4
F12R0AA 3 2 F12R0BA
1. Pressure gauge (P/N 529 035 709) 1. Fuel pump outlet hose (fuel filter side)
2. T-adapter (P/N 529 035 710) 2. Fuel pump return line
3. Pressure relief valve (P/N 529 035 711) 3. Fuel relief valve on the return line side
CAUTION: Ensure to install the pressure relief
valve to allow excess pressure to flow back Install safety lanyard and observe fuel pressure.
through return line. Note the arrow on the valve.
Otherwise, fuel pump components might be dam- MINIMUM FUEL PUMP PRESSURE
aged. (when installing safety lanyard)
Install pressure gauge between disconnected 721 kPa (105 PSI)

hoses on fuel pump side (closed-loop installation
on fuel pump). Make sure the pressure-relief valve If pressure is within limits, fuel pump is working
is installed on the fuel pump return line side. adequately.
If pressure is below limits, ensure fuel filters are
not obstructed. There is one in-line fuel filter at the
fuel pump outlet hose and one filter at the inlet
underneath the pump. Otherwise, replace the fuel
pump.
Remove pressure gauge and reinstall fuel hoses.
At installation apply engine oil on O-ring.
Electrical Test
When connecting the safety lanyard to the DESS
post, the fuel pump should run for 2 seconds to
build up the pressure in the system.
If the pump does not work, disconnect the plug
connector from the fuel pump.
06-03-18 SMR2002-030 _06_03A.FM

Install a temporary connector to the fuel pump

with wires long enough to make the connection
outside the bilge and apply voltage (12 V) to this
test harness.
If pump does not run, replace the fuel pump.
Otherwise, check the continuity of the fuel pump
circuit.
Disconnect the AMP plug connector number 4 on
the MPEM.
Using a multimeter, check continuity between ter-
minals of circuits 24 and 26.
If wiring harness is good, try a new MPEM. Refer F12R0IA 1 2
to MPEM REPLACEMENT procedures elsewhere 1. Fuel pump
in this section. 2. Retaining screw
Otherwise, repair the wiring harness/connectors Disconnect electrical connector.

between AMP plug connector and fuel pump. Disconnect vent tube from fuel pump.
Fuel Pump Replacement
Disconnect inlet and outlet hoses from fuel pump
Removal using tool (P/N 529 035 714).
Open front storage compartment cover.
RX DI
Remove the storage basket.
Compress springs of pump module to reduce its
Remove glove box (see HULL/BODY section). height to allow pulling pump out.
Remove front vent tubes.
All Models
RX DI Pull fuel pump toward front of vehicle. Wipe off
Remove tube Y-connector. any fuel spillage in the bilge.
Remove tube bracket by unscrewing nuts from
bilge (front storage area).
F12R0JA 1
F12R0KA 1 1. Pull fuel pump toward front
1. Vent tube bracket Installation
2. Nut
For installation, reverse the removal process but
All Models pay attention to the following.
From glove box opening, remove fuel pump retain- Tighten fuel pump screws in a criss-cross sequence.i
ing nuts.
SMR2002-030 _06_03A.FM 06-03-19
FUEL DELIVERY SYSTEM DIAGNOSTIC FLOW CHART
NOTE: The tolerance for the pressure is ± 14 kPa (2 PSI).

Fuel pump runs
Fuel pump does not run Connect safety lanyard for 2 sec. then stops
Check fuses Install fuel pressure gauge on

Check lanyard connection fuel pressure line
Check pump module operation
Repair or replace if necessary
Connect safety lanyard

OK
Fuel pump runs Repair or replace
Fuel pressure Check for

Fuel pressure less more than blocked fuel
than 185 kPa (27 PSI) 185 kPa return line
(27 PSI)
Check fuel lines

Repair or yes for leaks Fuel pressure
replace Check fuel filters is 185 kPa Line OK
(27 PSI)
Replace Perform fuel

fuel pump fails
pump test Crank or start engine
module
Fuel pressure lower

test OK than 735 kPa (107 PSI)
Fast
pressure Replace
drop Perform fuel Check Fuel pressure Fuel pressure
fuel pump fails no yes
pump test for air greater than is 735 kPa
yes module leaks
no leaks 735 kPa (107 PSI)
(107 PSI)
Verify pass
fuel pump Repair
check valve Proceed to air leaks
fails compressor OK Check air Replace fuel
OK fails pressure test return pressure
line for regulator
Ensure Replace blockage
Air pressure less Air pressure more
air/fuel fuel pump than 621 kPa than 621 kPa
rail is not (90 PSI) (90 PSI)
leaking yes
no Check
Repair/replace
air/fuel rail RAVE no Check direct
fails OK line
Check fuel for air leaks injector
leaks OK
injector
Repair Repair air Direct
fails Replace
OK leaks compressor injector direct
OK injector
Replace fuel Replace air
injector pressure System OK
regulator
Check air/fuel rail for leaks OK
Replace fuel
fails
pressure NOTE: The tolerance for the Retest
regulator pressure is ± 14 kPa (2 PSI).
Repair/replace air/fuel rail
F12A06S
06-03-20 SMR2002-030 _06_03A.FM

ELECTRONIC MANAGEMENT Select the Activation tab.

Point the mouse cursor over the PTO TPS. Check
MPEM REPLACEMENT the ADC reading. It must be between 23 and 45.
General 1
Prior to replacing a suspected MPEM, ensure that Activation
all the recommendations in the general introduc-
tion of this section have been followed.
IMPORTANT: When MPEM is replaced, the safe-
ty lanyard(s), the TPS closed position and the TDC
their specific section for adjustment.
To allow transferring the previous recorded infor-
mation from the old MPEM to the new one, use the
vehicle communication kit (VCK) with the B.U.D.S.
software. Use Replace in the MPEM menu. Follows
instructions in its help system.
NOTE: If the old MPEM is working, it must be read
inside B.U.D.S. prior to removing it from the vehicle
to carry vehicle information and history to the new 30
MPEM. Besides, select the Setting tab and note
the Current Angle in the ignition offset area. When F12R1JA 3 2
installing the new MPEM, re-use this setting as a 1. “Activation” tab
preliminary setting. Then, proceed with the regular 2. Point on PTO TPS
3. ADC reading
procedure for the TDC setting. If the old MPEM is
not working, try to find a previous saved file from Point the mouse cursor over the MAG TPS. Check
B.U.D.S. the ADC reading. It must be between 37 and 59.
If either readings are not within those parameters,
Replacement they are out of range and the MPEM will be unable
Disconnect battery cables. to initialize. Proceed with THROTTLE BODY SYN-
CHRONIZATION as detailed in THROTTLE BODY.
 WARNING If the ADC’s are within range, proceed with the
Battery BLACK negative cable must always required resets.
be disconnected first and connected last. After performing the required resets, ensure to
clear all faults from the newly replaced MPEM.
Disconnect AMP connectors from MPEM. Now, all faults must be inactive (except the Diag-
Remove MPEM. nostic Cap Missing fault).
Install the new MPEM to the vehicle. Start the engine and increase engine speed above
Reconnect AMP connectors to MPEM then bat- 5000 RPM to be sure no fault appears.
tery cables.
Transfer the data from the previous MPEM to the
new one using B.U.D.S. then proceed with the re-
quired resets after the following verification has
been done.
SMR2002-030 _06_03A.FM 06-03-21

THROTTLE POSITION SENSOR NOTE: In this particular case, by comparing the

signals from both sensors, the MPEM will gener-
(TPS) ate a fault code when the TPS is malfunctioning
due to specific “spots”.
General
To isolate the faulty TPS, disconnect one and test
The throttle position sensor (TPS) is a potentiom- the other.
eter that sends a signal to the MPEM which is pro-
portional to the throttle shaft angle. On the DI sys- Voltage Test — Both TPS
tem, two sensors are used for redundancy purposes.
The MPEM compares the signals from both sensors Check the voltage output from MPEM to the desired
and determines if there is an error and uses the most throttle position sensor.
appropriate sensor to operate the system. Disconnect plug connector from throttle position
sensor and connect a voltmeter to the wiring har-
ness.
Check the voltage readings on the PTO side as
follows.
CONNECTION VOLTAGE
Pin 1 with engine ground 5V
Pin 2 with engine ground 0-0.5 V
Check the voltage readings on the MAG side as

F12F05A 1 1 follows.
1. Throttle position sensor (TPS) CONNECTION VOLTAGE
IMPORTANT: Prior to testing the TPS, ensure Pin 1 with engine ground 5V
that mechanical components/adjustments are ad-
equate according to THROTTLE BODY in AIR IN- Pin 2 with engine ground 0-0.5 V
DUCTION SYSTEM above.
Pin 3 with engine ground 4.75-5 V
The MPEM may generate two types of fault codes
pertaining to the TPS. Refer to DI SYSTEM FAULT Remove and reinstall the safety lanyard to activate
CODES in DIAGNOSTIC PROCEDURES section the MPEM. There should be 5 Vdc in each test.
for more information. If voltage test is good, replace the TPS.
Wear Test If voltage test is not good, check the resistance of
the TPS circuit.
While engine is not running, activate throttle and
pay attention for smooth operation without physi- Resistance Test
cal stops of the cable.
Reconnect the TPS.
the B.U.D.S. software, use the Throttle Opening NOTE: Resistance values are different at idle on
display under Monitoring. each TPS.
Slowly and regularly depress the throttle. Observe MAG Side
the needle movement. It must change gradually Disconnect the AMP plug connector number 3 on
and regularly as you move the throttle. If the nee- the MPEM.
dle “sticks”, bounces, suddenly drops or if any dis-
crepancy between the throttle movement and the Using a multimeter, check resistance value be-
needle movement is noticed, it indicates a worn tween terminal 10 and 14.
TPS that needs to be replaced. The resistance should be 1600 - 2400 Ω.
06-03-22 SMR2002-030 _06_03A.FM

Check the resistance between terminal 5 and ter-

1 2
minal 14 with the throttle plate in idle position.
The resistance should be 2500 Ω.
PTO Side
the MPEM.
tween terminal 3 and 18.
The resistance should be 1600 - 2400 Ω.
The resistance should be 1000 Ω. F12R0LA
Check the resistance between terminal 1 and ter- MAG SIDE THROTTLE BODY
minal 18 with the throttle plate in idle position. 1. Allen screws
Apply Loctite 243 on screw threads, install the
Test Results — Both TPS new TPS.
If resistance values are correct, try a new MPEM. Re- NOTE: Both TPS do not need to be replaced at the
fer to MPEM replacement procedures elsewhere in same time.
this section.
Reinstall remaining removed parts.
If resistance values are incorrect, repair the wiring
Proceed with the CLOSED TPS ADJUSTMENT.
See below.
tor and the TPS.
Replacement Closed TPS Adjustment

NOTE: Although this operation is called “adjust-
ment”, it is not really an adjustment. Rather, it per-
Remove the air duct. forms a reset of the values in the MPEM.
Disconnect the connector of the TPS. This reset is very important. The setting of the TPS
Loosen two Allen screws retaining the TPS. will determine the basic parameters for all fuel
mapping and several MPEM calculations.
Remove TPS.
NOTE: Reset must be done each time the throttle
position sensor (TPS) is loosened or removed or
throttle body(ies) is(are) replaced or MPEM is re-
placed.
CAUTION: An improperly adjusted TPS may
lead to poor engine performance and emission
compliance could possibly be affected.
SMR2002-030 _06_03A.FM 06-03-23

Use the vehicle communication kit (VCK) with the Otherwise, validate the information center is
B.U.D.S. software to perform this adjustment. working by activating the tachometer using the
Ensure the throttle body plate stop lever rest against software B.U.D.S. under Activation (first ensure
its stopper. Open throttle approximately one quarter information center is in tachometer mode). If it
then quickly release. Repeat 2 - 3 times to settle does not display 3000 RPM, the information cen-
throttle plate. If stopper does not rest against its stop ter may be faulty and needs to be tested.
lever, perform throttle cable adjustment. Refer to If the information center correctly displayed 3000
THROTTLE BODY in AIR INDUCTION SYSTEM RPM, perform the following tests.
above.
NOTE: Take into account that a CPS fault can be
Push the Reset button in the Setting section of triggered by bent or missing encoder wheel teeth.
B.U.D.S. Check the teeth condition. Also, bad connections
NOTE: There is no idle speed adjustment to per- in magneto connector could generate electrical
form. The MPEM takes care of that. If TPS are not noise that would make you wrongly think the CPS
within the allowed range while resetting the is faulty. Check pins and wires.
closed TPS, the MPEM will generate a fault code
and not accept the setting. Encoder Wheel Inspection
Start engine and make sure it operates normally To check the encoder wheel for bent teeth, pro-
through its full engine RPM range. If fault codes ap- ceed as follows.
pear, refer to DI SYSTEM FAULT CODES in DIAG- Remove magneto cover. Refer to magneto system
NOSTIC PROCEDURES section for more informa- in ENGINE section.
tion.
Install a dial indicator on crankcase casting. Posi-
tion the gauge on a tooth and set it to zero (0).
CRANKSHAFT POSITION Rotate flywheel and check needle movement. The
SENSOR (CPS) maximum allowed difference between teeth is
0.15 mm (.006 in). Otherwise, straighten the tooth
2 1 or replace the encoder wheel.
F12R0OA
1. Magneto cover
2. CPS connector
Check for RPM display at the information center F12R1HA
while cranking engine (first ensure information 1. Encoder wheel

center is in tachometer mode). If it displays ap- 2. Dial indicator
proximately 300 RPM, the CPS circuitry is properly
Properly reinstall cover.
working.
The encoder wheel for bent teeth can also be in-
spected by the following alternative method.
Remove magneto cover. Refer to MAGNETO SYS-
TEM in ENGINE section.
06-03-24 SMR2002-030 _06_03A.FM

Install a pointed wire on one of the threaded hole Voltage Test

of crankcase with the screw as shown in the fol-
Unplug magneto connector.
lowing illustration.
Check connector pins for corrosion or damage.
1 2 Remove and reinstall the safety lanyard to activate
the MPEM.
Check the voltage readings on the harness side as
follows:
CONNECTION VOLTAGE
0 V ± a small mV
Pin 4 with engine ground
tolerance
Pin 5 with engine ground 12 V
If voltage tests good, the CPS is defective and

needs replacement.
F12R1MA If voltage does not test good, perform the follow-
ing tests.
1. Pointed wire
2. Screw on the threaded hole
Resistance Test
Rotate the flywheel one time and adjust the point-
er so that it slightly touches the highest tooth. Us- Check the continuity of the wiring harness.
ing a feeler gauge, check and measure the clear- Disconnect the AMP plug connector number 2 on
ance between each tooth and pointer. the MPEM.
Using a multimeter, check continuity of circuits 6,
7 and 14.
If wiring harness is good, it could be either the CPS
or the MPEM. Try a new part one at a time. When
trying a new MPEM, refer to MPEM REPLACE-
MENT procedures elsewhere in this section.
Otherwise, repair the wiring harness/connectors
2 1 between AMP plug connector and the CPS.
Replacement
Remove tuned pipe.
Unscrew front engine support and slightly lift en-
gine to have access to magneto cover screws.
Block engine in this position.
Disconnect connector and remove magneto cover.
F12R1NA
Remove CPS.
1. Pointed wire
2. Feeler gauge
The maximum allowed difference between teeth

is 0.15 mm (.006 in). Otherwise, straighten the
tooth or replace the encoder wheel.
SMR2002-030 _06_03A.FM 06-03-25

Using a multimeter, recheck resistance value be-

tween terminals 16 and 19.
If resistance value is correct, try a new MPEM. Re-
fer to MPEM REPLACEMENT procedures else-
tor and the MATS.
Replacement
Remove the air duct.
Disconnect the connector of the MATS.
F12R0NA 1 Pull MATS out while turning right and left.
1. CPS inside magneto cover Install the new MATS.
Apply Loctite 243 on screw threads then install the Reinstall remaining removed parts.
new CPS.
Reinstall remaining removed parts. WATER TEMPERATURE SENSOR
(WTS)
MANIFOLD AIR TEMPERATURE
SENSOR (MATS)
F12R0PA 1
1. Water temperature sensor (WTS)
F12R0MA 1
PTO SIDE THROTTLE BODY
Resistance Test
1. Manifold air temperature sensor (MATS) Disconnect the plug connector from the WTS and
check the resistance of the sensor itself.
Resistance Test The resistance should be between 2280 Ω and
Disconnect the plug connector from the MATS 2740 Ω.
and check the resistance of the sensor itself. Otherwise, replace the WTS.
The resistance should be between 2280 Ω and If resistance tests good, reconnect the WTS and
2740 Ω. disconnect the AMP plug connector number 4 on
Otherwise, replace the MATS. the MPEM.
If resistance tests good, reconnect the MATS and Using a multimeter, recheck resistance value be-
disconnect the AMP plug connector number 4 on tween terminals 9 and 11.
the MPEM.
06-03-26 SMR2002-030 _06_03A.FM

If resistance value is correct, try a new MPEM. Re- Ensure sensor is correctly installed elbow adaptor.
fer to MPEM REPLACEMENT procedures else- Otherwise, the MAPS could generate a fault code
where in this section. for an unexpected sensor range at idle when it
If resistance value is incorrect, repair the wiring reads the atmospheric pressure. Ensure the cor-
harness/connectors between AMP plug connec- rect connector is plugged and not mixed with the
tor and the WTS. MAG TPS. Remove sensor and check for oil or dirt
on its end and if problem persists, check throttle
Replacement plate condition/position and the wiring harness.
Perform the following tests.
Remove air/fuel rail retaining screws.
Cut locking ties as necessary to allow lifting of Voltage Test
air/fuel rail in order to give access to the tempera- Check the voltage output from MPEM to the mani-
ture sensor. fold air pressure sensor (MAPS).
Disconnect WTS connector and remove WTS. Disconnect plug connector from throttle position
Apply Loctite 518 on threads of the WTS then in- sensor and connect a voltmeter between pin 1 and
stall. 3 and also between pin 1 and 2 of wiring harness.
Reinstall remaining removed parts. Remove and reinstall the safety lanyard to activate
the MPEM. There should be 5 Vdc in each test.
MANIFOLD AIR PRESSURE If voltage test is good, replace the MAPS.
SENSOR (MAPS) If voltage test is not good, check the continuity of
the MAPS circuit.
Resistance Test
the MPEM.
Using a multimeter, check continuity of circuits 3-3,
3-6 and 3-7.
If wiring harness is good, try a new MPEM. Refer
to MPEM REPLACEMENT procedures elsewhere
in this section.
between AMP plug connector and the MAPS.
Replacement
F12R0LB 1 Remove the air duct.
MAG SIDE THROTTLE BODY Disconnect MAPS connector and remove the MPAS.
1. Manifold air pressure sensor (MAPS)
Install the new MAPS paying attention to index its
NOTE: This sensor is a dual function device. When tab into the adaptor notch.
engine is started and it runs at idle speed, the sen- Reinstall remaining removed parts.
sor takes the atmospheric pressure and stores it in
the MPEM. Thereafter, it takes the manifold air
pressure at operating RPMS.
SMR2002-030 _06_03A.FM 06-03-27

EXHAUST GAS TEMPERATURE KNOCK SENSOR (KS)

SENSOR (EGT)
1
F12R0QA 1
1. Knock sensor (KS)
F12R0SA 2
1. Muffler Dynamic Test
2. Exhaust gas temperature sensor (EGT)
Resistance Test the B.U.D.S. software, monitor the knock sensor
using the Faults section.
Disconnect the plug connector from the EGT and
check the resistance of the sensor itself. Start the engine and bring engine RPM above
4500 RPM. If no fault code occurs, the knock sen-
The resistance should be between 2280 Ω and sor is good.
2740 Ω.
Otherwise, do the following.
Otherwise, replace the EGT.
Ensure sensor and head contact surfaces are clean
If resistance tests good, reconnect the EGT and and mounting bolt and washer are correct and prop-
disconnect the AMP plug connector number 4 on erly torqued down.
the MPEM.
Check the knock sensor resistance.
tween terminals 10 and 12. Disconnect the AMP plug connector number 4
from the MPEM module.
fer to MPEM REPLACEMENT procedures else- Static Resistance Test
terminal 2 and terminal 17 on the plug connector.
tor and the EGT. The resistance should be approximately 5 MΩ.
Otherwise, check the continuity of the knock sen-
Replacement sor circuit 4-2 and 4-17.
Disconnect EGT connector and remove EGT. If wiring harness is good, try a new MPEM. Refer
Apply Loctite 518 on threads of the EGT then in- to MPEM REPLACEMENT procedures elsewhere
stall. in this section.
Replug connector. Otherwise, repair the wiring harness/connectors
between AMP plug connector and knock sensor.
06-03-28 SMR2002-030 _06_03A.FM

Replacement Install leak test pump (P/N 529 021 800) on hose end
and pressurize air line to 69 - 103 kPa (10 - 15 PSI).
Unscrew and remove knock sensor.
Wait some time to see if pressure drops. If so,
Clean contact surface, apply Loctite 243 in thread- check line for leaks. Otherwise, the solenoid is de-
ed hole then install the new knock sensor. fective and needs to be replaced.
Torque screw to 20 N•m (15 lbf•ft). Using the vehicle communication kit (VCK) with
CAUTION: Improper torque might prevent sen- the B.U.D.S. software, energize the RAVE sole-
sor to work properly and lead engine to severe noid from the Activation section.
damage of internal components. The pressure should drop when the solenoid is ac-
Re-plug connector. tivated. If the solenoid does not work, disconnect
the plug connector from the solenoid.
RAVE SOLENOID Install a temporary connector to the solenoid with
A quick check can be done as follows. When en- side the bilge and apply voltage (12 V) to this test
gine is being stopped, the RAVE valves will open harness.
and close. This can be heard or seen by carefully
removing the cap and feeling the movement with If it does not work, replace the solenoid. Other-
a hand. wise, proceed with the resistance test below.
Another test can be done using the vehicle com- Reconnect hose to compressor.
munication kit (VCK) with the B.U.D.S. software, Unplug the outlet hose from RAVE solenoid.
using the Monitoring section. Start engine and
bring its RPM to approximately 6000 and look at 4
the RAVE solenoid LED. It should turn on, indicat-
ing the RAVE system is working on the electronic
side. However, pneumatic test still have to be per-
formed to validate the mechanical operation.
Leakage/Voltage Test
NOTE: The solenoid activates both RAVE valves
at the same time.
Unplug the RAVE solenoid supply hose from air
compressor.
F12R0TA 3 1 2
1. RAVE solenoid
2. Supply hose from air compressor
3. Check valve
4. Outlet hose to RAVE valves
Install leak test pump on hose end and apply pres-

sure. If pressure can not be held, check hoses for
leaks. If hoses test good, connect pump directly
to each RAVE valve nipple and pressurize. If pres-
sure drops, replace the defective seal inside RAVE
valve.
Take into account that the RAVE may be mechani-
cally stuck in the cylinder slot. Open the RAVE and
F12R0RA 1 2 check for free operation. Refer to ENGINE and look
in TOP END.
1. Air compressor
2. Disconnect RAVE supply hose
SMR2002-030 _06_03A.FM 06-03-29
Pressure Relief Circuit IGNITION COIL

When RAVE valve is released, the pressure es-
NOTE: The MPEM energizes the primary side of
cape from this vented hose. If the RAVE valves
each ignition coil individually. It can detect open
does not return when the solenoid is released, en-
and short circuit in the primary winding but it does
sure the return spring is in good condition, this
not check the secondary winding.
hose is not kinked or plugged and the solenoid al-
lows pressure to bleed there. Using the vehicle communication kit (VCK) with
the B.U.D.S. software, energize the ignition coil
Although it is not related with RAVE operation, we
suggest to verify the check valve operation which
prevent the pressure going down to crankcase. In- You should hear the spark occurring. In doubt, use an
stall a hose pincher after the T-fitting to adequately inductive spark tester or a sealed tester — available
pressurize the check valve portion. from after-market tool/equipment suppliers — to pre-
vent spark occurring in the bilge. Otherwise, perform
3 2 the following checks.
 WARNING
Never make a spark test with spark plug re-
moved. Flammable vapors may be present in
the bilge and ignited which could cause an
explosion.
Primary Winding
Disconnect the plug connector from the ignition
coil and check the resistance of the primary circuit.
F12R0TB 1
1. RAVE solenoid
2. Pressure relief hose
3. Install hose pincher here
Resistance Test
Reconnect the solenoid and disconnect the AMP
If resistance value is correct, try a new MPEM. Re- F12R0UA 3 1
fer to MPEM REPLACEMENT procedures else- 1. PTO side ignition coil
2. Mag side ignition coil
where in this section. 3. Primary winding connector
The resistance should be between .45 - .55 Ω at
20°C (68°F).
tor and solenoid.
Otherwise, replace the ignition coil.
If resistance tests good, reconnect the ignition
coil connector and disconnect the AMP plug con-
nector number 3 on the MPEM.
06-03-30 SMR2002-030 _06_03A.FM


tween terminals 21 and 22 for MAG side and ter-  WARNING
minals 20 and 23 for PTO side. Do NOT use coil tester on metal work bench.
If resistance value is correct, try a new MPEM. Re- Follow manufacturer instructions.
fer to MPEM REPLACEMENT procedures else- 1. With ignition coil removed from craft, hook high
where in this section. tension leads from tester to ignition coil high
If resistance value is incorrect, repair the wiring tension cables.
harness/connectors between AMP plug connec- 2. Connect 2 smaller tester leads to primary of ig-
tor and the ignition coil. nition coil.
Secondary Winding 1
Static Test
NOTE: An ignition coil with good resistance mea-
surement can still be faulty. Voltage leak can occur
at high voltage level which is not detectable with
an ohmmeter. A dynamic test is more effective.
Remove high tension lead from ignition coil.
the terminals C and the coil post.
The resistance should be between 6800 and
10200 Ω at 20°C (68°F). 2
If not within specification, replace the ignition coil. F12H0UA
Otherwise, perform the DYNAMIC TEST below.

TYPICAL
Measure resistance of the high tension leads. 1. Lead to secondary
They must be as follows. Otherwise, replace the 2. Leads to primary
lead. 3. Turn power switch to 12 volts and you should
NOTE: It is not necessary to remove the spark observe spark jumping at a predetermined gap
plug cap. of 7 to 8 mm (.276 to .311 in).
IMPORTANT: Always replace leads with genuine If there is no spark, if it is weak or intermittent, the
parts. Otherwise, fuel injection system operation coil is defective and should be replaced.
may be impaired.
MODEL SIDE VALUE OHM
 WARNING
Always reconnect spark plug cables at the same
MAG 5700 spark plugs where they come from. The cable
RX DI
PDM 4300 coming out the edge of the electrical box must
MAG 5700 be connected to the MAG side spark plug. Oth-
LRV DI erwise, severe backfire may occur with possible
PTO 4900 damage to exhaust system components. The
white tape on the ignition coil should match the
Check continuity between ignition coil ground cir- white tape on the high tension cable.
cuits and engine.
Dynamic Test
Use an ignition coil tester, available from after-market
tool/equipment suppliers.
SMR2002-030 _06_03A.FM 06-03-31

Normally TDC setting should not be required. It

2 3 1 has been set at factory and it should remain cor-
rectly set since every part is fixed and not adjust-
able. The only time the TDC setting might have to
be changed would be when replacing the crank-
shaft, the magneto rotor, the CPS, the encoder
wheel or the MPEM. If the TDC setting is found
to be incorrect, you should first check for proper
crankshaft alignment. This might be the indication
of a twisted crankshaft.
With this ignition system, the TDC setting can be
checked with either the engine hot or cold. Also,
the TDC setting is to be checked at any RPM with
the timing light. The TDC setting is best checked
F12R0UB
at idle speed as it is more accurate and easier than
at higher speed, also it will keep the engine tem-
1. MAG side ignition coil at bottom
2. Mag side ignition coil wire on edge of electrical box perature lower for a longer time. Ensure to prop-
3. Edge of electrical box erly cool the engine through the flushing fitting.
NOTE: If PTO ignition coil is replaced, ensure to NOTE: When checking the TDC setting, the spark
reinstall the white tape on the new coil on if it is advance has to be locked to allow proper verifica-
not present. tion of the TDC marks. See TDC SETTING below.
TDC SETTING Static Test

1. Disconnect MAG side spark plug wire and con-
General nect wire to grounding device then remove spark
Before checking TDC setting with a stroboscopic plug.
timing light (dynamic test), it is mandatory to CAUTION: Never crank engine with spark plugs
scribe a timing mark on the PTO flywheel (static removed unless spark plug cables are connect-
test) corresponding to the specific engine. ed to the grounding device.
Also, the mark scribed on the PTO flywheel can 2. Remove PTO flywheel guard.
be used to troubleshoot a broken magneto woo- 3. Remove middle screw securing the engine to
druff key. the rear engine mount. Reinstall screw with tim-
CAUTION: The relation between the PTO fly- ing mark pointer tool.
wheel mark position and crankshaft position may
change as the PTO flywheel might move on 1
crankshaft when engine is ran. This will result in
a false ignition timing reading. Always verify
PTO flywheel mark position before checking ig-
nition timing with an appropriate timing light.
If mark does not align with tool, repeat static
test to ensure flywheel has not moved before
changing the ignition timing.
NOTE: Do not use the factory mark found on the
PTO flywheel to check TDC setting or troubleshoot
any problems.
F12R1IA
1. Timing mark pointer tool (P/N 295 000 135)
06-03-32 SMR2002-030 _06_03A.FM

4. Install and adjust a TDC gauge (P/N 295 000 143) NOTE: This specification is of the type “indirect
in MAG side spark plug hole. measurement” relative to the piston movement
5. Ensure to install its roller to allow proper reading since we are measuring at a 45° angle through the
of the gauge. Proceed as follows: spark plug hole.
– Rotate magneto flywheel clockwise until pis- 7. Scribe a thin mark on PTO flywheel aligned with
ton is just Before Top Dead Center. timing mark pointer tool.
NOTE: This mark becomes the reference when
1 2 3 using the stroboscopic timing light.
CAUTION: The static test cannot be used as a
TDC setting procedure, therefore, always check
the TDC setting with a stroboscopic timing light.
8. Remove TDC gauge.
9. Reinstall spark plug and connect wire.
Dynamic Test
To check TDC setting, use Bombardier timing light
(P/N 529 031 900).
F12R0VA 5 4
1. Outer ring
2. Adaptor lock nut
3. Adaptor
4. Roller
5. Roller lock nut
– Install roller on dial gauge end. Ensure to po-

sition roller edge parallel with the dial gauge A00B4FA
face. Secure in this position by tightening roll-

er lock nut. This will keep the roller in the 10. Connect timing light pick-up to MAG side spark
proper axis for measurement accuracy. plug wire.
– Loosen adaptor lock nut then holding gauge 1
with dial face directed toward you when you
are in line with the crankshaft, screw adaptor
in spark plug hole.
– Slide gauge far enough into adaptor to obtain
a reading then finger tighten adaptor lock nut.
– Since we are working with an indirect mea-
surement, ensure that dial gauge face is po-
sitioned in the same direction as the connect-
ing rod.
– Rotate magneto flywheel clockwise until pis-
ton is at Top Dead Center.
– Unlock outer ring of dial and turn it until “0”
(zero) on dial aligns with pointer. F00H1QA
– Lock outer ring in position. TYPICAL

1. Timing light pick-up
6. From this point, rotate magneto flywheel back
1/4 turn then rotate it clockwise to reach
7.87 mm (.310 in).
SMR2002-030 _06_03A.FM 06-03-33
IMPORTANT: To check the TDC setting, the spark CAUTION: If the TDC setting is adjusted too ad-
advance curve must be locked first. This allows to vanced, this will cause serious damage to the
perform TDC setting at any RPM by keeping the engine.
ignition timing “frozen” so that it does not vary
Adjustment
with engine RPM. See TDC SETTING below for
more information. In this operation, the ignition timing light and
B.U.D.S. are used to synchronize the MPEM TDC
CAUTION: If the spark advance curve is not
reference with the engine crankshaft. This timing
locked using B.U.D.S. then a wrong ignition tim-
adjustment will affect the timing of ignition as well
ing will be seen as the ignition curve does not
as direct injector timings. The aim of the adjust-
match the locked ignition timing.
ment is to align the mark on the flywheel with the
11. Start engine and check marks at idle speed. pointer at idle using the timing light and B.U.D.S.
Point beam of timing light straight in line with When this is achieved, then the MPEM TDC refer-
timing mark pointer. ence is synchronized with the engine crankshaft.
NOTE: Look at the mark at the same angle as it
was scribed so that parallax error is minimized. 1
1
2
4
3 5
F12R0WA
F06H07A
1. “Setting” tab
2. Ignition offset section
3. “Locked” box
1. Timing light straight in line with pointer
4. Current angle in MPEM
5. Arrows to change the angle
CAUTION: If engine is to be run more than a few
seconds, engine must be cooled using the flush 1. Choose the Setting tab and look under Ignition
kit. Offset.
NOTE: If mark on PTO flywheel is perfectly align- 2. Check the Locked box to “freeze” the timing at
ed with timing mark pointer, no adjustment is re- the correct value.
quired. If mark does not align with pointer, recheck 3. The VCK displays the number that is stored in
PTO flywheel mark before performing the TDC the MPEM.
setting to ensure PTO flywheel has not loosen or
tightened. 4. Now click the up or down arrow to change the
number of the current angle so that the TDC
TDC Setting setting marks align when checking with the tim-
ing light. Each step makes an adjustment of 1/4
General degree.
To correct the TDC setting, the data of the MPEM NOTE: Each time the setting is changed on the
is changed using the VCK (Vehicle Communication screen, the new value is also changed in the
Kit) (P/N 529 035 844). Look in Setting section of MPEM, so there may be a slow response, do not
the software B.U.D.S. make changes too quickly.
NOTE: For more information on the VCK, refer to 5. When marks align, uncheck the Locked box to
its online help. The MPEM programmer will not finish.
work to perform this operation on the DI engines.
06-03-34 SMR2002-030 _06_03A.FM

NOTE: This will write the new value immediately Safety Lanyard Removed
to the MPEM. There is no need to write the doc- Connect test probes to switch BLACK and BLACK/
ument to the MPEM for the TDC setting unless YELLOW wires. Measure resistance, there should
other changes were made. However, we recom- be NO continuity (open circuit).
mend to reset the service hours when you per-
form a service action such as the TDC setting. Connect one test probe to the WHITE/GRAY wire
and the other test probe to the switch terminal.
NOTE: The MPEM features a permanent (non- Measure resistance, it must be close to 0 ohm.
volatile) memory and keeps the TDC setting pro-
grammed even when the watercraft battery is dis- Connect one test probe to the BLACK wire and the
connected. other test probe to the switch ring. Measure resis-
tance, it must be close to 0 ohm.
Engine Start/Stop Switch Verification Safety Lanyard on Switch
A quick operation test can be done using the vehi- Connect test probes to switch BLACK and BLACK/
cle communication kit (VCK) with the B.U.D.S. soft- YELLOW wires. Measure resistance, it must be
ware, using the Monitoring section. Press the start close to 0 ohm.
button and look at the Start button LED. It should
turn on, indicating the starting system is working SPARK PLUGS
on the input side (start button, MPEM and wiring).
You know now the problem is on the output side Disassembly
(MPEM output signal to starting solenoid, wiring
harness going to the solenoid, starter motor. Refer First unscrew the spark plug one turn.
to STARTING SYSTEM for testing procedures). Clean the spark plug and cylinder head with pres-
Otherwise, check the input side as follows. surize air then completely unscrew.
Disconnect the YELLOW/RED wire of the start/
stop switch. Using an ohmmeter, connect test Heat Range
probes to YELLOW/RED wire and to ground. The proper heat range of the spark plugs is deter-
Measure resistance, it must be an open circuit mined by the spark plugs ability to dissipate the
(switch is normally open). Depress and hold switch, heat generated by combustion.
the ohmmeter should read close to 0 ohm. Other- The longer the heat path between the electrode tip
wise, replace switch. to the plug shell, the hotter the spark plug operat-
If the switch tests good, check continuity of cir- ing temperature will be — and conversely, the
cuits 2-8 and 2-11 using a multimeter. shorter the heat path, the colder the operating tem-
perature will be.
If wiring harness tests good, it could be the MPEM.
Try a new MPEM referring to MPEM REPLACE- A “cold” type plug has a relatively short insulator
MENT procedures elsewhere in this section. nose and transfers heat very rapidly into the cylin-
der head.
Safety Lanyard Switch Verification Such a plug is used in heavy duty or continuous
If 2 short beeps are not heard when installing the high speed operation to avoid overheating.
safety lanyard, refer to DIAGNOSTIC PROCEDURES. The “hot” type plug has a longer insulator nose
The following continuity tests can also be per- and transfers heat more slowly away from its firing
formed using an ohmmeter: end. It runs hotter and burns off combustion de-
posits which might tend to foul the plug during
Disconnect switch wires. prolonged idle or low speed operation.
SMR2002-030 _06_03A.FM 06-03-35

1 2
1 2
A00E0BA
A00E09A
1. Cold 1. Proper socket

2. Hot 2. Improper socket
CAUTION: Severe engine damage might occur SPARK GAP

ENGINE TORQUE
if a wrong heat range plug is used. PLUG mm (in)
A too “hot” plug will result in overheating and pre- Hand tighten
NGK 1.1
ignition, etc. DI + 1/4 turn with
ZFR4F-11 a socket (.043)
A too “cold” plug will result in fouling or may cre-
ate carbon build up which can heat up red-hot and
cause pre-ignition or detonation. CRANKING SYSTEM
Fouling See above for start/stop switch and the DESS post
testing. Refer to STARTING SYSTEM section for
Fouling of the spark plug is indicated by irregular other tests.
running of the engine, decreased engine speed
due to misfiring, reduced performance, and in-
creased fuel consumption. This is due to a loss of DI SYSTEM TEST SUMMARY
compression. Other possible causes are: pro-
longed idling, or running on a too rich mixture or Pressure Tests
incorrect fuel. The plug face of a fouled spark plug
has either a dry coating of soot or an oily, glossy VALUE
COMPONENT
kPa (PSI)
coating given by an excess either of oil or of oil
with soot. Such coatings form a conductive con- 621 ± 14 (90 ± 2)
nection between the center electrode and ground. Air compressor
at cranking
Spark Plug Installation Fuel pressure 185 ± 14 (27 ± 2)

regulator when installing safety lanyard
Prior to installation make sure that contact surfac-
es of the cylinder head and spark plug are free of 738 ± 14 (107 ± 2)
grime. Fuel pressure inline test at cranking or
when engine is running
1. Using a wire feeler gauge, set electrode gap ac-
cording to the following chart. Fuel pump 721 (105) minimum at cranking
2. Apply anti-seize lubricant over the spark plug
threads to prevent possible seizure.
3. Hand screw spark plug into cylinder head. Then,
tighten the spark plug clockwise an additional
1/4 turn with a proper socket.
06-03-36 SMR2002-030 _06_03A.FM

Electrical Tests
TERMINAL
COMPONENT CONNECTOR WIRE COLOR VALUE
NUMBER
26 and pin B PU/PK
Fuel pump AMP no. 4 0 ohm (continuity)
24 and pin D BK/PK
Fuel injector MAG 7 and 13 BL/PU and BL/BK
AMP no. 4 1.7 - 1.9 ohms
Fuel injector PTO 8 and 14 GR/PU and GR/BK
Direct injector
5 and 15 BL/BR and BL/PK
MAG AMP no. 4 1 - 1.6 ohms
Direct injector PTO 6 and 21 GR/BR and GR/PK
1 and engine ground PU/BR 5V
TPS 2 and engine ground BK/BR 0 - 0.5V
Throttle position 3 and engine ground PU/BR 4.75-5 V
sensor MAG
(TPS) 10 and 14 PU/BR and BK/BR 1600 - 2400 ohms
AMP no. 3 5 and 14 WH/BR and BK/BR 2500 ohms at idle
5 and 10 WH/BR and PU/BR 1200 ohms at idle
1 and engine ground PU/RD 5V
TPS 2 and engine ground BK/RD 0-0.5 V
Throttle position 3 and engine ground WH/RD 0V
sensor PTO
(TPS) 3 and 18 BK/RD and PU/RD 1600 - 2400 ohms
AMP no. 4 1 and 3 WH/RD and BK/RD 1000 ohms at idle
1 and 18 WH/RD and BK/RD 2500 ohms at idle
0 V (with a small mV
CPS Pin 4 and ground BK
tolerance)
(Deutsche
Pin 5 and ground GY/RD 12 V
conn.)
Pin 6 and ground GY/YL 5V
Crankshaft
position sensor Pin 7 and pin 6
GY/YL
(CPS) of CPS
Pin 6 and pin 5
AMP no. 2 GY/RD 0 ohm (continuity)
of CPS
Pin 14 and pin 4
BK
of CPS
Manifold air
temperature AMP no. 4 16 and 19 WH/GY and BK/WH 2280 - 2740 ohms
sensor (MATS)
Water temperature
AMP no. 4 9 and 11 TA/OR and BK/OR 2280 - 2740 ohms
sensor (WTS)
Pin 3 and pin 1
PU/BL
of MAPS
Manifold air
Pin 6 and pin 3
pressure sensor AMP no. 3 WH/BL 0 ohm (continuity)
of MAPS
(MAPS)
Pin 7 and pin 2
BK/BL
of MAPS
SMR2002-030 _06_03A.FM 06-03-37

TERMINAL
NUMBER
Exhaust gas
AMP no. 4 10 and 12 TA/GY and BK/TA 2280 - 2740 ohms
temperature (EGT)
Knock sensor (KS) AMP no. 4 2 and 17 BK/BL and YL/BL 5 M ohms
Rave solenoid (RS) AMP no. 4 20 and 23 PU/GY and BK/GY 24 ohms
.45 - .55 ohms
AMP no. 3 21 and 22 RD/GN and WH/GN
primary winding
Ignition coil MAG 6800 - 10200 ohms
Coil terminal C
— — secondary winding w/o
and coil post
high tension leads
.45 - .55 ohms
AMP no. 3 20 and 23 RD/BL and WH/BL
primary winding
Ignition coil PTO 6800 - 10200 ohms
Coil terminal C
and coil post
high tension leads
High tension leads MAG — — 5700 ohms lead alone
(RX DI models) PTO — White tape 4300 ohms lead alone
(LRV DI models) PTO — White tape 4900 ohms lead alone
06-03-38 SMR2002-030 _06_03A.FM

GENERAL
Here is the basic order suggested to diagnose a
suspected fuel injection related problem:
– Check the chart in TROUBLESHOOTING sec-
tion to have an overview of problems and sug-
gested solutions.
– Check if there is a MAINT signal reported by the
vehicle information center. If so, use the VCK
(Vehicle Communication Kit) and look for fault
codes to diagnose the trouble.
– Check all fuses.
– Check air/fuel rail pressure.
– Check spark plugs condition.
– Check RAVE valves if stuck.
– Check fuel pump pressure.
– Check air compressor pressure.
SMR2002-031_06_04A.FM 06-04-1
DESS SYSTEM
Basic Self-Diagnostic Mode
It is self-activated when the safety lanyard cap is being installed on the watercraft post. It gives immediate
monitoring. Some codes may occur only when pressing the start/stop button. Refer to the following chart.
SIGNAL CAUSE REMEDY
2 short beeps • Safety lanyard is recognized • Ignition is authorized, engine can be started normally.
(while installing safety by the MPEM.
lanyard on watercraft • Good contact between safety
post) lanyard cap and DESS post.
1 long beep • Bad connection between safe- • Remove and replace the safety lanyard on the post
(while installing safety ty lanyard cap and post. until 2 short beeps are heard to indicate the system
lanyard on watercraft is ready to allow engine starting.
post or when pressing
start/stop button) • Unprogrammed or defective • Use the safety lanyard that has been programmed for
safety lanyard. the watercraft. If it does not work, check safety lan-
yard condition with the programmer. Replace safety
lanyard if reported defective. If it still does not work,
enable advanced diagnostic mode to obtain more de-
tails about the failure.
• Salt water or dirt in safety • Clean safety lanyard cap to remove dirt or salt water.
lanyard cap.
• Improper operation of MPEM • Enable advanced diagnostic mode to obtain more de-
or defective wiring harness. tail about the failure.
8 short beeps • Defective MPEM • Replace MPEM.

(memory).
Other beeps • Refer to COMPONENT FAILURE WARNING SYSTEM

below.
06-04-2 SMR2002-031_06_04A.FM
Advanced Self-Diagnostic Mode

It needs to be enabled manually. Proceed as follows:
1. Remove safety lanyard cap from watercraft post.
2. Press 5 times on the watercraft start/stop button.
NOTE: 1 short beep and 1 long beep must be heard. They validate beginning of diagnostic mode.
3. Install safety lanyard on watercraft post.
4. Press the watercraft start/stop button again.
NOTE: If everything is correct, engine will start. Otherwise, refer to the following chart.
SIGNAL CAUSE REMEDY
No beep • Engine actually starts. • Everything is correct.
1 long and • No safety lanyard has ever been pro- • Use MPEM programmer or the VCK
1 short beeps grammed in watercraft MPEM. 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.
2 short beeps • MPEM can not read the digital code of • Check safety lanyard cap condition
the safety lanyard cap or the magnet is with the MPEM programmer or the
defective. VCK. Replace safety lanyard if report-
ed defective.
• Mixed wires at safety lanyard post • Check post wiring harness.

connectors or bad connections.
2 long beeps • Wrong safety lanyard or bad connec- • Use the safety lanyard that has been
tion of the DESS wires. programmed for the watercraft. If the
problem is not resolved, check safety
lanyard cap condition with the MPEM
programmer or the VCK. Replace safe-
ty lanyard if reported defective.
3 short beeps • Wiring harness of DESS post is ground- • Check wiring harness and safety lan-
ed or there is a short circuit. yard post.
If you need to listen again to the coded beeps, remove safety lanyard and repeat the procedure to activate
the diagnostic mode.
If there is more than one problem, the MPEM will send only one error code. When the problem is solved,
the MPEM will send a second code and so on until all problems are resolved.
SMR2002-031_06_04A.FM 06-04-3
FAULT DETECTION AND COMPENSATORY ACTIONS

For a basic overview of the monitoring system and the limp home modes, see OVERVIEW section.
COMPONENT FAILURE WARNING SYSTEM

Sensor Failures
Refers to open or short circuit failures on sensors, drivers, injectors or ignition.
BUZZER LIMP HOME MODE
PROBLEM INFO CENTER RED LED BUZZER
CODE ➀
Manifold air
pressure sensor “MAINT” ON OFF 6 Limited RPM
(MAPS)
Manifold air
temperature sensor “MAINT” ON OFF 6 Limited RPM
(MATS)
Limited RPM
Throttle position
“MAINT” ON ON 4 (idle speed if both
sensor (single TPS)
TPS’s fail)
Limited RPM
Water temperature
“MAINT” ON OFF/(ON) 6/(4) (code 4 if EGT also
sensor (WTS)
fails)
Direct injector
“MAINT” ON OFF 6 Limited RPM
(single injector)
Fuel injector
(single injector)
Ignition
(no firing on one “MAINT” ON OFF 6 Limited RPM
cylinder)
RAVE solenoid “MAINT” ON OFF 6 Limited RPM
Starter solenoid “MAINT” ON OFF 6 Engine may not start
Fuel pump “MAINT” ON OFF 6 Limited RPM
Exhaust gas Limited RPM
temperature sensor “MAINT” ON OFF/(ON) 6/(4) (code 4 if WTS
(EGT) also fails)
Fuel level sensor “MAINT” ON OFF 6 None
Diagnostic cap fault “MAINT” ON OFF 6 None
Knock sensor “MAINT” ON OFF 6 Limited RPM
Engine drowned
Engine will not run.
mode activated None None ON 2
Release throttle
(it is not a fault)
06-04-4 SMR2002-031_06_04A.FM
System Failures
Refers to operating conditions outside normal and/or safe ranges such as demand system failures, ex-
treme voltages, over temperature conditions or low fuel/oil levels.
CODE ➀
Manifold air pressure
sensor (MAPS),
ATM fault (bad “MAINT” ON OFF 6 Limited RPM
atmospheric
pressure reading)
Throttle position
“MAINT” ON ON 3 Limited RPM
sensor (single TPS)
Throttle position
“MAINT” ON ON 4 Idle RPM
sensor (dual TPS)
Throttle position
sensor None OFF OFF 6 None
(single adaption fault)
Throttle position
sensor “MAINT” ON OFF 6 Limited RPM
(dual adaption fault)
Limited RPM
Sensor supply fault
“MAINT” ON ON/OFF 4/(6) (code 6 and idle RPM
(TPS and MAPS)
if both in fault)
Encoder (CPS) fault
(bad pattern)
Low battery
“12 V LOW” ON OFF 6 None
voltage
Very low battery “12 V LOW”
ON ON 4 Limited RPM
voltage “MAINT”
High battery
“MAINT” ON OFF 6 None
voltage
Very high battery
“MAINT” ON OFF 6 Idle RPM
voltage
High water
“HI-TEMP” ON ON 1 None
temperature
Exhaust
over temperature
Low oil level “OIL-LOW” ON ON 5 None
Low fuel level “FUEL-LO” ON ON 4 None
Setup fault
(TDC or TPS not set “MAINT” ON OFF 6 Idle RPM
on a new MPEM)
MPEM fault “MAINT” ON OFF 6 Engine will not start
➀ To see how the normal operation is recovered from the limp home mode, see the DI Fault Codes chart
elsewhere in this section. Look in column “Normal operation resumes if fault removed and...”.
SMR2002-031_06_04A.FM 06-04-5
Buzzer Code
BUZZER BUZZER PATTERN NOTE

CODE
ON
6 OFF Always OFF
2 SEC. 15 MIN.
5 ON
2 second beep every 15 minutes
OFF
2 SEC. 58 SEC.
4 ON
2 second beep every 58 seconds
OFF
2 SEC. 2 SEC.
3 ON 2 second beep every 2 seconds

OFF
1 SEC. 1 SEC.
2 ON 1 second beep every second
OFF
1 ON Always ON (continuously beep)

OFF
F12H13S
VCK  WARNING
(vehicle communication kit) If the computer you are using is connected to
The VCK (Vehicle Communication Kit) (P/N 529 the 110 Vac power outlet, there is a potential
035 844) is the primary tool to diagnose fuel injec- risk of electrocution when working in contact
tion related problems. with water. Be careful not to touch water
while working with the VCK.
B.U.D.S. is designed for the DI model to allow sen-
sor inspection, diagnostic options and adjustment IMPORTANT: When using the software B.U.D.S.,
such as the Throttle Position Sensor (TPS) and the with the DI engines, ensure that the protocol “947
TDC setting. DI” is properly selected in “MPI” under “Choose
For more information pertaining to the use of the protocol”.
software B.U.D.S., use its help which contains de- Refer to the tables below for the fault codes you
tailed information on its functions. will find in the B.U.D.S.
06-04-6 SMR2002-031_06_04A.FM
DI SYSTEM FAULT CODES – Electrical noise might also lead engine to occa-
sional cutout without generating a fault code
General when engine is restarted. When looking at the
fault code, pay attention to the “count” value in
The faults registered in the MPEM are kept when the software B.U.D.S. A value between 1 and 9
the battery is disconnected. confirms an electrical noise problem. A value of
Be aware that a red light blinking with the MAINT 10 and above will generate a fault code.
message may not be for a fault code. It may be a – When installing a new MPEM. It is not properly
maintenance inspection reminder. Press and hold programmed from the factory. The MPEM must
the SET button of the information center for 2 sec- be returned to be properly “activated”.
onds. If the blinking continues, it is a fault code.
Use the VCK (Vehicle Communication Kit) to see – If everything is in good condition, replace the
it. Otherwise, it was a maintenance reminder. MPEM.
IMPORTANT: After a problem has been solved, When using the service action suggested in the
ensure to clear the fault(s) in the MPEM using the Fault section of B.U.D.S., the system circuits are
VCK. This will properly reset the appropriate referred as 4-23 for instance. It means Amp con-
counter(s). This will also records that the problem nector no. 4 and the circuit wire no. 23 as found in
has been fixed in the MPEM memory. the wiring diagram.
Many fault codes at the same time is likely to be TPS (Throttle Position Sensor) Faults
burnt fuse(s). Faults which are reported in B.U.D.S. fall into two
For more information pertaining to the code faults groups TPS faults and adaption faults. These are
(state, count, first etc.) and report, refer to B.U.D.S. displayed on the B.U.D.S. system as TPS OUT OF
online help. RANGE and TPS ADAPTION FAILURE.
Supplemental Information for Some

Specific Faults
ECU fault code P0606: This code may occur in
the following situations:
– Electrical noise is picked up by the MPEM. Ensure
that all connections are in good condition, also
grounds (battery, MPEM, engine and ignition sys-
tem), they are clean and well tightened and that all
electronic components are genuine — particularly
in the ignition system. Installing resistive caps,
non-resistive spark plug cables (or modified
length), non-resistive spark plugs or knock sensor
wiring/routing may lead to generate this fault code.
SMR2002-031_06_04A.FM 06-04-7
TPS “OUT OF RANGE” Fault

It is caused by the sensor reading going out of its allowable range. This fault can occur during the whole
range of movement of the throttle.
To diagnose this fully, it is recommended to operate the throttle through its full range. It is also recom-
mended to release the throttle quickly as this may also show up a fault that is intermittent.
POSSIBLE CAUSES RESULT ACTION
Check if wrong connector is connected to TPS Yes • Fix.
Check if sensor is loose Yes • Fix and reset closed TPS.
Inspect sensor for damage or corrosion Yes • Replace and reset closed TPS.
Inspect wiring (voltage test) Failed • Repair.
• If bad wiring, repair.

Inspect wiring and sensor (resistance test)
Failed • If bad TPS, replace and reset closed TPS.
Test sensor operation (wear test) • Replace and reset closed TPS.
TPS “ADAPTATION FAILURE” Fault

It is caused by the idle position moving out of an acceptable range.
Sensor has been replaced and TPS closed

Yes • Reset closed TPS.
position not reset
Throttle body has been replaced and TPS

closed position not reset
MPEM has been replaced and TPS closed

position not reset
Throttle cable too tight Yes • Fix and reset closed TPS.
Sensor is loose Yes • Fix and reset closed TPS.
Throttle bracket is loose Yes • Fix and reset closed TPS.
Idle screw or synchronization screw worn

Yes • Fix and reset closed TPS.
or loose
06-04-8 SMR2002-031_06_04A.FM
DI System Fault Code Chart
NORMAL OPERATION
RESUMES IF FAULT
FAULT DETECTED
FAULT DETECTED
SENSOR/CIRCUIT
REMOVED AND...
WHILE ENGINE
WHILE ENGINE
ECU INTERNAL
NOT RUNNING
COMPONENT/
FAULT CODE
DIAGNOSED
DETECTED
RUNNING
SERVICE ACTION
NAME
FAULT
AND
POSSIBLE CAUSES
Service action:
Check for 1 - 1.6 ohm resistance between system circuits 4-15
Direct Open or and 4-5. Check for + 12 volts on pin A of injector connector (color).
P1100 injector AIR_INJ_1 short Yes No Return to
MAG circuit idle Possible causes:
Damaged injector, damaged circuit wires, damaged connector,
damaged ECU output pins. ECU failure.
Service action:
Direct Open or Return to and 4-6. Check for + 12 volts on pin A of injector connector (color).
P1101 injector PTO AIR_INJ_2 short Yes No idle
circuit Possible causes:
Service action:
Check for 1.7 - 1.9 ohm resistance between system circuits 4-13
Open or and 4-7. Check for + 12 volts on pin A of injector connector (color).
P0201 Fuel injector FUEL_INJ_1 short Yes No Return to
Service action:
Check for 1.7 - 1.9 ohm resistance between 4-14 and 4-8. Check
Open or for + 12 volts on pin A of injector connector (color).
PTO circuit idle Possible causes:
Open or Service action:
Ignition coil, short Check for .45 - .55 ohm resistance between system circuits 3-21
primary circuit on Return to and 3-22. Check for + 12 volts on pin A of coil connector (color).
P0351 winding IGN_CYL_1 ignition Yes No idle Possible causes:
MAG primary Damaged coil, damaged circuit wires, damaged connector, dam-
circuit aged ECU output pins. ECU failure.
short Check for .45 - .55 ohm resistance between system circuits 3-20
Ignition coil, and 3-23. Check for + 12 volts on pin A of coil connector (color).
P0352 primary IGN_CYL_2 circuit on Yes No Return to
winding PTO ignition idle Possible causes:
primary Damaged coil, damaged circuit wires, damaged connector, dam-
Service action:
Check for 12 volts on pin 5 and 5 volts on 6 and 0 volts on pin 4 of
Wrong encoder harness connector. Check system circuits 2-6, 2-7, 2-14.
P0335 Encoder Encoder pattern Yes No Return to
(CPS) idle Possible causes:
sensed Damaged sensor, damaged circuit wires, damaged connector,
damaged ECU pins. ECU failure. Damaged tooth wheel. Check
correct rectifier regulator operation.
SMR2002-031_06_04A.FM 06-04-9
NORMAL OPERATION
RESUMES IF FAULT
FAULT DETECTED
FAULT DETECTED
SENSOR/CIRCUIT
REMOVED AND...
WHILE ENGINE
WHILE ENGINE
ECU INTERNAL
NOT RUNNING
COMPONENT/
FAULT CODE
DIAGNOSED
DETECTED
RUNNING
NAME SERVICE ACTION
FAULT
AND
POSSIBLE CAUSES
Service action:
Check for 5 volts on pin 1 and 0-0.5 volts on pin 3 and 0 volts on
pin 2. Check system circuits 4-1, 4-2, 4-18. Check with throttle
closed the resistance between 1 and 2 is 2000 ohms and between
2 and 3 is 1000 ohms and between 1 and 3 2500 ohms. Check for
Sensor out Return to linear resistance rise when opening throttles. Check physical stops
P0120 TPS, PTO TPI_1 of range Yes No idle for wear.
Possible causes:
Damaged Sensor, damaged circuit wires, damaged connector,
damaged ECU pins, ECU failure, damaged or out of alignment
throttle bodies or sensor.
Service action:
Check for 5 volts on pin 1 and 4.75-5.0 volts on 3 and 0volts on pin
2. Check system circuits 3-5, 3-10, 3-14. Check with throttle closed
the resistance between 1 and 2 is 2500 ohms and between 2 and
3 is 2500 ohms and between 1 and 3 1200 ohms. Check for linear
P0220 TPS, MAG TPI_2 Sensor out Yes No Return to resistance rise when opening throttles. Check physical stops for
of range idle wear.
Possible causes:
Service action:
Throttle Check cable adjustment. Check Idle stop for wear check throttle
Full reset. angles at idle.
P1102 TPS, PTO TPI_1_ADAP position Yes No Key off
adaption and on Possible causes:
failure No initialisation after throttle body or ECU changes throttle idle
stop drifted.
Service action:
Throttle Check cable adjustment. Check Idle stop for wear. Check throttle
position Full reset. angles at idle.
P1103 TPS, MAG TPI_2_ADAP adaption Yes No Key off
and on Possible causes:
failure No initialisation after throttle body or ECU changes throttle idle.
Stop drifted.
Service action:
Check for resistance approx. 2280 ohms to 2736 ohms at temper-
ature of 19 to 21°C (66 to 70°F) between system circuits 4-9 and
Sensor out Return to 4-11.
P0116 WTS COOL_SENS of range Yes No idle
Possible causes:
Damaged sensor, damaged circuit wires, damaged connector,
damaged ECU pins. ECU failure.
Service action:
Check for debris or blockage in cooling system. Check for resis-
Overheat As soon as tance approx. 2280 ohms to 2736 ohms at temperature of 19 to
P0217 WTS COOL_RED warning Yes No fault is not 21°C (66 to 70°F) between system circuits 4-9 and 4-11.
present
Possible causes:
Engine overheated, damaged sensor.
Service action:
P0110 MATS MCT_SENS of range Yes No idle
Possible causes:
06-04-10 SMR2002-031_06_04A.FM
NORMAL OPERATION
RESUMES IF FAULT
FAULT DETECTED
FAULT DETECTED
SENSOR/CIRCUIT
REMOVED AND...
WHILE ENGINE
WHILE ENGINE
ECU INTERNAL
NOT RUNNING
COMPONENT/
FAULT CODE
DIAGNOSED
DETECTED
RUNNING
SERVICE ACTION
NAME
FAULT
AND
POSSIBLE CAUSES
Service action:
Check system circuits 3-3, 3-6, 3-7. Check sensor connector for 5
volts on pin 1 and 0 volts on pin 3 and 0 volts on pin 2. Check
Sensor out Return to Sensor housing is correctly inserted into manifold.
P0106 MAPS MAP Yes No
of range idle Possible causes:
Check sensing port for dirt or blockage. Sensor failure, unexpect-
ed reading at idle. Sensor fallen out of housing. Leaking Inlet
system, ECU failure.
Service action:
Bad Full reset. volts on pin 1 and 0 volts on pin 3 and 0 volts on pin 2.
P0105 MAPS MAP_ATM atmospheric Yes No Key off Possible causes:
reading and on Check sensing port for dirt or blockage, damaged sensor, dam-
aged circuit wires, damaged connector, damaged ECU pins. ECU
failure.
Service action:
P1400 EGT EXH_SENS of range Yes No idle
Possible causes:
Service action:
Check for debris or blockage in cooling system. Check tune pipe
Overheat As soon as injection valve.
P1401 EGT EXH_RED warning Yes No fault is not
present Possible causes:
Exhaust system overheated, damaged sensor damaged circuit
wires.
Service action:
As soon as TBD.
Fuel level Sensor out
P0460 sensor FUEL_SENS of range Yes No fault is not Possible causes:
present Damaged sensor, damaged circuit wires, damaged connector,
Service action:
Check for resistance of 6-8 ohms between system circuits 4-24
Open or Yes, Yes, Return to and 4-26.
P0230 Fuel pump FUEL_PUMP short short open idle
circuit circuit circuit Possible causes:
Damaged pump, damaged circuit wires, damaged connector,
Service action:
Yes, Check for resistance of 30 ohms between system circuits 4-23
Open or open Yes, and 4-20.
P0475 RAVE RAVE short and open Return to
solenoid circuit short circuit idle Possible causes:
circuit Damaged solenoid, damaged circuit wires, damaged connector,
Service action:
Starting Yes, Check for resistance of 6ohms between system circuits 3-19 and
system Open or open Yes, As soon as 3-15.
P1300 solenoid CRANK short and open fault is not
circuit short circuit present Possible causes:
(winding) Damaged solenoid, damaged circuit wires, damaged connector,
circuit
Battery Battery As soon as Possible causes:
P0563 voltage BV_HI_WARN voltage Yes Yes fault is not Battery failure, rectifier failure, battery terminal connection.
high present
SMR2002-031_06_04A.FM 06-04-11
NORMAL OPERATION
RESUMES IF FAULT
FAULT DETECTED
FAULT DETECTED
SENSOR/CIRCUIT
REMOVED AND...
WHILE ENGINE
WHILE ENGINE
ECU INTERNAL
NOT RUNNING
COMPONENT/
FAULT CODE
DIAGNOSED
DETECTED
RUNNING
NAME SERVICE ACTION
FAULT
AND
POSSIBLE CAUSES
Battery Battery Full reset. Possible causes:

P1500 voltage BV_HI_RED voltage Yes Yes Key off and Battery failure, rectifier failure, battery terminal connection.
very high on
Service action:
Check fuse.
Battery As soon as Check system circuits 3-25 to battery + terminal, 2-26 to regulator
P0562 Battery BV_LO_WARN voltage Yes Yes fault is not 2 pin connector pin A, 2-25 to regulator 2 pin connector pin B.
voltage low present Possible causes:
Battery failure, rectifier failure, damaged circuit wires, battery
terminal connection, damaged magneto, damaged connectors.
Service action:
Check fuse, check system circuits 3-25 to battery + terminal, 2-26
Battery to regulator 2 pin connector pin A, 2-25 to regulator 2 pin connec-
Battery Return to tor pin B.
P1501 voltage BV_LO_RED voltage Yes Yes idle
very low Possible causes:
Service action:
Sensor Sensor Check for shorts to ground or corrosion on the following system
supply (TPS, 5 volt Return to circuits 3-10 or 3-3.
P0122 MAG and XDRP_1 supply Yes Yes idle Possible causes:
MAPS) failure Damaged circuit wires, associated sensor failure (TPI 2 or MAP),
ECU fault.
Service action:
Sensor Check for shorts to ground or corrosion on system circuit 4-18.
Sensor 5 volt Return to
P0222 supply (TPS, XDRP_2 supply Yes Yes idle Possible causes:
PTO) failure Damaged circuit wires, associated sensor failure (TPI 1), ECU
fault.
Service action:
TDC and Reinitialize Initialize ECU.
P1600 ECU SETUP ECU not Yes Yes from
initialized B.U.D.S. Possible causes:
ECU not initialised, TDC not setup, throttle sensors not initalised.
Service action:
Internal Full reset. Check ignition leads, coils and correct spark plugs, replace ECU.
P0606 ECU ECU_FAULT ECU faults Yes Yes Key off Possible causes:
and on Incorrect software, ignition noise causing errors, internal EE-
PROM failure.
Service action:
Bring engine to 4500 RPM. If fault code appears, check for resis-
Knock Knock Yes, Return to tance approx. 4.8 ohms between system circuits 4-2 and 4-17.
P0325 sensor KNOCK_SENS sensor over No idle
failure 4500 Possible causes:
Diagnostic Service action:
Diagnostic cap is not As soon as Reinstall cap on wiring harness.
P1601 cap COMMS_CAP installed Yes Yes fault is not
on wiring present Possible causes:
harness Cap is not installed on wiring harness.
06-04-12 SMR2002-031_06_04A.FM
Section 07 COOLING SYSTEM
TABLE OF CONTENTS 0
CIRCUIT, COMPONENTS AND CARE................................................................................... 07-02-1
CIRCUIT .............................................................................................................................. 07-02-10
COMPONENTS .................................................................................................................. 07-02-14
CARE .................................................................................................................................. 07-02-17
SMR2002-052_07_01ATOC.FM 07-01-1
Subsection 02 (CIRCUIT, COMPONENTS AND CARE)
CIRCUIT, COMPONENTS AND CARE 0

GTI and GTI LE Models (717 engine)
Loctite
567
Loctite
567 Tuned pipe
Bleed water
hose inlet hose
Water
injection
hose
Loctite
567
Engine
water
return
hose
Loctite
567
Engine water
supply hose
Engine 1.2 Nm

drain hose (11 lbfin)
F17E04T Pump support
SMR2002-032_07_02A.FM 07-02-1
GTX RFI Models (787 RFI engine)

1
Water Loctite 592
injection
hose
Loctite
592
1.2 Nm
(11 lbfin)
Loctite 567
Tuned
pipe
water
inlet
hose 1.2 Nm
(11 lbfin)
Loctite 567
Regulator Inlet
valve water Outlet
supply hose
3
4
7 Outlet 2
0.11 Nm Inlet
(1 lbfin)
Loctite
592
8
Engine
drain hose
0.6 Nm
(5 lbfin) 6
5 Nm
(44 lbfin) 5
F15E04T
07-02-2 SMR2002-032_07_02A.FM
GTX Models (947 carburetor-equipped engine)
Loctite
567
1 1.2 Nm
(11 lbfin)
Loctite
567 Loctite
567
Loctite
567 Loctite
567 1.2 Nm
(11 lbfin)
Loctite
567
2
4
7
0.11 Nm
(1 lbfin)
Loctite
8 567
0.6 Nm
6 (5 lbfin)
5 Nm
5 (44 lbfin)
F02E09V
Loctite 567
SMR2002-032_07_02A.FM 07-02-3
XP and RX Models (947 carburetor-equipped engine)
Loctite
567
Loctite
567 Loctite
567
Loctite
567 Loctite
567
Loctite
567
4
Loctite
7 567
0.11 Nm
(1 lbfin)
8
0.6 Nm
(5 lbfin) 6
5 Nm
(44 lbfin) 5
Loctite 567
F08E07T
07-02-4 SMR2002-032_07_02A.FM
RX DI and LRV DI (947 DI engines)
Loctite 567
Loctite 567
Loctite
567
Loctite
567
1
Loctite
567
Loctite
567
Loctite Loctite 243
567 Loctite
primer N
Body
3
Silicone Loctite
2 sealant 296
4
Loctite
7 567
0.11 Nm
(1 lbfin)
8
0.6 Nm
(5 lbfin) 6 Loctite 518
5 Nm
(44 lbfin) 5
Loctite 567
F12E0XS
SMR2002-032_07_02A.FM 07-02-5
717 Engines
Temperature sensor activates

monitoring beeper when temperature
exceeds 96 - 99°C (205 - 210°F)
Uppermost
point
of circuit
(tuned pipe)
allows bleeding
Fresh water
Calibrated enters engine
cylinder head for
head limits additional
water flow combustion
chamber cooling
Calibrated
outlet fitting
limits
Engine water water flow.
hose outlet ALSO used
as flushing
connector
Water flows
through tuned
pipe and
manifold water
jackets
Water injected directly Tuned pipe bleed hose

into exhaust gases for injects water into
noise reduction and muffler to cool exhaust
performance components
improvement Pressure
zone
Cooling System
Indicator (CSI): Lowest point of circuit
Small stream of allows draining Calibrated outlet
water flows out whenever engine is fitting limits
of bleed outlet located stopped water flow
under bumper
line on front
port side
F17E06S
07-02-6 SMR2002-032_07_02A.FM
F15E06S
Water Water injected Serial cooling
from in the tuned system: Bleed
cylinder pipe controlled cylinder head hose
by the water combustion (upper Water supply
Water flows head to Engine hose of the
through the tuned flow regulator chambers are point Water
water
SMR2002-032_07_02A.FM
valve for noise cooled with of circuit) regulator
tuned pipe pipe return injected
787 RFI Engines
reduction and the water from valve

and manifold water hose into muffler
water jackets, jacket performance the jet pump to cool
improvement (from Cooling
then to the cylinder exhaust
cylinder components System
water Indicator
water jackets jacket) (CSI) at
stern eyelet
Magneto Quick Magneto heat

heat connect exchanger Engine Engine heat
exchanger hose outlet hose Engine exchanger
drain Engine water
water fitting supplies hose from heat water outlet
supply for easy water to the supply hose exits
cylinder exchanger hose
hose engine engine heat heat outlet at the exhaust
draining exchanger exchanger outlet for
noise reduction
07-02-7
Water injected in the tuned pipe
F16E02S
07-02-8
controlled by the water flow
regulator valve for noise reduction
and performance improvement Engine water
Temperature sensor supply hose Water injected
activates monitoring fitting into muffler to cool
Water flows out beeper when exhaust components
of tuned pipe temperature exceeds
water jacket 86-94°C (187-201°F)
Drain hose
(lowest point
of circuit)
947 Engine — Carburetor-Equipped Models

Bleed hose
(upper point
of circuit)
Engine water Engine water
return hose supply hose
from tuned
pipe water
Water flows out of exhaust manifold jacket
water jacket and through tuned pipe
water jacket before exiting the tuned pipe
Cooling System Exhaust hose
Hull (front portside) Indicator (CSI) (GTX only)
SMR2002-032_07_02A.FM
Water injected in Water flows through water jackets Water flows through
the tuned pipe to cool the magneto area and the crankcase water jackets to cool the
F12E0WS
Water injected
controlled by the Temperature air compressor into muffler to
water flow sensor cool exhaust
regulator valve for activates Crankcase components
noise reduction monitoring
SMR2002-032_07_02A.FM
and performance
947 DI Engines
beeper when Temperature

improvement temperature Magneto cover Air sensor activate
exceeds compressor monitoring
Water flows out 80°C (176°F) beeper when
of tuned pipe temperature
water jacket exceeds
100°C (212°F)
Quick
connect
hose fitting
for easy
engine
draining
Drain hose
Engine water (lowest point
supply hose of circuit)
from jet
pump
Engine water
Water flows out of exhaust return hose
manifold water jacket and through from tuned Air
Side of hull pipe water compressor
tuned pipe water jacket before Cooling System
exiting the tuned pipe jacket silencer
Indicator (CSI)
07-02-9
CIRCUIT
CAUTION: All hoses and fittings of the cooling
system have calibrated inside diameters to as-
sure proper cooling of the engine. Always replace
using appropriate Bombardier part number.
717 Engines
A Serial Cooling System is utilized on the 717 en-
gines, which offers an efficient cooling of the
combustion chamber to prevent the possibilities
of detonation.
The water supply is taken from a pressurized area
in the jet pump between the impeller and venturi.
F01D7HB 1
Water enters the cylinder head, cooling the com-
bustion chamber to prevent detonations. Then, 1. Water passages
water exits cylinder head toward tuned pipe.
No water enters crankcase.
3 2 When engine is running, water must flow from
bleed outlet indicating that water circulates.
CAUTION: When investigating for no water flow
in the cooling system, check all elbows and
straight fittings as well as all hoses for blockage.
For a minimum back pressure in the exhaust, en-
gine water outlet hose is not connected to the ex-
haust. It has its own outlet at the rear of the hull.
Draining of the cooling system is accomplished by
a drain hose located at the lowest point of the cir-
1 4 cuit.
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 pas-
sages located below exhaust ports from tuned
pipe.
F01E0FB 1
717 ENGINE
1. Drain hose
07-02-10 SMR2002-032_07_02A.FM
787 RFI Engines Water is directed to the water inlet fitting at cylin-
The 787 RFI engines features a heat exchanger sys- der head.
tem. This system allows water coming out of the
1
cylinder head to circulate through a magneto heat
exchanger and the crankcase heat exchanger.
1
F15E07A 2 3 4
1. Quick connect hose fitting
2. Engine heat exchanger water supply hose
3. Engine drain hose from cylinder heat exchanger F08E05A
4. Water outlet hose to exhaust outlet
The engine heat exchanger supply hose has a quick
connect hose fitting to facilitate engine draining. DI Models
Water from inlet hose also supplies the water reg-
ulator on muffler and magneto cover and crankcase
cover.
Water then is expulsed through the pump support
drain.
All 947 Engines
Water circulates through the one piece cylinder
head which features improved combustion cham-
ber and better spark plug cooling.
F02E0BA 1 2
1. Heat exchanger water supply hose
2. Quick connect hose fitting
The water coming out of the engine heat exchang-

er is evacuated at the exhaust outlet for noise re-
duction.
947 Engines
The 947 engines has a conventional cooling sys-
tem. The water is entering the engine by the water
inlet fitting at the cylinder head.
As with other models, the water supply is provid- F06D21A
ed by a pressurized area in the jet pump between
the impeller and venturi.
SMR2002-032_07_02A.FM 07-02-11
Water enters cylinder block water jackets and is DI Models

directed to the water jackets of the exhaust man- Water flows out of tuned pipe water jacket from
ifold and tuned pipe head through passages locat- upper fitting of tuned pipe and is directed to the
ed above and below exhaust ports. air compressor, then to the air silencer at the tran-
som.
Water continues to flow in the crankcase water
jacket to cool the crankcase area to then be ex-
pulsed to the transom area.
All 947 Engines
the drain hose connected to a fitting at the bottom
of the cylinder-block, on tuned pipe side.
F06D20A 1
1. Water passages
Water exits tuned pipe water jackets through an

outlet fitting.
F06E0IA 1
1. Drain hose
Bleeding of the cooling system is accomplished by

the bleed hose located at the uppermost point of
the circuit at the tuned pipe. The bleed hose also
serves as the Cooling System Indicator (CSI).
F06E08A 1
1. Engine water outlet
Water circulates in the water outlet hose and is

expelled out of the cooling system through a fit-
ting located in the jet pump support on the tran-
som of the watercraft.
Water flows out of tuned pipe water jacket from
upper fitting of tuned pipe and is expulsed to the
cooling system indicator. F06E0BA 1
1. Bleed hose
07-02-12 SMR2002-032_07_02A.FM
The water supply of the water flow regulator is pro-

vided by the water supply hose coming from the
pump.
F06E0AA 1
1. Injection fitting
F06E09A 1
All Models
1. Water flow going to CSI
CAUTION: Never modify cooling system arrange-
The lower hose of the valve is the water supply ment, otherwise serious engine damage could
and the upper hose is the regulated injection water occur.
for the tuned pipe.
TECHNICAL DATA
TYPE:
TLCS (Total Loss Cooling System).
COOLANT FLOW:
2 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).
1 SYSTEM FLUSHING:
3 Fitting hose adapter.
F06E0CA
MONITORING BEEPER:
1. Water from engine water supply hose Turns on at 86 - 94°C (187 - 201°F).
2. Regulated injection water to the tuned pipe
3. Muffler
Regulated water is injected in the tuned pipe by a

calibrated fitting.
SMR2002-032_07_02A.FM 07-02-13
COMPONENTS The elbow fitting can be identified by using the

number stamped onto the fitting or by measuring
Clamp its inside diameter. Refer to the following illustra-
tion and chart.
To cut or secure non-reusable Oetiker clamps of
cooling system hoses, use pliers (P/N 295 000 070).
16
A
1
1
F00E04A
B
1. Stamped number
A. Outlet diameter = 4.6 mm (.181 in)
B. Inlet diameter = 5.5 mm (.219 in)
2
F01B2KA
STAMPED
1. Cutting clamp NUMBER FITTING INLET OUTLET
2. Securing clamp
ON P/N DIAMETER DIAMETER
FITTING
Elbow Fitting
Water injection used on exhaust system cools the 5.5 mm 4.6 mm
16 293 700 016
exhaust gases to obtain maximum performance (.219 in) (.181 in)
from the tuned pipe. The elbow fitting no. 1 has a 4.0 mm 3.5 mm
calibrated inside diameter to optimize water flow 48 293 710 048
(.157 in) (.139 in)
in tuned pipe.
The water injection also helps in reducing noise lev-
el and cools components of the exhaust system. Water Flow Regulator Valve
CAUTION: The elbow fittings are calibrated and A water flow regulator valve is mounted on mod-
can not be interchanged with one of a different els with the 787 RFI and 947 engines so that they
size as severe engine damage could result. can produce the maximum horsepower output
and yet maintain the necessary diameter of the
injection fitting at the tuned pipe head for unob-
structed water flow.
07-02-14 SMR2002-032_07_02A.FM
The water flow regulator valve no. 2 is mounted

directly onto the muffler.
F01E1FA 3 1 2
TYPICAL
3
1. Water supply hose of regulator valve F01E2BA
2. Regulated water to injection fitting
3. Water injected into the muffler LOW SPEED OPERATION
1. Water entering regulator valve
NOTE: The water injected into the muffler is not 2. Water exiting regulator valve (less restriction)
regulated by the valve. A calibrated water injection 3. Water injected in the muffler
fitting of 3.0 mm (.118 in) on carburetor-equipped At higher speed, water pressure increases in the
models and 4.0 mm (.156 in) on DI models inside supply hose of the regulator valve and gradually
diameter limits water flow into the muffler. overcomes the return spring of the regulator valve.
The water flow regulator valve has a calibrated Less water is being delivered to the injection fitting
spring and a tapered needle which regulate the at the tuned pipe.
injected water in the tuned pipe.
CAUTION: Do not change anything on the wa-
ter flow regulator valve, otherwise serious en-
gine damage can occur. In many countries it is
illegal to tamper with this valve as this will af-
fect the EPA certification.
At low speed, water pressure in the supply hose
of the regulator valve is not sufficient to overcome
the spring of the regulator valve; more water is
being delivered to the injection fitting at the tuned
pipe. 2
F01E2CA
3
HIGH SPEED OPERATION

2. Water exiting regulator valve (more restriction)
3. Water injected in the muffler
SMR2002-032_07_02A.FM 07-02-15
Adjustment
The water flow regulator valve has been calibrated 1
at the factory and should not be modified.
NOTE: Water flow regulator valves ordered from
the parts channel are also calibrated. The valve cap
on the DI models is sealed and it is not adjustable.
If the maximum engine speed cannot be attained
or if the engine has poor performance, the water
flow regulator valve should be considered in the
troubleshooting of the problem.
Disassembly
Remove the cover no. 4 of the valve by releasing
the spring no. 3. F01E1SA
 WARNING 1. Fitting
Firmly hold cover to valve base. The spring Unscrew the tapered needle no. 6.
inside the valve is applying a pressure against NOTE: Hold the valve to prevent it from turning.
the cover.
F01E1TA
F01E1RA 1. Tapered needle
1. Spring Remove the tapered needle from valve housing.

2. Cover
1
Remove fitting no. 5 from valve housing.
F01E20A
1. Remove tapered needle
07-02-16 SMR2002-032_07_02A.FM
Pull the valve slightly. Using pliers, release the clamp For winterization of cooling system, refer to STOR-
which retains the bellows no. 8. AGE.
Remove valve no. 7 and bellows no. 8. GTI and GTI LE Models
When servicing the hull, always rotate watercraft
counterclockwise (seen from the rear). Rotating
watercraft on the opposite side could allow resid-
ual water in tuned pipe to enter the engine and
cause damage.
Max. 90°
F01E21A
Loosen clamp to separate valve from bellows.
F01L45C
All Other Models

When servicing the hull, always rotate watercraft
clockwise (seen from the rear). Rotating water-
craft on the opposite side could allow residual wa-
ter in tuned pipe to enter the engine and cause
F01E24A 1 damage.
1. Clamp
max. 90°
Inspection
Inspect parts for damage. Verify especially bellows
for cracks.
Assembly
Assembly is essentially the reverse of disassembly
procedures.
CARE
For flushing purposes, the cooling system is equipped
with either a fitting spigot or a hose adapter de-
pending upon the model.
For flushing operation, a coupler hose is available
(unnecessary for models with the hose adapter) to
connect to the fitting spigot. A garden hose is
F06L0GA
used to flush the whole system by backwash. For
flushing procedure, refer to FLUSHING AND LU- TYPICAL
BRICATION.
SMR2002-032_07_02A.FM 07-02-17
Towing the Watercraft in Water 1

Special precautions should be taken when towing
a Sea-Doo watercraft in water.
Maximum recommended towing speed is 24 km/h
(15 MPH).
When towing your watercraft in water, pinch the
water supply hose from the jet pump housing to the
engine with a large Hose Pincher (P/N 529 032 500).
F08E03A
XP MODELS
1. Hose pincher on water supply hose
F01B23A
This will prevent the cooling system from filling

which may lead to water being injected into and
filling the exhaust system. Without the engine run-
ning there isn’t any exhaust pressure to carry the
water out the exhaust outlet.
CAUTION: Failure to do this may result in dam-
age to the engine. If you must tow a stranded wa-
tercraft in water and do not have a hose pincher
be sure to stay well below the maximum towing
F07E03A 1
speed of 24 km/h (15 MPH).
GTX MODELS
Snugly install the hose pincher on the water sup-
1. Hose pincher
ply hose as shown in the following illustrations.
F07E04A 1
F02E04A 1
GTX RFI MODELS
GTI AND GTI LE MODELS 1. Hose pincher
1. Hose pincher on water supply hose
07-02-18 SMR2002-032_07_02A.FM
F12E01A 1
TYPICAL — RX SERIES AND LRV DI MODELS
1. Hose pincher on water supply hose on this side of the T-fitting
CAUTION: When finished towing the watercraft,

the hose pincher must be removed before oper-
ating it.
SMR2002-032_07_02A.FM 07-02-19
TABLE OF CONTENTS 0
FUEL CIRCUIT........................................................................................................................ 08-02-1
GENERAL ........................................................................................................................... 08-02-7
REMOVAL........................................................................................................................... 08-02-7
INSPECTION ...................................................................................................................... 08-02-9
ASSEMBLY......................................................................................................................... 08-02-10
FUEL SYSTEM PRESSURIZATION ................................................................................... 08-02-11
AIR INTAKE ............................................................................................................................ 08-03-1

REMOVAL........................................................................................................................... 08-03-5
ASSEMBLY......................................................................................................................... 08-03-6
CARBURETOR ....................................................................................................................... 08-04-1

GENERAL ........................................................................................................................... 08-04-2
REMOVAL........................................................................................................................... 08-04-2
CLEANING ......................................................................................................................... 08-04-3
DISASSEMBLY AND INSPECTION................................................................................... 08-04-3
ASSEMBLY......................................................................................................................... 08-04-5
INSTALLATION .................................................................................................................. 08-04-7
ADJUSTMENTS ................................................................................................................ 08-04-7
SMR2002-052_08_01ATOC.FM 08-01-1
Subsection 02 (FUEL CIRCUIT)
FUEL CIRCUIT 0
GTI and GTI LE Models
Body 3 Nm
(27 lbfin)
2 Nm
(18 lbfin)
7
GTI/GTI LE 6 Nm
6 (53 lbfin) 3
1
1.2 Nm
(11 lbfin) 1.2 Nm
(11 lbfin)
22 Nm
(16 lbfft) 1.2 Nm
4 Nm (11 lbfin)
4 Nm 4 (35 lbfin)
12
(35 lbfin)
3 Nm 11
(27 lbfin)
5 10
Dielectric
grease
4 Nm 4
(35 lbfin)
8
1.2 Nm Engine
(11 lbfin)
9
14
13
F06F18S
SMR2002-033_08_02A.FM 08-02-1
GTX Models
3 Nm
Body (27 lbfin)
2 Nm
(18 lbfin)
6 Nm
(53 lbfin)
7 3
6 1
1.2 Nm
(11 lbfin) 2
1.2 Nm
(11 lbfin) 1.2 Nm
(11 lbfin)
1.2 Nm
(11 lbfin)
22 Nm
(16 lbfft)
3 Nm
4 Nm 4 (27 lbfin)
(35 lbfin) 12
1.2 Nm
11 (11 lbfin)
10
5
4 Nm
4 Nm 4 (35 lbfin)
(35 lbfin) Dielectric
grease 8
9
1.2 Nm Engine
(11 lbfin)
1.2 Nm
(11 lbfin)
13
14
F06F0RS
08-02-2 SMR2002-033_08_02A.FM
XP Models
1.2 Nm
(11 lbfin)
Engine
1
2 6
1.2 Nm 1.2 Nm

(11 lbfin) (11 lbfin)
6 Nm
(53 lbfin) 1.2 Nm
(11 lbfin)
2 Nm
(18 lbfin)
12
22 Nm 10 11
(16 lbfft)
4
8
4 Nm 13
5 (35 lbfin)
4 9
13
14
F08F06S
SMR2002-033_08_02A.FM 08-02-3
GTX RFI Models
Body
6 7
11
4 Nm 4 10
(35 lbfin)
5 22 Nm
(16 lbfft)
8
4 Nm 4
(35 lbfin)
13
14
F02F27S
08-02-4 SMR2002-033_08_02A.FM
RX (carburetor-equipped models)
3 Nm
Body (27 lbfin)
2 Nm
(18 lbfin)
6 Nm
7 (53 lbfin)
3
6 1
1.2 Nm
(11 lbfin) 2
1.2 Nm
(11 lbfin) 1.2 Nm
(11 lbfin)
1.2 Nm
(11 lbfin)
22 Nm
(16 lbfft)
3 Nm
4 Nm 4 (27 lbfin)
(35 lbfin) 12
1.2 Nm
11 (11 lbfin)
10
5
4 Nm
4 Nm 4 (35 lbfin)
(35 lbfin) Dielectric
grease 8
9
1.2 Nm Engine
(11 lbfin)
1.2 Nm
(11 lbfin)
13
14
F06F0RV
SMR2002-033_08_02A.FM 08-02-5
DI Models
6
7
17
16
4 Nm
4 (35 lbfin)
18
22 Nm
(16 lbfft)
5 8
13
4 Nm
4 (35 lbfin)
14
F12F15S
08-02-6 SMR2002-033_08_02A.FM
GENERAL
 WARNING
DI Models: The fuel system of a fuel injection
system hold much more pressure than on a
carbureted watercraft. Prior to disconnecting
a hose or to removing a component from the
fuel system, follow the recommendations de-
scribed in ENGINE MANAGEMENT (DI) under F01B04A 1
FUEL SYSTEM.
1. Securing clamp
 WARNING
Whenever repairing the fuel system, always
verify for water infiltration in reservoir. Re-
place any damaged, leaking or deteriorated
fuel lines.
When working with fuel, pay attention to the fol-

lowing warning.
 WARNING
Fuel is flammable and explosive under cer-
tain conditions. Always work in a well venti- 1
F01B05A
lated area. Always wipe off any fuel spillage
from the watercraft. 1. Securing clamp in limited access
When replacing fuel lines on SEA-DOO water-

To secure or cut Oetiker clamps on fuel lines, use
craft, be sure to use “B1” hoses as available from
pliers (P/N 295 000 070).
Bombardier parts department. On DI models, use
hoses ass’y available as parts replacement only.
This will ensure continued proper and safe opera-
tion.
 WARNING
Use of improper fuel lines could compromise
fuel system integrity.
REMOVAL
1
Fuel Filter
F01B03A
All Models except XP, GTI, GTI LE, RFI and DI
1. Cutting clamp Models
Open storage compartment cover.
Remove basket.
XP Models
Open engine cover and remove basket.
SMR2002-033_08_02A.FM 08-02-7
GTI, GTI LE Models GTX RFI Models

Remove seat. The fuel pump assembly has to be removed from
the fuel tank to have access to the fuel filter. Refer
Carburetor-Equipped Models to ENGINE MANAGEMENT (RFI).
Turn the fuel valve to OFF position.
DI Models
 WARNING A replaceable inline filter is located near the fuel
The engine must not be running and fuel tank. Refer to ENGINE MANAGEMENT (DI) sec-
valve must be set to OFF position. Gasoline is tion.
ditions. Always work in a well ventilated area.  WARNING
The inline filter needs to be replaced only with
Unscrew fuel filler cap to remove any fuel pres- 4 Oetiker clamps (2 on each side).
sure in system.
Unscrew the fuel filter bowl no. 2 counterclock- CAUTION: A pressure test needs to be com-
wise then pull toward the bottom. plete after replacement.
Fuel Baffle Pick Up

All Models except GTX RFI and DI
NOTE: The baffle pick up has an integrated fuel
sender for the fuel gauge.
2
F01F01A 2
TYPICAL
Step 1 : Loosen counterclockwise
Step 2 : Pull 3
Pull fuel filter no. 1 toward the bottom.
F01F20A
1. Pick up tube
2. Fuel sensor
3. Baffle pick up
Disconnect BLACK negative cable, then RED pos-

itive cable of battery.
 WARNING
the specified order, BLACK negative cable first.
RX, GTI AND GTI LE Models

Open storage compartment cover.
F01F04A Remove storage basket from watercraft (if so
TYPICAL
equipped).
08-02-8 SMR2002-033_08_02A.FM
Remove rear panel of storage compartment (if so Fuel tank

equipped).
All Models
Siphon fuel tank.
NOTE: On all models (except GTX, GTX RFI and
Remove steering assembly. Refer to STEERING LRV DI), it is necessary to remove the engine. Re-
SYSTEM for procedure. fer to REMOVAL and INSTALLATION section.
GTX Models Siphon fuel tank.
Syphon fuel tank. Remove fuel baffle pick up or electric fuel pump
Remove glove box. on RFI and DI models. Refer to the above section.
Detach all fuel tank straps.
XP Models
Pull out fuel tank.
Tilt seat. Refer to HULL/BODY for procedure.
Remove access plug on body. INSPECTION
Syphon fuel tank.
Fuel Filter
All Models except RFI and DI All Models except GTX RFI and DI
Disconnect fuel lines from baffle pick up and loos- Inspect fuel filter condition. Carefully use low
en lower clamp no. 10. pressure compressed air to clean fuel filter. Re-
place filter if permanently clogged or damaged.
1
Fuel Filter Bowl
Check filter bowl for water contamination.
Gasket
Inspect gasket condition. Make sure gasket no. 3
is well positioned into the filter bowl no. 2.
F02F1OA 2
TYPICAL
1. Disconnect fuel hoses
2. Loosen lower clamp
Disconnect wiring harness of fuel sender.

Remove baffle from fuel tank.
All Models
Remove upper clamp no. 12 from adapter no. 11
and slide adapter from baffle.
F01F02A
Push inward on the 3 clips at the base of the baffle
in order to remove the filter. Pry base off using a 1. Gasket in bowl
small slotted screwdriver (if necessary).
Electric Fuel Pump

RFI and DI Models
Refer to appropriate ENGINE MANAGEMENT
section.
SMR2002-033_08_02A.FM 08-02-9
Fuel Tank
 WARNING
Ensure that there is no leakage from the fuel All Models
filter. Visually inspect the inside and outside of the fuel
tank necks for crack(s). If crack(s) are existing, re-
RFI Models place fuel tank no. 14.
The filter at fuel pump inlet is not replaceable indi- Check with your finger to feel the inside and out-
vidually. The complete fuel pump unit has to be side surfaces of fuel tank. Flex fuel tank necks to
replaced. Refer to ENGINE MANAGEMENT. ensure there are no hidden cracks.
DI Models 4 2
Inspect inline filter condition. Carefully use low
pressure compressed air to clean. Replace if per-
manently clogged or damaged.
1
NOTE: The fuel filter needs to be replaced after
250 hours.
Fuel Filler Hose

All Models F07F06A
3 A 5
Verify fuel filler hose no. 5 for damage. Always en- 1. Tank upper surface
sure that clamps no. 4 are well positioned and 2. Inspect outside, above upper surface
3. Normal molding seam
tightened. Torque clamps to 4 N•m (35 lbf•in). 4. Inspect inside, above upper surface
5. Base of the neck
A. Approx. 4 mm (5/32 in)
Pressure Relief Valve
This valve will eliminate fuel spillage when the wa- NOTE: A fuel tank is comprised of 3 components:
tercraft is upside down. If pressure is built up in the tank, the fuel pick up neck and the filler neck.
fuel system the valve should open at 3.5 kPa (0.5 The necks are injection molded and the tank is
PSI) for XP, DI and RFI models and at 10 kPa (1.5 then blow molded over the necks. During the
PSI) for all other models to release the pressure. molding process, a small molding seam may ap-
pear on the inner side of the necks at approximate-
 WARNING ly 4 mm (5/32 in) from the base of the neck. It is a
normal situation to have a molding seam and it
If pressure relief valve is stuck, the pressure should not be confused with a crack.
in fuel system will build up and it may cause
fuel leakage in engine compartment.
ASSEMBLY
NOTE: It is a one-way valve with an arrow to indi- Assembly is essentially the reverse of disassem-
cate the air flow. bly procedures. However pay particular attention
to the following.
Check Valve
Black side of the one-way check valve no. 7 is the Baffle Pick Up
valve outlet. It allows air to get in reservoir. All Models except GTX RFI and DI
Baffle Pick Up Filter Slide adapter no. 11 onto baffle pick up no. 8 until
it stops on rib. Install clamp no. 12.
All Models except GTX RFI and DI Install baffle pick up no. 8 into fuel tank and push it
Inspect filter no. 9 of baffle pick up. Clean or re- until it sits on fuel tank neck. Install clamp no. 10
place as necessary. and torque both clamps to 3 N•m (27 lbf•in).
08-02-10 SMR2002-033_08_02A.FM
FUEL SYSTEM PRESSURIZATION – Turn fuel valve to OFF position (except GTX RFI
and DI).
 WARNING – Pressurize fuel system to 34 kPa (5 PSI).
Whenever doing any type of repair on water- – If no leaks are found, turn fuel valve to ON po-
craft or if any components of the fuel system sition and pressurize once more.
are disconnected, a pressure test must be – If pressure is not maintained locate leak and
done before starting engine. Ensure to verify repair/replace component leaking. To ease leak
fuel line ends for damage. Always cut dam- search spray a solution of soapy water on com-
aged end before reinstallation. ponents, bubbles will indicate leak location.
NOTE: The system must maintain a pressure of
Pressure Test (supply and vent circuits) 34 kPa (5 PSI) during 10 minutes. Never pressurize
All Models over 34 kPa (5 PSI).
Proceed as follows: Reconnect air inlet hose of fuel tank to body.
– Fill up fuel tank.  WARNING
– Disconnect air inlet hose of fuel tank from body. If any leak is found, do not start the engine
– Install a hose pincher (P/N 295 000 076) on fuel and wipe off any fuel leakage. Do not use
tank vent hose. 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
RE
S
coming out when removing hose pincher. This will

OU
T
indicate that pressure relief valve and the outlet

1 2 fitting are not blocked.
Remove hose pincher from fuel tank vent hose.
High Pressure Test (fuel pump circuit)

RFI and DI Models
Refer to the appropriate ENGINE MANAGEMENT
F01F0KA section.
 WARNING
TYPICAL
1. Disconnect air inlet hose
2. Install a hose pincher to vent hose
Prior to installing the safety lanyard, refer to
– Connect pump gauge tester (P/N 529 021 800) the appropriate ENGINE MANAGEMENT sec-
to air inlet hose. tion for safety precautions to take.
NOTE: This pump is included in the ENGINE LEAK
TESTER KIT (P/N 295 500 352).
SMR2002-033_08_02A.FM 08-02-11
Subsection 03 (AIR INTAKE)
AIR INTAKE 0
717 Engines
1
3
10 Nm
(89 lbfin) 9
2
10 Nm
(89 lbfin)
8
5
6
Loctite 518 10 Nm

(89 lbfin)
10
Loctite
243
7
Loctite 243
Loctite 518
15
F02F2CS
Loctite 243
SMR2002-034_08_03A.FM 08-03-1
787 RFI Engine
10 Nm 9
(89 lbfin)
2
Loctite
243
10 Nm
(89 lbfin)
5
10
10 Nm
(89 lbfin)
Loctite 8
243
6
7
F15F01T
08-03-2 SMR2002-034_08_03A.FM
Loctite 243
3
11 12
Loctite
14 243
13
F08F0DT
SMR2002-034_08_03A.FM 08-03-3
947 DI Engines
Loctite 243
2
11 12
Loctite 243
14 4
13
Super
Lube Loctite
243
3
F12F14S
08-03-4 SMR2002-034_08_03A.FM
REMOVAL Flame Arrester Base

717 and 787 RFI Engines Remove flame arrester no. 5.
Remove screws no. 8 retaining support no. 6 of
Air Intake Silencer Cover flame arrester base to the cylinder head cover (717
Unlock the 6 retaining slides holding air intake si- engine) or to the exhaust manifold (787 engine).
lencer cover no. 1 and remove cover.
1
1 2
F01F2OA
TYPICAL
1. Air intake silencer cover
2. Unlock F00F03A
TYPICAL
Air Intake Silencer Base 1. Remove support
Remove screws no. 2 of retaining plate no. 3.
Remove screws no. 10 from flame arrester base
Pull out retaining plate no. 3 and air intake silencer then withdraw base.
base no. 4.
NOTE: On GTI and GTI LE models, withdraw
1
both arrester supports no. 15.
All 947 Engines

Air Intake Silencer
Pull hair pin out to allow removal of clip no. 2.
F00F02A 2 1
1. Retaining plate
2. Remove screws
F00F0FA

2. Clip
3. Hair pin
SMR2002-034_08_03A.FM 08-03-5
Unlock the clip no. 2 on top of air intake silencer. XP Model

Remove bolts retaining both air ducts to engine (both Pull the air silencer forward to remove it from the
sides). lower bracket no. 4 and remove it in a rotating move-
ment.
F08F08A 1 1 F08F0AA
1. Remove bolts XP MODEL

Pull air ducts out. The air intake silencer is a molded piece and it can
not be opened. It has an integrated flame arrester.
ASSEMBLY
Assembly is essentially the reverse of removal
1 procedures. However pay particular attention to
the following.
CAUTION: Do not modify air intake system,
otherwise calibration will be affected.
717 Engines
Flame Arrester Base
Apply Loctite 518 on mating surfaces of flame ar-
rester base no. 7.
Apply Loctite 243 (blue) on screws no. 10 and
torque to 10 N•m (88 lbf•in).
F08F09A
Flame Arrester
1. Air duct
Inspect condition of flame arrester no. 5. Replace
On XP model, detach retaining straps and pull oil or clean as necessary.
reservoir out.
NOTE: Do not disconnect oil lines.  WARNING
Push the air intake silencer out of the carburetor Do not operate watercraft without flame ar-
adapter no. 3 and throttle body. rester.
GTX and RX Models

Pull the air intake silencer rearward to remove it
from the lower bracket no. 4 and remove it in a
rotating movement.
08-03-6 SMR2002-034_08_03A.FM
Gasket All 947 Engines

Inspect condition of gasket no. 9. Make sure to NOTE: Make sure the air intake silencer is retained
properly install gasket. by the lower bracket no. 4.
Place protector pads on duct supports. Use slot in
All 947 Engines rubber to insert pad on bracket eyelet. Side tongue
of protector pad should be toward outside of vehi-
Air Intake Silencer cle and bent downward toward the exhaust flange.
Ensure that support plate edges no. 14 are prop- Put air ducts in intake adapters and secure them
erly crimped to air intake silencer. Use pliers as on duct supports with hexagonal screws no. 13,
necessary. wide washers, narrow washers and elastic stop
Make sure that gaskets no. 11 are installed into nuts. A slight lift will be required to make the bolts
carburetor holes of air intake silencer or throttle line up with brackets.
bodies on DI engines.
1 2 3 7 8
Check O-rings no. 12 on carburetor intake adap-
tors or throttle bodies on DI engines and change
them if necessary.
NOTE: Apply Super Lube grease (P/N 293 550
014) to mating surface of air intake silencer no. 1.
Install air intake silencer on carburetor intake adap-
tor or throttle bodies on DI engines and latch in
place.
Clip air intake silencer back in place.
 WARNING
While doing so, ensure that the clip snaps
firmly, securing the air intake silencer in a
tight fit; if not, bend the clip using pliers until
you feel that the clip is tight enough.
Properly reinstall hair pin to secure clip no. 2. F06F0VA 4 6 5

TYPICAL — 947 CARBURETOR-EQUIPPED ENGINES
947 DI Engines 1. Hexagonal screw M6
2. Wide flat washer
Ensure the elbow adaptor is well inserted and that 3. Insulator
it has not pushed the gasket inside the air box. 4. Air duct
5. Protector pad
6. Duct support eyelet
7. Narrow flat washer
8. Hexagonal stop nut M6
SMR2002-034_08_03A.FM 08-03-7
Subsection 04 (CARBURETOR)
CARBURETOR 0
For fuel system on RFI and DI models, refer to appropriate ENGINE MANAGEMENT section.
Mikuni BN-40i and BN-46i
Loctite
243
20 Nm
12 (15 lbfft) 6
20
Synthetic
grease
Synthetic
grease
14
21 13
9
Loctite 243
3
8
11
7
1 15
Anti-seize
13 lubricant 19
5 4
2
PTO/MAG
PTO
20
18
17
16
F02F1ZT
SMR2002-035_08_04A.FM 08-04-1
GENERAL
The following illustration shows which part of the
carburetor begins to function at different throttle
plate openings.
2
4 2
6
F06F0LA
TYPICAL
1. Pulse line
2. Loosen gear clamp
3 1
Disconnect fuel supply line from fuel pump.
F01F13A
Disconnect fuel return line.
VIEW FROM AIR INTAKE OPENING
1. Throttle plate openings Disconnect oil injection pump cable, throttle cable
2. Throttle plate closed and choke cable.
3. Throttle plate wide opened
4. Low-speed screw Remove screws no. 20 and lock washers no. 21
5. Pilot jet
6. Main jet and high-speed screw retaining carburetor(s).
The carburetor(s) is (are) equipped with a fuel ac- 1 1
celerator pump.
The fuel accelerator pump is linked to the throttle
valve via a linkage.
A metering jet in the fuel inlet hose controls fuel
flow to the pump.
A check valve on the fuel outlet hose helps to
prime the system.
REMOVAL
To remove carburetor(s) from engine, proceed as
follows:
Remove air vent tube support (GTI and GTI LE F07F03A 1 1
models).
TYPICAL
Remove air intake silencer. Refer to AIR INTAKE. 1. Remove screws
Turn fuel valve to OFF position.
Remove carburetor(s).
Disconnect pulse line.
08-04-2 SMR2002-035_08_04A.FM
CLEANING 1
The carburetor exterior surfaces should be cleaned
with a general solvent and dried with compressed
air before disassembly.
CAUTION: Be careful at carburetor cleaning not
to remove paint. Paint removal will cause carbu-
retor to rust very rapidly. Repaint if necessary.
Carburetor body and jets should be cleaned with
a carburetor cleaner. Follow manufacturer’s in-
structions. F01F0XA 2
TYPICAL
 WARNING 1. Pump gauge tester
2. Install on pulse nipple
Solvent with a low flash point such as gaso-
line, naphtha, benzol, etc., should not be used Diaphragm must stand pressure for 10 seconds.
as they are flammable and explosive. If pressure drops, replace diaphragm no. 3.
CAUTION: Heavy duty carburetor cleaner may Fuel Pump Valve

be harmful to the rubber parts, O-rings, etc. Check fuel pump valve operation as follows:
Therefore, it is recommended to remove these
parts prior to cleaning. Connect a clean plastic tubing to the inlet nipple of the
fuel pump body no. 4 and alternately apply pressure
Inspect O-rings, diaphragms and gaskets. and vacuum with the mouth. The inlet valve should
release with pressure and hold under vacuum.
DISASSEMBLY AND INSPECTION
Inspect parts for corrosion damage (shaft, throttle  WARNING
plate, spring, screw, check valve housing, etc.). Some fuel may be present in fuel pump. Be
careful not to swallow fuel when under vacuum.
Needle Valve
Inspect needle valve tip for a grooved condition. If
worn, needle and seat must be replaced as a
matched set.
1
Low Speed Screw
Check tip of low speed screw no. 2 for a grooved
condition. Replace if necessary. 2
Diaphragm
Pump Diaphragm Leak Test
Using a suitable pump gauge tester, perform the F01F0WA 3
following test proceeding as follows:
TYPICAL
– Install pump gauge tester (P/N 295 000 114) on 1. Fuel outlet nipple
pulse nipple. 2. Pulse nipple
3. Inlet nipple
– Pump tester until it reaches 28 kPa (4 PSI).
Repeat the same procedure at the outlet nipple of
the fuel pump body no. 4. This time the outlet
valve should hold with pressure and release under
vacuum.
Inspect valves. The pumping area should be free
of holes, tears or imperfections. Replace as needed.
SMR2002-035_08_04A.FM 08-04-3
Internal Fuel Filter – Obstruct outlet nipple with a finger and hold
while pumping.
To verify condition of filter no. 5, proceed as follows:
– Pump tester until it reaches 28 kPa (4 PSI).
Remove pump cover no. 16, gasket no. 17, dia-
phragm no. 18 and then pump body no. 4 and di- 1 2 3
aphragm no. 19.
Remove filter no. 5 from carburetor body then
clean filter and blow carefully with compressed air
(low pressure).
Replace filter if damaged.
1 F06F07A
1. Pump gauge tester

2. Hose installed to inlet nipple
3. Outlet nipple obstructed
Diaphragm must stand pressure for 10 seconds.

F01F0YA If pressure drops, replace accelerator pump dia-
TYPICAL
phragm.
1. Filter Verify accelerator pump check valves operation as
follows:
Fuel Accelerator Pump
Connect a clean plastic tubing to the valve inlet
Disconnect inlet and outlet hoses from accelerator nipple and alternately apply pressure and vacuum.
pump nipples. The check valve should release with pressure and
hold under vacuum.
 WARNING
Some fuel may be present in fuel pump.
F06F06A 1 2
TYPICAL
1. Fuel inlet hose
2. Fuel outlet hose
Using a suitable pump gauge tester, perform the

following test proceeding as follows:
F06F08A 1
– Install pump gauge tester (P/N 295 000 083) on
inlet nipple of accelerator pump no. 20. TYPICAL
1. Apply pressure and vacuum at inlet nipple
08-04-4 SMR2002-035_08_04A.FM
To check the injector, install pump gauge tester to Needle Valve Lever
the injector hose.
Rounded end of needle valve lever no. 8 must be
NOTE: Injectors are also equipped with check flush with surrounding metering chamber floor
valves. and not with body assembly. Place the end of a
ruler over lever to check adjustment.
1
1 2
F04F0JB 2
TYPICAL
1. Install pump gauge tester to injector hose
2. Injector
Pump tester. Injector check valve should open at

F01F0ZA
19.4 kPa ± 4.7 (2.8 ± .6 PSI).
1. Metering chamber floor
NOTE: If the obtained pressure is too low, the 2. Lever end
check valve is leaking. If it is too high, less fuel will 3. Flush
be delivered which may lead to engine hesitation
To adjust, bend lever very slightly to change its height.
under acceleration.
CAUTION: When adjusting lever, do not pry it so
ASSEMBLY that it applies pressure on needle. This could dam-
age valve seat/needle.
When assembling pump, ensure to properly posi-
tion components together. Refer to previous illus- 1 2
trations if necessary.
Choke Plate and Throttle Plate

When installing plate no. 6 onto shaft no. 7, close
plate so that it centers into carburetor bore. Firmly
tighten screws.
F01F0HA
CAUTION: Always apply Loctite 243 (blue) on
screw threads prior to installing screws. HIGH LEVER
Step 1 : Depress here
Step 2 : Push tab down
SMR2002-035_08_04A.FM 08-04-5
CAUTION: Do not stretch or cut spring.

1 2
LEAK TEST
Needle valve must stand a pressure of 69 kPa
(10 PSI) for 30 seconds. Otherwise, hold carbure-
tor upside down, pour oil over needle valve and
apply pressure.
Check for bubbles. If they come from seat or
F01F34A O-ring, bubbles will exit around seat. Retighten as
LOW LEVER necessary.
Step 1 : Depress here If it still leaks remove needle and seat and replace
Step 2 : Pry up here O-ring.
If bubbles come from needle, replace needle and
POP-OFF Pressure Test seat.
Proceed as follows:
– Install pump gauge tester on carburetor fuel in- Main Jet and Pilot Jet
let nipple. Pilot jet no. 10 and main jet no. 9 are replaceable.
– Obstruct fuel return nipple with a finger. Different jet sizes are available to suit temperature
and altitude conditions. Always inspect spark plug
– Pump tester until inlet release pressure is tip condition when dealing with pilot jet and main
reached (seen by a sudden pressure drop). jet. Spark plug tip condition gives a good indication
of carburetor mixture setting.
3 1
CAUTION: Adjustments vary with temperature
and altitude. Always observe spark plug condi-
tion for proper jetting.
NOTE: To have access to pilot jet no. 10 or main
jet no. 9, check valve housing must be removed.
2
1
F01F10A 2
TYPICAL
1. Pump gauge tester
2. Install on inlet nipple
3. Obstruct outlet nipple
Refer to the following table for pop-off pressure 3

specifications:
POP OFF PRESSURE

MODELS
min./max. (PSI)
GTI , GTI LE 36/40
XP, GTX 19/23

4
NOTE: Pressure test should be performed three
times to obtain a valid reading.
If pop-off pressure is not within specification, F01F11A
check control lever adjustment. Replace spring as TYPICAL

necessary. 1. Pilot jet
2. Gasket
3. Main jet
4. Check valve housing removed
08-04-6 SMR2002-035_08_04A.FM
Check Valve Assembly INSTALLATION

The check valve is needed if a back pressure oc-
curs into carburetor. It will prevent fuel from flow- Carburetors
ing back into carburetor lower portion. At installation, pay attention to the following:
Inspect check valve no. 11. It should be free of Install carburetor(s) with gasket(s) to intake mani-
holes, tears or imperfections. Replace as needed. fold (rotary valve cover for the 787 RFI engine).
Apply synthetic grease on screws no. 20. Then,
1 install screws no. 20 with lock washers no. 21
and torque to 20 N•m (15 lbf•ft).
Fuel Lines and Hose Clamps

If fuel line ends are damaged, cut damaged end
before reinstallation.
F01F12A Properly install clamps.
1. Check valve
 WARNING
NOTE: Prior to check valve assembly installation, Make sure there is no leak in fuel system.
remember to set gasket.
For fuel system pressurization, refer to FUEL CIR-
Diaphragm and Cover CUIT.
Install diaphragm no. 3 with its integrated O-ring
into carburetor groove. Make sure that the tab of ADJUSTMENTS
cover no. 12 is inserted into carburetor notch.
GTI/LE California
O-Ring Carburetor Adjustment
When installing O-rings no. 13 of low speed and There is no mixture adjustment to be performed
high speed screws, apply some BOMBARDIER by the dealer.
LUBE (P/N 293 600 016) to prevent sticking.
IMPORTANT: Trying to bypass the anti-tamper
Fuel Accelerator Pump screws could damage the carburetor. It could also
change the engine emission level and lead the en-
Lubricate pump plunger, roller and cam with syn- gine not to meet the California emission control reg-
thetic grease (P/N 293 550 010) and roller shaft ulations.
with BOMBARDIER LUBE (P/N 293 600 016).
Twin Carburetor Synchronization
NOTE: Trying to bypass the anti-tamper screws
could damage the carburetor. It could also change
the engine emission level and lead the engine not to
meet the California emission control regulations.
With idle speed screw not touching throttle lever
stopper on MAG carburetor, both throttle plates
are in closed position.
F06F06B 2 1
TYPICAL
1. Apply synthetic grease to plunger
2. Apply BOMBARDIER LUBE on roller shaft
SMR2002-035_08_04A.FM 08-04-7
F01F31A 1 2 F01F32A 1 2
TYPICAL TYPICAL
1. Stopper 1. Throttle lever PTO side
2. Idle speed screw 2. Marks
Loosen jam nuts on carburetor linkage and adjust CAUTION: Throttle plates must open simulta-
linkage with adjustment nut. neously, otherwise this will cause engine to vi-
Make sure threads length is the same on each brate and/or misfire.
side of linkage and flat surfaces of both ends are
parallel with each other. Throttle Cable Adjustment
NOTE: Do not activate throttle lever unnecessari-
1 ly. Carburetors are equipped with fuel accelerator
pump. This pump is injecting fuel into carburetors
each time throttle lever is depressed.
717 Engine
Lubricate cable with BOMBARDIER LUBE lubricant.
2 Throttle lever must reach handlebar grip without
causing strain to cable or carburetor cable bracket.
F01F1YA 3
1. Jam nuts
2. Adjustment nut
3. Flat surfaces
Tighten jam nuts and torque to 3 N•m (27 lbf•in).

NOTE: Grease carburetor linkage at both ends
with synthetic grease (P/N 293 550 010).
1
Connect linkage between both carburetor levers. F01K08A
Ensure both throttle plates are still in closed posi-
tion. 1. Must touch handlebar grip
NOTE: The linkage installation is done with the Ensure carburetor throttle plate(s) is (are) fully open
marks located near PTO carburetor throttle lever at full throttle position. At this position, throttle le-
to ease adjustment if to be performed in the wa- ver stopper is almost in contact (0.5 mm (1/64 in))
tercraft. with carburetor body.
NOTE: Apply a light pressure on the throttle plate(s),
a slight play should be obtained.
strain on cable and/or damage cable bracket or
throttle lever at handlebar.
To adjust, loosen jam nut then turn adjustment nut
as necessary.
08-04-8 SMR2002-035_08_04A.FM
F01G0YC 3 1 2
717 ENGINE
1. Adjustment nut
2. Jam nut
3. Throttle lever stopper
Tighten jam nut and recheck adjustment.
 WARNING
Make sure idle speed screw contacts stopper
when throttle lever is fully released at handle-
bar. F08F0CA 2 1 4 3
THROTTLE CABLE ASSEMBLY
After throttle cable adjustment, always proceed
1. Sensor
with the oil injection pump cable adjustment. Re- 2. Throttle lever section
fer to OIL INJECTION PUMP. 3. Carburetor section
4. Oil pump section
CAUTION: Improper oil injection pump synchro-
nization with carburetor can cause serious en- NOTE: Always perform the throttle cable adjust-
gine damage. ment in the specified order, as described in follow-
ing procedure.
947 Engine Unscrew idle adjustment screw to obtain a small
Throttle cable is equipped with a sensor which will gap between stopper and screw.
send a signal to the MPEM at 80% throttle open-
ing in order to control the spark advance.
F06F0KA 1
1. Idle speed screw
SMR2002-035_08_04A.FM 08-04-9
Ensure throttle plates are completely closed on

both carburetors.
Loosen jam nut and turn adjustment nut to elimi-
nate all the slack in the throttle cable between sen-
sor and carburetor.
Tighten jam nut.
F02F21A 1 2 3
1. Jam nut
2. adjustment nut
3. Throttle cable
Throttle lever must reach handlebar grip without

causing strain to cable or carburetor cable bracket.
F02F20A 1 2 3
947 ENGINE
1. Throttle cable
2. Adjustment nut
3. Jam nut
1
Turn idle adjustment screw clockwise until it comes F01K08A
in contact with stopper. Refer to IDLE SPEED 1. Lever must touch handlebar grip
SCREW ADJUSTMENT section for the proper ad-
justment. CAUTION: Improper cable adjustment will cause
Adjust oil pump cable. Refer to OIL INJECTION strain on cable and/or damage cable bracket or
PUMP. throttle lever at handlebar.
NOTE: It is important to adjust oil pump cable prior All models except GTI LE California
to finalize adjustment of throttle cable.
CAUTION: Improper oil injection pump syn- Low Speed Screw Adjustment
chronization with carburetor throttle opening
can cause serious engine damage.
Adjust throttle cable to obtain proper lever position
at full throttle.
1
Turn adjuster knob as required to obtain proper
throttle lever adjustment.
F06F0GA
717 ENGINE
1. Low speed screw
08-04-10 SMR2002-035_08_04A.FM
CAUTION: Do not attempt to adjust high speed

1 screw by removing plastic cap.
F06F0HA
947 ENGINE
1. Low speed screw (PTO side shown)
CAUTION: Do not attempt to set engine idle speed F06F0IA 1

with low-speed screw. 717 ENGINE
Tighten low speed screw until a slight resistance 1. High speed screw
is felt. Then, back it off to the specification as per
following chart.
ENGINE TYPE LOW SPEED SCREW
717 1.0 ± 0.25 turns
947 1.5 ± 0.25 turns
NOTE: Turning screw clockwise leans mixture and

turning screw counterclockwise enriches mixture.
Start and warm up engine.
Check that engine idles and runs smoothly. Make F06F0PB
1
sure engine reacts quickly to throttle lever de-
pression. If necessary, readjust low speed screw 947 ENGINE
1. High speed screw (PTO side shown)
(± 1/4 turn).
NOTE: On twin carburetor engines, both low speed Idle Speed Screw
screws must be adjusted exactly the same way.
Turning screw no. 15 clockwise increases engine
Never adjust screws more than 1/4 turn at a time.
idle speed and turning screw counterclockwise de-
creases engine idle speed.
All models except GTI LE California
High Speed Screw
The high speed screw no. 14 is sealed with a plas-
tic cap that allows an adjustment of 1/4 turn.
NOTE: Turning screw 1/4 turn counterclockwise en-
riches mixture and turning screw clockwise leans
mixture.
SMR2002-035_08_04A.FM 08-04-11
1 Fuel Accelerator Pump

All Engines
Ensure throttle cable is properly adjusted and idle
speed is set at 1500 RPM for the 717 engines and
1400 RPM for the 947 engines in water.
With the engine not running, loosen adjustment
screw lock nut. Use a feeler gauge between lever
tab and pump plunger. Turn adjustment screw to
achieve approximately 0.05 - 0.15 mm (.002 - .005 in)
gap. Tighten adjustment screw lock nut.
F01G0YD
717 ENGINE
1. Idle speed screw
F02F1QA
2
TYPICAL
1. Adjustment screw
2. Small gap
F06F0KA 1 NOTE: Turning the adjustment screw clockwise will

increase the gap.
947 ENGINE
1. Idle speed screw
Choke Camble
NOTE: On twin carburetor engines, there is only Ensure choke lever has a free-play of 0.5 to 2.0 mm
one idle speed screw. (1/64 to 5/64 in).
Connect an induction-type tachometer (P/N 529
014 500) on spark plug cable of magneto side to 1
measure engine speed.
NOTE: To adjust idle speed, ensure flame arrester
and air intake silencer are installed.
Start engine and bring to normal operating temper-
ature.
CAUTION: If watercraft is out of water, engine F07F02A A
TYPICAL
Turn screw so that engine idles at 1500 RPM in 1. Choke lever
water or 3000 RPM out of water. A. Free play of 0.5 to 2.0 mm (1/64 to 5/64 in)
To adjust, loosen jam nut on carburetor bracket,

then turn adjustment nut as necessary.
Tighten jam nut and recheck adjustment.
08-04-12 SMR2002-035_08_04A.FM
Section 09 LUBRICATION SYSTEM
TABLE OF CONTENTS 0
OIL INJECTION SYSTEM ...................................................................................................... 09-02-1
GENERAL ........................................................................................................................... 09-02-6
OIL SYSTEM PRESSURIZATION ...................................................................................... 09-02-6
OIL INJECTION PUMP .......................................................................................................... 09-03-1

OIL PUMP IDENTIFICATION ............................................................................................. 09-03-5
REMOVAL........................................................................................................................... 09-03-5
DISASSEMBLY .................................................................................................................. 09-03-5
CLEANING ......................................................................................................................... 09-03-5
ASSEMBLY ........................................................................................................................ 09-03-6
ADJUSTMENT ................................................................................................................... 09-03-7
CHECKING OPERATION.................................................................................................... 09-03-10
SMR2002-052_09_01ATOC.FM 09-01-1
Subsection 02 (OIL INJECTION SYSTEM)
OIL INJECTION SYSTEM 0

27 Nm
(20 lbfft)
3.5 Nm
(31 lbfin) 1
Dielectric
Grease
1
4
3.5 Nm
(31 lbfin)
1.2 Nm
(11 lbfin) 3
F17G02S
SMR2002-036_09_02A.FM 09-02-1
XP Models
Steering harness
Oil pump
F08G03S
09-02-2 SMR2002-036_09_02A.FM
GTX Models
27 Nm
(20 lbfft)
3.5 Nm 1
(31 lbfin)
Dielectric 2
grease
1 3.5 Nm
(31 lbfin)
F07G0CS
SMR2002-036_09_02A.FM 09-02-3
GTX RFI Models
27 Nm
(20 lbfft)
1 3.5 Nm
(31 lbfin)
FR
ON
T 2
1.2 Nm 1 3.5 Nm

(11 lbfin) 4 (31 lbfin)
1.2 Nm
(11 lbfin)
3
F15G01S
09-02-4 SMR2002-036_09_02A.FM
DI Models
Under Air
Compressor
27 Nm
(20 lbfft)
3.5 Nm 1
(31 lbfin)
3
2
3.5 Nm 1
(31 lbfin)
Dielectric
grease
4
F12G07S
SMR2002-036_09_02A.FM 09-02-5
GENERAL Carburetor-Equipped Models

– Connect pump gauge tester (P/N 529 021 800)
Whenever repairing the oil injection system, al-
to check valve of oil injection reservoir vent.
ways verify for water infiltration in reservoir.
Perform also a pressure test of the oil injection DI Models
system. Connect pump gauge tester (P/N 529 021 800) to
disconnected tube at throttle body.
All Models except the XP
All Models
Clamp and Hose NOTE: Use the same pump included in the EN-
Verify oil filler neck hose no. 2 for damage. Always GINE LEAK TESTER KIT (P/N 295 500 352).
ensure that clamps no. 1 are well positioned and
tightened. Torque clamps to 3.5 N•m (31 lbf•in). 1
All Models
Check Valve
Black side of the one-way check valve no. 3 is the
valve outlet. It allows air to get in reservoir.
Oil Filter
Oil filter no. 4 should be replaced annually.
F01G0IA
OIL SYSTEM PRESSURIZATION TYPICAL

1. Connect pump to check valve
 WARNING – Pressurize oil system to 21 kPa (3 PSI).
Whenever oil system components are dis-
connected or replaced, a pressure test must All Models
be done before starting engine. Ensure to ver- – If pressure is not maintained, locate leak and
ify oil line ends for damage. Always cut dam- repair/replace component leaking. To ease leak
aged end before reinstallation. search spray a solution of soapy water on compo-
nents, bubbles will indicate leak location.
Pressure Test DI Models
Proceed as follows:
Verify check valve inside filler neck if pressure
– Fill up oil reservoir. does not hold. Also ensure air can enter through
– Install a hose pincher to rotary valve shaft oil check valve in the opposite direction.
supply hose (except 947 engines).
All Models
– Install a hose pincher to rotary valve shaft oil
return hose (except 947 engines).
21 kPa (3 PSI) for at least 10 minutes. Never pres-
– Install a hose pincher to oil injection pump sup- surize over 21 kPa (3 PSI).
ply hose.
CAUTION: If any leak is found, do not start the
DI Models engine and wipe off any oil leakage.
Install a hose pincher to return line of air compres- – Disconnect pump gauge tester and remove
sor. hose pinchers. On DI models, reconnect line at
throttle body.
Disconnect oil tank vent line on PTO side throttle
body.
09-02-6 SMR2002-036_09_02A.FM
Subsection 03 (OIL INJECTION PUMP)
OIL INJECTION PUMP 0

717 Engine
Synthetic
Grease
6 Nm 4
10 Nm (53 lbfin)
(89 lbfin)
5
6 Nm 3
(53 lbfin) Loctite
6 243
Loctite 2
243
8 Nm
(71 lbfin)
8 Nm
(71 lbfin)
4.5 Nm
(40 lbfin) 5 Nm
Loctite (44 lbfin)
243
F00G03T
SMR2002-037_09_03A.FM 09-03-1
787 RFI Engine
4.5 Nm
(40 lbfin) 1
9
6
3 Nm 6 Nm
4.5 Nm
(40 lbfin)
F07G0DS
09-03-2 SMR2002-037_09_03A.FM
6 Nm
(53 lbfin)
6
Loctite
243
6 Nm 1
(53 lbfin) 6
4.5 Nm 8
(40 lbfin)
Molykote
111
To MPEM
4.5 Nm
(40 lbfin)
F07G0ES To carburetor
SMR2002-037_09_03A.FM 09-03-3
DI Models
6 Nm
(53 lbfft)
6
Loctite
243
6
6 Nm
(53 lbfft)
Loctite
243
1
Oil pump
4.5 Nm 8
(40 lbfft)
Molykote
111
Throttle cable
F12G08S
09-03-4 SMR2002-037_09_03A.FM
OIL PUMP IDENTIFICATION Remove 2 Allen screws no. 6 with flat washers
retaining oil injection pump to intake manifold
Pump Lever no. 2.
Different engines need different pumps. See iden- Remove pump.
tification on lever. 947 Engine
CAUTION: Always mount proper pump on en- Remove tuned pipe head. Refer to EXHAUST SYS-
gine. TEM.
OIL PUMP DI Models
ENGINE TYPE
IDENTIFICATION
The cable end has a slight press fit in the lever.
717 105Q-5 Using a small screwdriver, pry cable end out.
787 RFI 06 787 RFI and 947 Engines
947 09 Disconnect oil injection pump cable no. 7.
Remove 2 Allen screws no. 6 with flat washers
NOTE: The following procedures can be done with- retaining oil injection pump to magneto housing
out removing the engine from hull. cover.
Pull pump.
REMOVAL
Disconnect oil hoses from fittings of oil injection
Oil Injection Pump pump.
717 Engine
Remove air intake silencer (refer to AIR INTAKE).
DISASSEMBLY
Remove carburetor (refer to CARBURETOR). NOTE: Some oil pump parts are not available in
single parts. A gasket set is available for the pump.
Remove rotary valve cover (refer to ROTARY VALVE).
If the pump is found defective, it should be replaced
Remove Allen screws no. 5 retaining intake man- by a new one.
ifold no. 2 to rotary valve cover.
Separate intake manifold from rotary valve cover. CLEANING
To separate oil pump from intake manifold no. 2,
remove oil pump gear no. 3 using gear holder (P/N Discard all seals and O-rings. Clean metal compo-
420 277 905) and unscrew lock nut no. 4. nents in a solvent.
A00C17B
1. Gear holder
SMR2002-037_09_03A.FM 09-03-5
ASSEMBLY 787 and 947 Engines
717 Engine Oil Injection Pump and Shaft

Oil Injection Pump and Intake Manifold Make sure shaft no. 8 is installed in crankshaft
end.
Install oil injection pump no. 1 to intake manifold
Install pump. Secure with flat washers and screws
no. 2. Torque screws no. 6 to 6 N•m (53 lbf•in).
no. 6. Torque to 6 N•m (53 lbf•in).
CAUTION: Whenever oil injection lines are re-
Install oil injection pump cable.
moved, always make the routing as shown.
DI Models
1
F01D4SA 1
TYPICAL
1. Small oil line
Oil Pump Gear F12G02A
Install gear no. 3 to oil injection pump shaft. Torque

lock nut no. 4 to 6 N•m (53 lbf•in).
NOTE: Make sure 1 washer is installed on each
side of gear.
Install intake manifold no. 2 to rotary valve cover
and torque screws no. 5 to 10 N•m (89 lbf•in).
F12G03A
F01D4RC A
TYPICAL
A. 10 N•m (89 lbf•in)
09-03-6 SMR2002-037_09_03A.FM
717 Engine
1
2
F12G04A 2 1 F01D4RE 3
1. Cable end completely inserted TYPICAL
2. Cable end NOT seated on the steps 1. Jam nut
2. Adjustment nut
CAUTION: Ensure cable end is completely en- 3. Aligned marks
tered in its housing. Ensure it is NOT seated on 787 RFI Engine
the steps.
ADJUSTMENT
CAUTION: As oil injection pump adjustment is
dependent on throttle cable position, make
sure to perform throttle cable adjustment first
except if otherwise specified.
Preliminary Synchronization
NOTE: To check synchronization of pump as a rou-
tine maintenance, see Final Synchronization.
Make sure idle speed screw on carburetor is prop-
erly set on Carburetor-Equipped Models.
Refer to CARBURETOR for throttle cable adjust-
ment procedure.
NOTE: On a twin carburetor engine, make sure F07G02B 1
carburetors are properly synchronized. 1. Aligned marks
Turn oil pump cable adjustment nut to align refer-
ence marks on pump.
NOTE: A mirror may be used to facilitate this ver-
ification.
SMR2002-037_09_03A.FM 09-03-7
Loosen jam nut and turn cable adjustment nut to The adjustment is located under the throttle body
obtain proper pump setting. bracket.
The adjustment nut and jam nut for the oil injection 1 2
pump cable are located at the cable support on the
throttle body.
F16F01A
1. Oil pump cable adjustment

2. Throttle cable
F07F0WB 1 2
Adjust the cable to the rich position. Use the long-
1. Oil pump cable
2. Adjustment nut est mark.
947 Engine
NOTE: The adjuster knob and jam nut for the oil 1
injection pump cable are located on the oil pump
cable.
1 2
F07G08A
1. Adjuster knob
2. Jam nut
947 DI Engines
Loosen jam nut and turn cable adjustment nut to F16G03B
obtain pump mark alignment. Refer to following
photos. 1. Mark on pump must be facing longest mark on lever
09-03-8 SMR2002-037_09_03A.FM
All Engines
1
Start and bring engine to normal operating temper-
ature.
must be cooled using the flush kit. If air bubbles
are present in the oil injection system, bleed
system before operating engine.
Adjust idle speed to specification on Carburetor
Equipped Models. Refer to CARBURETOR.
NOTE: On RFI engines, refer to FUEL INJECTION
for idle speed adjustment procedure.
NOTE: On DI engines, there is no idle speed ad-
justment to perform.
Stop engine.
F07G02A
Final Synchronization 787 RFI ENGINE

Eliminate throttle cable free-play by depressing 1. Bleed screw
throttle lever until a slight resistance is felt. In this
position, marks on pump body and lever must 1
align.
If necessary, turn cable adjustment nut to obtain
pump mark alignment. Refer to above illustrations.
Tighten jam nut and recheck alignment marks.
CAUTION: Proper oil injection pump adjustment
is very important. Any delay in the opening of
pump can result in serious engine damage.
Bleeding
CAUTION: Oil injection system must be bled and
adjustment checked before operating engine.
Ensure oil injection reservoir is sufficiently filled.
Install a dry rag below oil injection pump.
Loosen bleed screw to allow oil to flow.
F16G02A
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.
F01D4SC 1
717 ENGINE
1. Bleed screw
SMR2002-037_09_03A.FM 09-03-9
Check small oil lines of pump. They must be full NOTE: The engine should have a rich mixture,
of oil. idling irregularly and emitting smoke at exhaust
outlet.
1
If not, remove pump assembly and check the
pump gear (717 engine) or shaft (787 RFI and 947
engines) for defects, replace as necessary. Test
pump as described below:
NOTE: Through normal use, oil level must not
drop in small tubes. If oil drops, verify check valve
operation. Replace as necessary.
Bench Test
Connect a hose filled with injection oil to main line
fitting. Insert other hose end in an injection oil con-
tainer. Using a counterclockwise (reverse position)
rotating drill rotate pump shaft. Oil must drip from
F07G06A 2 fittings in parts of rotary valve cover while holding
lever in a fully open position.
1. Lines must be full of oil
2. Oil pump
2
If not, proceed as follows.
All Models except DI
Run engine at idle speed while manually holding
pump lever in fully open position. Do not activate
throttle lever. 1
DI Models
– Use the VCK (Vehicle Communication Kit) P/N
529 035 676. Look in the MONITORING section
of the software B.U.D.S.
– Use the “Oil lines bleeding” function that al-
lows to “lock” the engine RPM in idle speed
while the throttle is fully depressed to ease the
bleeding operation.
– Since oil cannot be seen through the small oil 4
lines, press and hold the vehicle throttle to wide
open position for 45 seconds. 3
F01G02A
All Models
TYPICAL
CAUTION: If watercraft is out of water, engine 1. Supply oil line to an oil container
must be cooled using the flush kit. 2. Hold lever in fully open position
3. Counterclockwise (reverse) rotating drill
4. Oil must drip here
CHECKING OPERATION For an accurate test, each port should be checked
separately to ensure equal delivery on both ports.
On Watercraft
To obtain a precise result of the oil pump delivery
NOTE: Oil line supply must be full of oil. See rate, rotate it counterclockwise at 1500 RPM for a
bleeding procedure above. total time of 5 minutes.
Start engine and run at idle while holding the pump NOTE: To ensure accuracy of test, oil lines should
lever in fully open position. Oil must advance into be completely filled before starting test.
small oil lines.
09-03-10 SMR2002-037_09_03A.FM
Compare the results with the chart below. If oil

pump is out of specification, replace it.
OIL PUMP FLOW RATE AT

ENGINE
1500 RPM (5 minutes)
717 9.9 - 12.1 mL (each port)
787 RFI 5.7 - 6.9 mL (each port)
947 8.3 - 10.1 mL (each port)
947 DI 7.5 - 9.1 mL (each port)
SMR2002-037_09_03A.FM 09-03-11
Section 10 ELECTRICAL SYSTEM
TABLE OF CONTENTS 0
IGNITION SYSTEM................................................................................................................ 10-02-1
GENERAL ........................................................................................................................... 10-02-1
MULTI-PURPOSE ELECTRONIC MODULE (MPEM)........................................................ 10-02-3
THROTTLE CABLE ............................................................................................................. 10-02-6
IGNITION TIMING ............................................................................................................. 10-02-7
IGNITION SYSTEM TESTING PROCEDURE .................................................................... 10-02-14
SPARK PLUGS ................................................................................................................... 10-02-18
CHARGING SYSTEM............................................................................................................. 10-03-1

GENERAL ........................................................................................................................... 10-03-1
BATTERY ............................................................................................................................ 10-03-5
STARTING SYSTEM .............................................................................................................. 10-04-1

GENERAL ........................................................................................................................... 10-04-4
STARTING SYSTEM TROUBLESHOOTING ..................................................................... 10-04-5
STARTER REMOVAL.......................................................................................................... 10-04-6
STARTER DISASSEMBLY.................................................................................................. 10-04-6
CLEANING ......................................................................................................................... 10-04-8
PARTS INSPECTION .......................................................................................................... 10-04-9
STARTER ASSEMBLY........................................................................................................ 10-04-9
STARTER INSTALLATION ................................................................................................. 10-04-11
STARTER SPECIFICATION ................................................................................................ 10-04-13
INSTRUMENTS AND ACCESSORIES .................................................................................. 10-05-1

GENERAL ........................................................................................................................... 10-05-1
INSPECTION ...................................................................................................................... 10-05-4
DIGITALLY ENCODED SECURITY SYSTEM ........................................................................ 10-06-1

GENERAL ........................................................................................................................... 10-06-1
SMR2002-052_10_01ATOC.FM 10-01-1
Subsection 02 (IGNITION SYSTEM)
IGNITION SYSTEM 0
GENERAL 717 Engines
The flywheel contains 4 permanent magnets and
NOTE: For DI models, refer to ENGINE MANAGE-
spins around the generating coil. This electric cur-
MENT section.
rent flows to the Multi-Purpose Electronic Module
The ignition system consist of different sub-systems (GTI and GTI LE models).
neto for the ignition system (0 to 40 000 Vac). Part
of the AC current is rectified and regulated for the
charging system.
1
MAGNETO OUTPUT
MODEL WATT
GTI and GTI LE 160 @ 6000 RPM
GTX, RX and XP 180 @ 6000 RPM

2
GTX RFI 270 @ 6000 RPM

Three types of ignition systems are used:
– Digital Capacitor Discharge Ignition (CDI)
F00H0EA
– Direct Current-Digital Capacitor Discharge Igni-
1. Flywheel
tion (DC-CDI) 2. Generating coil
787 RFI Engines
Magneto System
Crankshaft Position Sensor (CPS)
The magneto is the primary source of electrical
energy. It transforms magnetic field into electric The CPS is an inductive speed sensor located on
current (AC). the magneto housing and is working in conjunc-
tion with a 60 teeth ring gear which has 2 teeth
missing on the gear. The inductive sensor regis-
ters the 58-tooth sequence.
SMR2002-038_10_02A.FM 10-02-1
An AC voltage is generated by the sensor and is

sent to the ECU to calculate the crankshaft posi-
tion and the engine speed. 7
1 4 3
6
1 5 1
N N
2 2
A00E4JA S S
1. Coil
2. Magnet
3. Rotor protrusion
4. Magnetic field outside of coil
5. Magnetic field crossing coil
6. Current to MPEM
7. Rotor
F07H0CA
Ignition Coil
1. Crankshaft position sensor (CPS)
Ignition coil induces voltage to a high level in sec-
ondary windings to produce a spark at spark plug.
Trigger Coil GTI and GTI LE Models
947 Engines The ignition coil steps up the voltage input from
The trigger coil is mounted outside the rotor (in- the Multi-Purpose Electronic Module to high volt-
side the magneto housing of the engine) and is not age current for both spark plugs.
adjustable. The ignition coil is located in the rear electrical box.
On GTI and GTI LE models, the electric box is
located under air admission.
GTX, RX and XP Models
MPEM. Each coil will provide high voltage to its
corresponding spark plug.
This ignition system allows spark plugs to spark
independently.
CAUTION: Do not interchange spark plug cables.
F06D0DA 1
1. Trigger coil
Its purpose is to signal the engine position to the

Multi-Purpose Electronic Module. The rotor has 4
protrusions that, when coupled with the trigger
coil, accomplish the signaling.
10-02-2 SMR2002-038_10_02A.FM
Both coils are located inside the electrical box. Dynamic Ignition Advance Curve
1 2 3 947 Carburator-Equipped Models
The throttle cable features a Hall Effect Switch that
flattens the advance curve until it reaches 80%
throttle.
This feature provides smoother midrange perfor-
mance, while maintaining maximum performance
at wide-open throttle. At 80% throttle and above,
the cable switches ON, and the ignition advances
as much as 12 degrees at certain RPM’s.
MULTI-PURPOSE ELECTRONIC
MODULE (MPEM)
The MPEM is directly powered by the battery. It
F06H37A 6 5 4 has a micro-processor inside of its sealed case.
TYPICAL — GTX, RX AND XP MODELS
The MPEM is responsible of the following electri-
1. Ignition coil PTO
2. Ignition coil MAG cal functions:
3. Starter cable
4. Positive battery cable – interpreting information
5. Solenoid
6. Fuse – distributing information
GTX RFI Models – start/stop function
The digital inductive ignition system on the RFI – timer
models allows the spark plugs to spark indepen- – Digitally Encoded Security System
dently on each piston stroke. – ignition timing curve
– engine rev limiter.
Some fuses are directly mounted onto the MPEM.
All the electrical system is controlled by the MPEM.
It has internal micro-processor and is directly pow-
ered by the battery.
will keep the programmed safety lanyard(s) active
and other vehicle information, even when the bat-
tery is removed from the watercraft.
MPEM Functions
Automatic Power Shut-Down
F06H36A 1 The MPEM is equipped with an automatic power
1. Ignition coil shut-down. This feature prevents the battery from
loosing its charge if the safety lanyard cap is left
CAUTION: Do not interchange spark plug ca-
on the switch when the engine is not running.
bles. Reverse spark plug cables will not allow
the RFI to run and will cause backfires. After connecting the safety lanyard cap, the MPEM
will remain in standby mode during the next 10
minutes, waiting for a starting. If start/stop button
is not depressed, then the MPEM will be automat-
ically powered down.
SMR2002-038_10_02A.FM 10-02-3
Antistart Feature Engine RPM Limiter

When connecting a safety lanyard cap on the switch The MPEM will limit the maximum engine speed.
the DESS system inside the MPEM is activated
Engine Stopping
and will emit audible signals:
There are two ways to stop the engine.
– 2 short beeps indicate a right safety lanyard is
being used and gauges are supplied with cur- Press and hold start/stop switch or remove the
rent for 33 seconds. The MPEM will thus allow safety lanyard cap from the switch.
the engines to start. If the engine is stopped by removing the safety lan-
– 1 long beep indicates a wrong safety lanyard is yard, it is possible to restart the engine as explained
being used or that the antistart feature is defec- in the engine starting section.
tive. Current to gauges is cut after the audible If safety lanyard cap is reconnected within 6 sec-
signal is emitted and the engines cannot be onds, the current supply to gauges is cut for a brief
started. moment and comes back on with the audible sig-
A wrong safety lanyard is a safety lanyard which nal of safety lanyard validation.
is defective or not programmed in the MPEM mem- Low-Fuel Level Warning Device
ory.
When the fuel level in the reservoir is low, the fuel
To better understand the antistart feature, refer to level sensor transmits a signal to the MPEM. The
DESS (DIGITALLY ENCODED SECURITY SYSTEM). MPEM sends out signals for the beeper (RFI mod-
If the MPEM responds differently from what is els only) and to the info center gauge.
mentioned above, refer to the troubleshooting When the oil level is low in the reservoir, The
section to find out why. MPEM sends out a signal to the info center gauge
Gauges Current Supply and the pilot lamp on the gauge will turn on.
The purpose of this function is to allow reading of Power Distribution
gauges without the engine running. It will give ac- The MPEM distributes power from battery to all
cess to all the functions of the info center gauge accessories. Accessories are protected by fuses
(if equiped) without starting the engine. integrated in the MPEM. For fuse identification,
Gauges are supplied with current for 33 seconds refer to IGNITION SYSTEM TESTING PROCE-
when connecting the safety lanyard cap on the DURE farther in this section.
switch or when pressing the start/stop switch
Overheat Sensor
without the safety lanyard on the DESS post.
When the engine temperature reaches a threshold
NOTE: On the GTX RFI models, the fuel pump will
value, the MPEM triggers a continuous beep to indi-
be activated for 1 second to build up pressure in
cate overheating.
the fuel injection system, only when connecting
the safety lanyard cap to the switch. Diagnostic Mode
Engine Starting In order to facilitate the use of the watercraft, a
system controls the digitally encoded security sys-
If the MPEM recognizes a valid safety lanyard, it
tem (DESS) and sends, through a buzzer, some
allows engine to start when the start/stop switch
audible signals informing the operator of a specific
is pressed.
situation. The diagnostic mode is divided into 2
If the safety lanyard is left on the DESS post for parts: the basic mode and the advanced mode. The
more than 10 minutes after stopping the engine, the basic mode is automatically activated when connect-
MPEM may send out 1 long beep when pressing ing the safety lanyard cap to the switch. The advance
the start/stop switch. The current supply to gauges mode can only be activated when pressing the
will be stopped as explained in the ANTISTART FEA- start/stop switch. Refer DIGITALLY ENCODED
TURE section. A light pressure on the safety lanyard SECURITY SYSTEM.
is required to allow the MPEM to read and validate
the safety lanyard, the engines can then be started.
If start/stop button is held after engine has started,
the MPEM automatically stops the starter when
the engine speed reaches 1000 RPM.
10-02-4 SMR2002-038_10_02A.FM

On these models, the MPEM is used as a electrical
box.
F06H0SA 1
TYPICAL
1. MPEM
F17H03A
Compared to the magneto system, the DC-CDI
TYPICAL system offers a more powerful and stable ignition
787 RFI Engines at low RPM.
The MPEM is also used with the Rotax Fuel Injec- Electrical Box
tion system.
The high amperage/voltage components are locat-
The RFI models use a Digital Inductive Ignition ed into the electrical box.
system. The Bosch ECU controls the ignition tim-
ing and dwell time. It receives input from the CPS The electrical box can be located either at the front
and signals the ignition coil when to fire. or at the rear of the watercraft.
1
F07H0BA F07H0WA
TYPICAL GTX MODEL

1. Electrical box
947 Engines
The 947 engine has a digital Direct Current-Capacitor
Discharge Ignition (DC-CDI) system within the
MPEM which receives the input from the trigger
coil and signals the ignition coils when to fire.
SMR2002-038_10_02A.FM 10-02-5
1 2 1
F08H0DA
XP MODELS
1. Electric box
F06H38A
THROTTLE CABLE
GTX RFI MODELS
1. Electrical box GTX, XP and RX Models
2. Rectifier/regulator
The throttle cable can be checked for proper oper-
ation with a timing light.
Mark the PTO flywheel, like when the ignition tim-
ing is checked. See IGNITION TIMING further.
Then, put another mark on the flywheel approxi-
mately 13 mm (1/2 in) to the more advanced state.
This will be a reference mark only.
Unplug the throttle cable connector. On the XP
models, it is located near the oil tank. On the GTX
models, remove the glove box to have access to
connector (refer to HULL/BODY section). For the
RX models, it is located on the LH side of fuel tank.
Install a test wire in the BLACK wire connector and
F12H01B 2 1 an other in the WHITE/BROWN wire connector
going to the MPEM.
GTI, GTI LE AND RX MODELS
1. Rear electrical box Start the vehicle and hold RPM at 3500. The first
2. Remove vent tubes timing mark should be lined up, if not adjust the
timing with the MPEM programmer.
Then, short the two test wires together. The tim-
ing should advance at this point; the reference
mark should be closer to the pointer.
Shut the engine off and plug the throttle cable con-
nector.
Check the timing again, if the timing is still in ad-
vanced state, the switch on the cable is stuck to
the ON position, and must be replaced.
10-02-6 SMR2002-038_10_02A.FM
IGNITION TIMING 947 Engines Only

With this DC-CDI system, the ignition timing can
Before checking ignition timing with a stroboscop-
be checked with either the engine hot or cold. Al-
ic timing light (dynamic test), it is mandatory to
so, the ignition timing is to be checked at 3500
scribe a timing mark on the PTO flywheel (static
RPM with the timing light.
test) corresponding to the specific engine.
NOTE: Between 3000 and 4000 RPM, the spark
Also, the timing mark scribed on the PTO flywheel
advance does not change. So when checking igni-
can be used to troubleshoot a broken magneto
tion timing at 3500 RPM, a change in engine speed
woodruff key.
within ± 500 RPM will not affect the timing mark
CAUTION: The relation between the PTO fly- when checked with the timing light.
wheel mark position and crankshaft position may
change as the PTO flywheel might move/tighten/ Static Test
loosen on the crankshaft. As an example on
threaded flywheels, when the engine is accel- All Engines
erated out of water, PTO flywheel may tighten 1. Disconnect MAG side spark plug wire and con-
then loosen when the engine is decelerated. nect wire to grounding device then remove
This will result in a false ignition timing read- spark plug.
ing. Always verify PTO flywheel mark position CAUTION: Never crank engine with spark plugs
before checking ignition timing with an appro- removed unless spark plug cables are connect-
priate timing light. If mark does not align with ed to the grounding device.
tool, repeat static test to ensure flywheel has
not loosen or moved before changing the igni- 2. Remove PTO flywheel guard.
tion timing. 717 Engines
NOTE: Do not use the factory mark found on the 3. Install timing mark pointer tool on engine using
PTO flywheel to check ignition timing or trouble- wing nuts previously removed.
shoot any problems.
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
on 947 engines (or the CPS on RFI models) and
the MPEM (or the ECU on the RFI models). If the
ignition timing is found incorrect, you should first
check for proper crankshaft alignment. This might
be the indication of a twisted crankshaft.
RFI Models F01H5SA 1
The fixed timing mode must be activated before TYPICAL
checking ignition timing. See FIXED TIMING 1. Timing mark pointer tool (P/N 295 000 130)
FUNCTION paragraph.
SMR2002-038_10_02A.FM 10-02-7
787 RFI Engines All Engines

4. Remove middle screw securing the engine to 6. Install and adjust a TDC gauge (P/N 295 000 143)
the rear engine mount. Reinstall screw with tim- in MAG side spark plug hole.
ing mark pointer tool.
1
F01H5TA
F06H05A
TYPICAL
1. Timing mark pointer tool (P/N 295 000 135) 1. TDC gauge on MAG side
947 Engines 7. Rotate PTO flywheel counterclockwise (when

5. Bend a wire like the following illustration. Un- facing it) until piston is at Top Dead Center.
screw the first screw at right of middle screw
securing the engine to the rear engine mount.
Reinstall screw with the special timing mark
80
90
70
pointer tool. 1
0
60
10
50
20
40
30
F00B18A
F01H4LA
TYPICAL
1. Adjust gauge dial at zero
10-02-8 SMR2002-038_10_02A.FM
8. From this point, rotate flywheel clockwise to reach

proper specification according to engine. Refer
to the following chart.
IGNITION TIMING
ENGINE
(BTDC)
717 2.59 mm (.102 in)
787 RFI 1.02 mm (.040 in)
947 2.99 mm (.118 in)
A00B4FA
Scribe a thin mark on PTO flywheel in the middle
of tool slot (717 engine) or aligned with timing
mark pointer tool (787 RFI and 947 engines). 717 Engines
NOTE: To perform this procedure, make sure to
use a stroboscopic timing light rated up to 6000
RPM. Otherwise, an inaccurate reading will be ob-
tained.
The ignition components are affected by temper-
ature variation, therefore, timing must be checked
when engine is cold, after idling for a MAXIMUM
of 20 seconds.
1. Connect an induction-type tachometer (P/N 529
014 500) to spark plug wire.
F01H5SB 1 2
TYPICAL
1. Tool slot
2. Flywheel mark

using the stroboscopic timing light.
timing procedure, therefore, always check the
timing with a stroboscopic timing light.
9. Remove TDC gauge. F00H0GA 1
1. Tachometer pick-up
Dynamic Test 2. Connect timing light pick-up to MAG side spark

To check ignition timing, use Bombardier timing plug wire.
light (P/N 529 031 900).
SMR2002-038_10_02A.FM 10-02-9
1 1
F00H0HA F06H06A
1. Timing light pick-up 1. Tachometer pick-up
3. Start engine and point timing light straight in line 2. Connect timing light pick-up to MAG side spark
with timing tool slot. Bring engine to 6000 RPM. plug wire.
1 1
F00H0IA F00H0HA
1. Timing light straight in line with tool slot 1. Timing light pick-up
CAUTION: If engine is to be run more than a few IMPORTANT: On 787 RFI engines to check the ig-
seconds, engine must be cooled using the flush nition timing, the timing advance curve must be
kit. locked first. This allows to perform ignition timing
4. Check if PTO flywheel mark aligns with timing at any RPM by keeping the timing “frozen” so
tool slot. that it does not vary with engine RPM. See FIXED
TIMING FUNCTION for more information.
NOTE: On this system, timing advance decreases
as engine speed increases. NOTE: Fixed Timing function must be activated
If timing mark aligns with tool slot, timing is prop-
erly set. If mark does not align with tool slot, re- 3. On 947 engines, start engine and rev it to 3500
check PTO flywheel mark before adjusting ignition RPM and point beam of timing light straight in
timing to ensure PTO flywheel has not loosen. line with timing mark pointer. On 787 RFI en-
gines, start engine and point the beam of a tim-
787 RFI and 947 Engines ing light on mark.
1. Connect an induction-type tachometer (P/N 529
014 500) to spark plug wire.
10-02-10 SMR2002-038_10_02A.FM
To adjust, loosen 3 armature plate retaining screws

1 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.
1
F06H07A
1. Timing light straight in line with tool slot
CAUTION: If engine is to be run more than a few A25E0VA 1

seconds, engine must be cooled using the flush
TYPICAL
kit. 1. Retaining screw
NOTE: If mark on PTO flywheel is perfectly align-
ed with timing mark pointer, no adjustment is re- Example 1
quired. If mark does not align with pointer, recheck When PTO flywheel mark is on right side of timing
PTO flywheel mark before adjusting ignition timing tool slot, it indicates advanced timing.
to ensure PTO flywheel has not loosen or moved.
Ignition Timing Adjustment

717 Engines
Remove magneto housing cover and wire support.
For removal of magneto, refer to MAGNETO SYS-
TEM.
Timing is performed by moving armature plate;
clockwise to retard spark occurrence or counter-
clockwise to advance.
F01H5UA 1
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.
A25E0RA 2
TYPICAL
1. To retard
2. To advance
SMR2002-038_10_02A.FM 10-02-11
Fixed Timing Function

1. Connect the communication cable to the MPEM
programmer and the other end to the safety lan-
yard switch on the craft.
2. Press the ON/C button on programmer and
enter your password.
3. Press 3 to choose Vehicle info in programmer.
4. Press 8 to choose Bosch system.
5. Press 1 to choose Diagnosis.
6. Press 4 to choose Adjustment.
7. Press 4 to choose Fixed timing.
F01H5VA 1 8. The programmer display Timing = 12.00 deg.
1. Retarded timing 9. Press any key to continue. Programmer will go
back one level to Adjustment.
In this case, turn armature plate counterclockwise
10. Press Menu to go back one level to Diagnosis.
when facing it.
11. Press Menu to go back one level to Bosch sys-
After adjustment, tighten armature plate retaining
tem.
screws.
12. Programmer now ask Quit Bosch Diagnosis?
CAUTION: Armature plate screws must have Loc-
Choose yes to quit.
tite 243 (blue) applied before tightening. Make
sure armature plate screws are well secured. Press 2 to choose Start Vehicle, the program-
mer will then ask Modify Max RPM, press menu
Reinstall removed parts. Refer to MAGNETO SYS-
then start engine with start/stop button.
TEM.
NOTE: If engine fail to start and as soon engine
Recheck ignition timing (make sure engine is cold).
stops revving (start/stop button has been released),
Repeat armature plate positioning procedure if Fixed Timing function is disabled. To reactivate func-
timing mark position is not adequate. tion, repeat complete procedure.
Timing Verification
To correct the ignition timing, the data of the MPEM
is changed using the MPEM programmer (P/N 529 With engine running, check timing.
035 718) or the VCK (Vehicle Communication Kit) CAUTION: If engine is to be run more than a few
(P/N 529 035 676). seconds, engine must be cooled using the flush
NOTE: For more information on the programmer, kit.
refer to the MPEM programmer guide (P/N 219 If timing is correct stop engine. This will automat-
700 138). ically disable Fixed Timing function.
If further adjustment is required refer to following
MPEM Programmer procedure.
787 RFI Engines
Timing Adjustment
To verify ignition timing on this engine, Fixed Tim-
ing function must be activated first. This function Unlike the other models, the ignition timing correc-
allows to check ignition timing at any RPM be- tion can be made from 4.5° (advanced) to - 2.25° (re-
cause it locks ignition timing at 12 degrees BTDC . tarded).
NOTE: Fixed Timing function must be activated The MPEM programmer will display correction
before starting engine. numbers from 1 to 8. Refer to the next timing cor-
rection chart.
10-02-12 SMR2002-038_10_02A.FM
Access the BOSCH SYSTEM in the MPEM pro- Knowing that, you select with the programmer the
grammer, then select ADJUSTMENT in the sub- higher or lower number to advance or retard the
menu. actual timing correction by referring to the follow-
Choose IGNITION in the ADJUSTMENT menu. ing chart.
The screen will display the actual ignition timing TIMING CORRECTION CHART
correction in degrees and it will also offer to adjust it.
PROGRAMMER
Refer to the following chart to find the number cor- IGNITION TIMING
NUMBER
CORRECTION
responding to the timing correction needed. (MPEM)
Choose the Fixed Timing function, start the en- 2 3°
gine and verify the timing agai. Repeat the above
3 2°
procedure if the timing is still incorrect.
4 1°
TIMING CORRECTION CHART 787 RFI
1 0
PROGRAMMER
IGNITION TIMING 5 - 1°
NUMBER
CORRECTION
(MPEM) 6 - 2°
1 4.50° 7 - 3°
2 3.75° 8 - 4°
3 3°
Examples:
4 2.25°
a. You found the flywheel mark advanced. You
5 .75° must retard the ignition timing.
6 0° – The programmer gives you the number 3. Re-
7 - 0.75° ferring to the chart, number 3 returns a cor-
rection of 2° (advanced) and this is too much
8 - 2.25°
in this case.
Ignition timing is set at 12° BTDC at any RPM, – You estimate the correction should be set to
when the Fixed Timing function is active. 1° (advanced) to align flywheel mark. Back in
the chart, look to find 1° (advanced). This
947 Engines gives number 4. Enter this number with the
Through the MPEM programmer, the ignition tim- programmer.
ing can be advanced up to 3° or retarded up to 4°. – You recheck the timing with the timing light
The MPEM programmer corrects the ignition tim- and if the mark is aligned, ignition timing is
ing in 1° increments. properly set.
CAUTION: If the ignition timing is adjusted too b. You found the flywheel mark advanced. You must
advanced, this will cause serious damage to the retard the ignition timing.
engine. – The programmer gives you the number 3. Re-
The timing mark on the PTO flywheel refers to the ferring to the chart, number 3 returns a cor-
physical component position when the spark must rection of 2° (advanced) and this is too much
occurs. The MPEM must be synchronized with in this case.
the mark. For instance, on a particular engine, the – You estimate the correction should be set to
timing correction may need to be advanced to 2° 1° (advanced) to align flywheel mark. Back in
so that the mark aligns with timing mark pointer the chart, look to find 1° (advanced). This
tool. This is not the real spark advance, just a cor- gives number 4. Enter this number with the
rection for the tolerances of the mechanical com- programmer.
ponents.
SMR2002-038_10_02A.FM 10-02-13
– You recheck the timing with the timing light 10. Press 8 to choose Save + Quit (even if item
and found that the flywheel mark is still too no. 8 is not visible on the display, it is active
advanced. You know now that the correction when you select it).
made previously was not enough and you es- 11. Press Enter to confirm yes you want to save
timate the correction should be set to - 2° (re- modifications to the MPEM.
tarded) to align flywheel mark. Back in the
chart, look to find - 2° (retarded). This gives 12. You must see Operation successful. This con-
number 6. Enter this number with the pro- firms that the new timing data has been stored
grammer. in the MPEM.
– You recheck the timing with the timing light 13. Unplug communication cable from safety lan-
and if the mark is aligned, ignition timing is yard switch on craft.
properly set. 14. Press Off to close the programmer.
c. You found the flywheel mark retarded. You At this point, you can install the watercraft safety
must advance the ignition timing. lanyard and start the engine to check the effect of
– The programmer gives you the number 4. Re- the correction on the ignition timing. If further ad-
ferring to the chart, number 4 returns a correc- justment is required, repeat the procedure.
tion of 1° (advanced) and this is not enough in NOTE: The MPEM features a permanent (non-
this case. volatile) memory and keeps the ignition timing
– You estimate the correction should be set to programmed even when the watercraft battery is
2° (advanced) to align flywheel mark. Back in disconnected.
the chart, look to find 2° (advanced). This
gives number 3. Enter this number with the VCK (Vehicle Communication Kit)
programmer. For the 787 RFI and 947 engines, can be used also
– You recheck the timing with the timing light the VCK (Vehicle Communication Kit) (P/N 295 035
and if the mark is aligned, the ignition timing 676) to adjust the ignition timing. Look the proper
is properly set. Setting section of the software B.U.D.S.
CAUTION: If the ignition timing is adjusted too
Proceed as Follows to Adjust the advanced, this will cause serious damage to the
Ignition Timing with the MPEM engine.
Programmer: Refer to the timing correction charts, used per
947 Engines MPEM Programmer, to find the number corre-
sponding to the timing correction needed.
1. Connect the communication cable to the
MPEM programmer and the other end to the
safety lanyard switch on the craft.
IGNITION SYSTEM TESTING
2. Press the ON/C button on programmer and
PROCEDURE
enter your password. All Engines
3. Press 3 to choose Vehicle info in programmer. When dealing with ignition problems, the follow-
4. Press 4 to choose Engine param. ing items should be verified in this order:
5. Press 2 to choose Timing adjust. 1. Spark occurrence/spark plug condition.
6. The programmer display a number that is 2. Battery condition.
stored in the MPEM. 3. Electrical connections.
7. Press Û to choose yes for modify then press 4. Engine start/stop switch.
Enter. 5. Safety lanyard switch.
8. Now punch in the number that corresponds to 6. Timer.
the degree you want for the ignition timing
then press Enter. 7. Multi-Purpose Electronic Module (MPEM).
9. Press Menu to go back one level. 8. Magneto output (717 engine).
9. Ignition coil output.
10-02-14 SMR2002-038_10_02A.FM
CAUTION: Whenever replacing a component Rev Limiter Verification

in ignition system, check ignition timing.
To check engine rev limiter, connect an induction
NOTE: To perform verification, a good quality mul- tachometer (P/N 529 014 500), start engine and
timeter such as Fluke 73 (P/N 529 022 000) should check its maximum speed.
be used.
RPM LIMITER
MODEL
Engine Start/Stop Switch Verification SETTING
Disconnect the YELLOW/RED wire of the start/stop GTI and GTI LE 7100 ± 50
switch. Using an ohmmeter, connect test probes
to YELLOW/RED wire and to ground. GTX, GTX RFI,
7200 ± 50
RX and XP
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
Safety Lanyard Switch Verification
It is not possible to accurately check the MPEM
If 2 short beeps are not heard when installing the condition without specialized tools. Therefore, re-
safety lanyard, refer to DIGITALLY ENCODED SE- place MPEM with a good known unit to conduct
CURITY SYSTEM. testing.
The following continuity tests can also be per- NOTE: Before replacing the MPEM, make sure all
formed using an ohmmeter: connectors are properly secured and there is no
Disconnect switch wires. water in connectors. Check also the signal and
power contacts in the AMP plug connectors. See
Safety Lanyard Removed
WIRING DIAGRAMS.
Connect test probes to switch BLACK and BLACK/
YELLOW wires. Measure resistance, there should Generating Coil Verification
be no continuity (open circuit).
717 Engines
Connect one test probe to the WHITE/GRAY wire
and the other test probe to the switch terminal. STATIC TEST
Measure resistance, it must be close to 0 ohm. Disconnect magneto wiring harness connector.
Connect one test probe to the BLACK wire and the Install the 4-pin magneto harness adapter (P/N 295
other test probe to the switch ring. Measure resis- 000 131).
tance, it must be close to 0 ohm.
Safety Lanyard on Switch
YELLOW wires. Measure resistance, it must be
close to 0 ohm.
F01B28A
Timer Verification TYPICAL

The timer is integrated into the MPEM. Check resistance with a multimeter. Refer to the
Always confirm first that the fuses are in good following table for values and wire colors.
condition.
ADAPTER
To confirm operation of timer, remove safety lan- PART NAME RESISTANCE
WIRE
yard from switch. After a 5 seconds delay, depress
start/stop button once. The timer should stay on BLACK with
Generating coil 40 - 76 Ω
for about 33 seconds (for example, gauge(s) will RED/BLACK
be activated) and then turn off.
SMR2002-038_10_02A.FM 10-02-15
1 2
F01B28A
3. Connect one of the multimeter probes to the

WHITE wire of the 6-pin magneto harness adapt-
er.
4. Connect the other multimeter probe to the
BLACK/YELLOW wire of the 6-pin magneto har-
ness adapter.
5. Measure resistance; it should be between 190
F01H5WA 4 3 -300 ohms.
1. Multimeter
2. Four-pin magneto harness adapter
3. RED/BLACK wire
4. BLACK wire
DYNAMIC TEST
1. Connect spark plug cables to grounding device.
2. Disconnect magneto wiring harness connector.
3. Install the 4-pin magneto harness adapter (P/N 295
000 131).
4. Connect positive test probe of the multimeter
to the RED/BLACK wire of the 4-pin magneto
harness adapter.
5. Connect negative test probe of the multimeter F01H5YA 4 3 2 1
to BLACK wire of the 4-pin magneto harness
1. Multimeter
adapter. 2. Six-pin magneto harness adapter
3. WHITE wire
6. Set multimeter to Vac scale. 4. BLACK/YELLOW wire
7. Crank engine and note result. The obtained val-
ue should be between 18 and 25 Vac. DYNAMIC TEST
8. If the generating coil is out of specification, re- 1. Disconnect magneto wiring harness connector.
place it. 2. Install the 6-pin magneto harness adapter (P/N
NOTE: If the generating coil tests good, discon- 295 000 136).
nect the primary wires of the ignition coil. Crank 3. Connect one of the multimeter probes to the
engine and check voltage at primary wires. It should WHITE wire of the 6-pin magneto harness adapter.
be at least 20 Vac. If there is insufficient or no volt-
4. Connect the other multimeter probe to the BLACK/
age, either the MPEM or wiring harness is defec-
YELLOW wire of the 6-pin magneto harness
tive.
adapter.
Trigger Coil Verification 5. Crank engine and note result. The obtained val-
ue should be between 0.2 and 0.5 Vac.
947 Engines
6. If the trigger coil is out of specification, replace it.
STATIC TEST: CONTINUITY
1. Disconnect magneto wiring harness connector.
2. Install the 6-pin magneto harness adapter (P/N
295 000 136).
10-02-16 SMR2002-038_10_02A.FM
Ignition Coil Verification NOTE: A short circuit will read 0 ohm (or close to)
on ohmmeter.
STATIC TEST
NOTE: An ignition coil with good resistance mea- 787 RFI Engines
at high voltage level which is not detectable with Primary Winding
an ohmmeter.
2 1
717 Engines
Primary Winding
3 3
F07H0EA 3
IGNITION COIL
1. Primary side
F17H04A 1 2 2. Secondary side
3. Ground wire
1. Primary side
2. Secondary side Disconnect the wire connector on the primary side
3. Ground plate of the ignition coil.
Disconnect the wire connectors on primary side Using a multimeter, check the resistance between
of the ignition coil. the terminals 1 and 2. Repeat a resistance test be-
Using a multimeter, check the resistance between tween terminals 2 and 3.
the primary side connectors of the coil. The resistance should be 0.3 to 0.6 Ω at 20°C.
The resistance should be 0.34 to 0.62 Ω at 20°C. If not within specification, replace the ignition coil.
If not within specification, replace the ignition coil. If the ignition coil test good, check the power sup-
Secondary Winding ply on the primary side.
The spark plug caps must be removed from high Disconnect the ignition coil 3-pin connector. Check
tension cables, because they are resistor caps. to see if there is approximately 6 Vdc between the
The cap resistance is 4.48 K ohms. RED wire and engine ground.
If there is no voltage, either the MPEM or the wir-
1 ing harness is defective.
Secondary Winding
2 Due to the integrated diode, it is not possible to
take any resistance measurement of the second-
ary winding on the GTX RFI models.
A00E0QA
1. Resistor cap
2. High-tension cable

the two high tension leads with the spark plug
caps removed.
The resistance should be 12 ± 3 KΩ at 20°C.
SMR2002-038_10_02A.FM 10-02-17
947 Engines 1. With ignition coil removed from craft, discon-

nect spark plug caps from high tension cables.
Primary Winding
2. Hook high tension leads from tester to ignition
coil high tension cables.
3. Connect 2 smaller tester leads to primary of ig-
nition coil.
F08H0EA
1. Remove the 1 female spade connector from the

primary side of the ignition coil.
2. With the multimeter set on the resistance scale,
connect the meter probes to the primary termi-
nal of the coil and the ground.
3. Resistance should be between 0.33 - 0.62 ohm. 2
Secondary Winding F00H14A
The spark plug caps must be removed from high TYPICAL

tension cables, because they are resistor caps. 1. Leads to secondary
The cap resistance is 4.48 K ohms. 2. Leads to primary
4. Turn power switch to 12 volts and you should

1 observe spark jumping at a predetermined gap
of 7 to 8 mm (.276 to .311 in).
2
If there is no spark, if it is weak or intermittent, the
coil is defective and should be replaced.
SPARK PLUGS
A00E0QA
Disassembly
1. Resistor cap
2. High-tension cable First unscrew the spark plug one turn.
Using a multimeter, check the resistance between Clean the spark plug and cylinder head with pres-
the high tension lead (spark plug cap removed) and surize air then completely unscrew.
the primary side spade connector. Repeat the pro-
cedure for the other spark plug cable. Heat Range
The resistance should be 12 ± 3.6 KΩ at 20°C. The proper heat range of the spark plugs is deter-
mined by the spark plugs ability to dissipate the
NOTE: A short circuit will read 0 ohm (or close to) heat generated by combustion.
on ohmmeter.
The longer the heat path between the electrode
DYNAMIC TEST tip to the plug shell, the hotter the spark plug op-
All Models erating temperature will be — and inversely, the
shorter the heat path, the colder the operating
Use an ignition coil tester, available from after- temperature will be.
market tool/equipment suppliers.
A “cold” type plug has a relatively short insulator
CAUTION: Do NOT use coil tester on metal work nose and transfers heat very rapidly into the cylin-
bench. Follow manufacturer instructions. der head.
10-02-18 SMR2002-038_10_02A.FM
Such a plug is used in heavy duty or continuous Fouling

high speed operation to avoid overheating.
Fouling of the spark plug is indicated by irregular
The “hot” type plug has a longer insulator nose running of the engine, decreased engine speed
and transfers heat more slowly away from its firing due to misfiring, reduced performance, and in-
end. It runs hotter and burns off combustion decreased fuel consumption. This is due to a loss of
posits which might tend to foul the plug during compression. Other possible causes are: prolonged
prolonged idle or low speed operation. 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
1 2 the center electrode and ground.
Spark Plug Analysis
A00E09A
1. Cold
2. Hot
CAUTION: Severe engine damage might occur A00E0AA 1 2 3

if a wrong heat range plug is used.
1. Overheated (light grey)
A too “hot” plug will result in overheating and pre- 2. Normal (brownish)
ignition, etc. 3. Fouled (black)
A too “cold” plug will result in fouling or may create The plug face (and piston dome) reveals the con-
carbon build up which can heat up red-hot and cause dition of the engine, operating condition, method
pre-ignition or detonation. of driving and fuel mixture. For this reason it is
advisable to inspect the spark plug at regular inter-
vals, examining the plug face (i.e. the part of the
plug projecting into the combustion chamber) and
the piston dome.
SMR2002-038_10_02A.FM 10-02-19
Spark Plug Installation

Prior to installation make sure that contact surfac-
es of the cylinder head and spark plug are free of
grime.
cording to the following chart.
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

SPARK TORQUE GAP
ENGINE
PLUG N•m (lbf•ft) mm (inch)
All
models NGK 0.4 - 0.5
24 (17)
except BR8ES (.016 - .020)
DI
NOTE: Refer to next page for NGK SPARK PLUG

SYMBOL EXPLANATION.
10-02-20 SMR2002-038_10_02A.FM
NGK Spark Plug Symbol Explanation
WIDE GAP
PREFIX SUFFIX
10: 1.0 mm (.040")
B R 8 E S 15
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")
Thread Heat rating Reach Firing end

diameter numbers construction
A: 18 mm E: 19 mm
(3/4") A: Special Design
2 Hot
B: 14 mm
F: Taper B: Single Ground
Special Alloy
Seat
C: 10 mm 4
H: 12.7 mm C: Dual Ground
D: 12 mm (1/2")
Special Alloy
E: 8 mm
5
L: 11.2 mm
G: Racing Type
(7/16")
J: 12 mm x 19 mm
Reach GV: Racing Version
of V-Type
6 Z: 21 mm
(53/54")
L: Half Heat Range
Construction 7 S: Standard Center
Electrode
M: Compact Type
Blank
P: Projected 8 V: Fine Wire Center
Electrode
Insulator Type 18 mm ø 12 mm
R: Resistor Type
(31/64") X: Booster Gap
9
U: Surface Discharge
14 mm ø 9.5 mm Y: V-Grooved Center
Electrode
(3/8")
Z: Inductive
Suppressor Type
10 Cold
F02H0MS
CROSSCUTS AND GAP STYLES OF SPARK PLUGS
Standard Projected Taper V-Type Surface

A01E1PS
Type Insulator Type Seat Type Discharge Type
SMR2002-038_10_02A.FM 10-02-21
Subsection 03 (CHARGING SYSTEM)
CHARGING SYSTEM 0
GENERAL Fuse
If the battery is regularly discharged, check fuse
Magneto condition.
The purpose of the charging system is to keep the The rectifier/regulator could be the culprit of a blown
battery at a full state of charge. fuse. To check, simply disconnect the rectifier/
The magneto is the primary source of electrical regulator from the circuit.
energy. It transforms magnetic field into electric If the fuse still burns, check for a defective wire.
current (AC).
CAUTION: Do not use a higher rated fuse as this
717 Engine cause severe damage.
The magneto has a three-pole coil. Capacity is 160 GTX RFI Models
watts.
The charging system is protected by 2 fuses.
947 Engine A 15 A fuse is mounted on the MPEM and a 20 A
The magneto has a 3 phase, “Y” wound stator on fuse is located in the rear electrical box.
18 poles. Capacity is 180 watts.
DI Models
787 RFI and 947 DI Engines The charging system is protected by 2 fuses.
The magneto has a 3 phase, delta wound stator A 25 A fuse is mounted on the MPEM and a 30 A
on 18 poles. Capacity is 270 watts. fuse is located in the rear electrical box.
Rectifier/Regulator All Other Models

Two 15 A fuses protect the charging system. The
All Models
first one is mounted on the MPEM and the other
The rectifier receives AC current from the magne- one is located in the rear electrical box.
to and transforms it into direct current (DC).
The regulator, included in the same unit, limits TESTING PROCEDURE
voltage at a maximum level (14.5 to 14.8 volts) to
prevent any damage to components. NOTE: First, ensure that battery is in good condi-
tion prior to performing the following tests.
717 Engine
A half-wave rectifier receives magneto AC current Rectifier/Regulator
and transforms it into direct current (DC) to allow NOTE: All models with a 947 engine, the rectifier/
battery charging. regulator is integrated in the MPEM.
947 Engine STATIC TEST: CONTINUITY
A dual 1/2 wave series rectifier receives the mag- Due to internal circuitry, there is no static test avail-
neto AC current and transforms it into direct cur- able.
rent (DC) to allow battery charging. DYNAMIC TEST
787 RFI and 947 DI Engines Current Test
The unit is using a 3 phase in series rectifier/regulator
which transforms (AC) from the magneto into (DC) to Carburetor-Equipped Engines and 947 DI
allow battery charging. Engines
Proceed as follows:
Battery – Start engine.
The battery is the DC source for the electric start- – Lay an inductive ammeter on positive cable of
er, the Multi-Purpose Electronic Module and all ac- battery.
cessories.
– Bring engine to approximately 6000 RPM.
SMR2002-039_10_03A.FM 10-03-1
Current reading should be approximately 4 am-

peres for the 717 engine and 5 amperes for the 947
carburetor-equipped and 947 DI engines. If not,
check magneto output prior to concluding that rec-
tifier is faulty.
787 RFI Engines 1
Proceed as follows:
– Open the rear electrical box.
– Remove the 20 A fuse from the holder with the
RED wire coming from the connector attached
to the electrical box.
F15F04A
1. RED/PURPLE wire
– Connect an ammeter across the fuse holder.

1
– Start engine.
– Note the reading. This is the current actually
consumed.
– Reinstall fuse.
– Substract the consumed current from the regu-
lator current. This gives the actual charging cur-
F15F03A
rent. It should be within 3 - 4 A.
1. RED wire
Charging current = Current from regulator - Consumed current
– Connect an ammeter across the fuse holder. If charging current is below specification, check
– Start engine. magneto output. If the magneto output is good,
– Bring engine to approximately 6000 RPM. try another rectifier/regulator. Recheck charging
current. If still out of specification, the fuel pump
– Note the reading. This is the current supplied by or the MPEM current draw is too high.
the regulator.
If charging current exceeds specification, replace
– Reinstall fuse. the rectifier/regulator.
– Remove the 20 A fuse from the holder with the
Voltage Test
RED/PURPLE wire coming from the connector
attached to the electrical box. All Models
Proceed as follows:
– Start engine.
– Connect a multimeter to battery posts. Set mul-
timeter to Vdc scale.
If multimeter reads over 15 volts, regulator is defec-
tive. Replace it.
10-03-2 SMR2002-039_10_03A.FM
NOTE: If it is continually necessary to add distilled ADAPTER RESISTANCE

water to the battery, this indicates an over voltage PART NAME
WIRE COLOR (Ω)
situation, requiring replacement of the rectifier/
regulator. If, on the other hand, the battery will not Battery YELLOW with
0.05 - 0.6
stay charged, the problem can be any of the charg- charging coil BLACK/YELLOW
ing circuit components. If these all check good,
you would be accurate in assuming the problem NOTE: A short circuit will read 0 ohm (or close to)
to be in the rectifier/regulator. on ohmmeter.
GTI and GTI LE Models 1 2 3
If there is no charging at the battery with the pre-
ceding voltage test, the following test can also be
performed.
Disconnect the connector housing of the rectifier/
regulator.
Using an appropriate terminal remover (Snap-on
TT600-4), remove the RED and BLACK wires from
the tab housing of the rectifier/regulator.
Reconnect the connector housing.
Connect the positive probe of a multimeter to the
RED wire and the negative probe to the BLACK wire.
F02H0KA
Set multimeter to Vdc scale.
Start and rev engine to 3500 RPM. The obtained 1. Multimeter
2. Magneto harness adapter
value should be between 12 and 25 Vdc. 3. YELLOW and BLACK/YELLOW wires
NOTE: If the rectifier/regulator is within the specifi- DYNAMIC TEST
cation, either the MPEM or wiring harness between
the rectifier and battery is defective. If the rectifier/ 1. Disconnect the magneto wiring harness connec-
regulator is out of specification and the battery charg- tor.
ing coil (or stator) test good, the rectifier/regulator is 2. Install the 4-pin magneto harness adapter (P/N 295
defective. 000 131) between connectors.
3. Connect test probes of the multimeter to the
Battery Charging Coil YELLOW and BLACK/YELLOW wires of the 4-pin
717 Engine magneto harness adapter.
4. Start and rev engine to 3500 RPM. The obtained
STATIC TEST: CONTINUITY value should be between 25 and 40 Vac.
1. Disconnect the magneto wiring harness connec- 5. If the battery charging coil is out of specifica-
tor. tion, replace it.
000 131) to the magneto wiring harness. Leave
wiring harness side disconnected.
3. Check resistance between the YELLOW and
BLACK/YELLOW wires of the magneto harness
adapter. Refer to the following table.
SMR2002-039_10_03A.FM 10-03-3
Stator 4 3 1
947 Engines
1. Disconnect the magneto wiring harness connec-
tor.
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 2
1. Multimeter
3. Positive (+) probe to YELLOW wire
4. Negative (-) probe to ground
5. Repeat test with the other two YELLOW wires of

the 6-pin magneto harness adapter.
NOTE: There should be no continuity (infinity) be-
tween the stator insulated coils and ground. If
there is a reading, the stator coils and/or the wiring
from the coils is grounded and needs to be re-
placed or repaired.
F01H5ZA 3 2 DYNAMIC TEST
1. Multimeter 1. Disconnect the magneto wiring harness connec-
2. Magneto harness adapter tor.
3. YELLOW wires
4. Place either meter lead into the remaining YEL- 000 136) between connectors.
LOW wire and note the resistance (same as
step no. 3). If the readings are out of specifica- 3. Connect test probes of the multimeter to two
tion, the stator will need to be replaced. of the YELLOW wires of the 6-pin magneto har-
ness adapter.
STATIC TEST: INSULATION
4. Set multimeter to Vac scale.
tor.
value should be between 45 and 70 Vac.
000 136) to the magneto wiring harness. Leave 6. If the stator is out of specification, replace it.
wiring harness side disconnected.
Magneto
3. Insert multimeter positive (+) probe to one of
the YELLOW wire of the 6-pin magneto harness 787 RFI Engines
adapter. STATIC TEST: CONTINUITY
4. Ground the multimeter negative (-) probe to the
engine or the stator iron core and note the read-
tor.
ing.
000 131).
10-03-4 SMR2002-039_10_03A.FM
3. Check resistance between the BLACK/YELLOW BATTERY

and the BLACK wires of the 4-pin magneto har-
ness adapter. The resistance should be between Troubleshooting
0.1 to 1.0 ohm.
4. Place either meter lead into the RED/BLACK wire SYMPTOM: DISCHARGED OR WEAK BATTERY
and note the resistance (same as step no. 3). If the CAUSE REMEDY
readings are out of specification, the stator will
need to be replaced. 1. Battery posts and/or Clean and coat with
cable terminal dielectric grease.
STATIC TEST: INSULATION oxidized.
1. Disconnect the magneto wiring harness connec- 2. Loose or bad Check wiring and
tor. connections. connector cleanliness,
2. Install the 4-pin magneto harness adapter (P/N 295 damaged or short circuit.
000 131) to the magneto wiring harness. Leave
3. Faulty battery Replace.
wiring harness side disconnected. (sulfated, doesn’t
3. Insert multimeter positive (+) probe to the keep a full charge,
BLACK/YELLOW wire of the 4-pin magneto har- damaged casing,
loose post).
ness adapter.
4. Ground the multimeter negative (-) probe to the 4. 15 amp fuse(s) burnt First check fuse.
engine or the stator iron core and note the read- or faulty rectifier. If it is in good condition,
ing. check rectifier/regulator.
5. Repeat test with the other BLACK and RED/ 5. Faulty battery charging Replace.
BLACK wires of the 4-pin magneto harness adapt- coil (or stator).
er.
NOTE: There should be no continuity (infinity) be- Removal
there is a reading, the stator coils and/or the wir-  WARNING
ing from the coils is grounded and needs to be Battery BLACK negative cable must always
replaced or repaired. be disconnected first and connected last.
DYNAMIC TEST Never charge or boost battery while installed
in watercraft.
tor.
2. Install the 4-pin magneto harness adapter (P/N 295 RX Models
000 131) between connectors. Remove LH side bilge vent tube at rear.
3. Connect test probes of the multimeter to the
BLACK/YELLOW and RED/BLACK wires of the
4-pin magneto harness adapter.
4. Set multimeter to Vac scale.
value should be between 45 and 70 Vac.
6. Repeat test with the BLACK wire and either the
RED/BLACK or BLACK/YELLOW wires of the
4-pin magneto harness adapter.
7. If the stator is out of specification, replace it.
F12H01A 1
1. LH side vent tube
SMR2002-039_10_03A.FM 10-03-5
All Models except GTI, GTI LE and GTX RFI CAUTION: Should any electrolyte spillage oc-
Models cur, immediately wash off with a solution of
Proceed as follows: baking soda and water.
1. Disconnect the BLACK negative cable first. Cleaning
2. Disconnect the RED positive cable last. Clean the battery casing, caps, cables and battery
3. Remove the vent line from the battery. posts using a solution of baking soda and water.
4. Remove the holding strap(s). CAUTION: Do not allow cleaning solution to en-
5. Withdraw battery from watercraft being careful ter battery.
not lean it so that electrolyte flows out of vent Remove corrosion from battery cable terminals
elbow. and battery posts using a firm wire brush. Rinse
with clear water and dry well.
GTI, GTI LE, GTX RFI and LRV DI Series
Remove 4 M6 bolts retaining seat support and re- Inspection
move upper section from watercraft.
Visually inspect battery casing for cracks or other
possible damage. If casing is damaged, replace
battery and thoroughly clean battery tray and close
area with water and baking soda.
Inspect battery posts for security of mounting.
Inspect for cracked or damaged battery caps, re-
1 1
place defective caps.
 WARNING
Battery caps do not have vent holes. Make sure
that vent line is not obstructed.
F07L18A Electrolyte Level

1. Remove bolts Check electrolyte level in each cell, add distilled wa-
ter up to upper level line.
Pull lower section with vent tubes toward the front
of the watercraft. CAUTION: Add only distilled water in an activat-
ed battery.
Disconnect battery cables and vent tube from bat-
tery. Battery Testing
Remove battery straps. There are 2 types of battery tests: electrolyte read-
Release battery from support and move it toward ing and load test. An electrolyte reading is made
the front of the watercraft. on a battery without discharging current. It is the
Pull battery from under resonator and remove bat- simplest and commonly used. A loaded test gives
tery from watercraft. more accuracy of the battery condition.
All Models Electrolyte Reading

Check charge condition using either a hydrometer
 WARNING or multimeter.
Electrolyte is poisonous and dangerous. Avoid With a multimeter, voltage readings appear in-
contact with eyes, skin and clothing. Wear a stantly to show the state of charge. Always re-
suitable pair of non-absorbent gloves when re- spect polarity. A fully charge battery will have a
moving the battery by hand. reading of 12.6 Vdc.
10-03-6 SMR2002-039_10_03A.FM
A hydrometer measures the charge of a battery in SPECIFIC GRAVITY READING

terms of specific gravity of the electrolyte. A fully USING A HYDROMETER
charge battery will have a specific gravity between
1.265 to 1.280. ELECTROLYTE
STATE OF TEMPERATURE
Most hydrometers give a true reading at 21°C (70°F).
CHARGE
27°C (80°F) 4°C (40°F)
100% 1.26/1.27 1.27/1.28
1 75% 1.21/1.22 1.22/1.23

50% 1.16/1.17 1.17/1.18
25% 1.12/1.13 1.13/1.14
0% 1.10 or less 1.11 or less
Load Test
A17E0JA
This is the best test of battery condition under a
starting load. Use a load testing device that has an
1. Specific gravity 1.265 adjustable load.
In order to obtain correct readings, adjust the initial Apply a load of 3 times the ampere-hour rating of
reading by adding .004 points to the hydrometer the battery. At 14 seconds into the test, check bat-
readings for each 5.5°C (10°F) above 21°C (70°F) tery voltage; if battery is in good condition, it will
and by subtracting .004 point for every 5.5°C have at least 10.5 Vdc.
(10°F) below 21°C (70°F).
This chart will be useful to find the correct reading. Battery Storage
CAUTION: Battery storage is critical for battery
ELECTROLYTE life. Regularly charging the battery during stor-
TEMPERATURE OPERATION TO age will prevent cell sulfation. Keeping the bat-
PERFORM tery in vehicle for storage may lead to contacts
°C °F degradation/corrosion and case damage if freez-
ing occurs. A discharged battery will freeze and
38 100 .012 Add break in area where freezing point is experi-
32 90 .008 to the enced. Electrolyte leakage will damage sur-
27 80 .004 reading
rounding parts. Always remove battery from ve-
21 70 CORRECT READING
hicle for storage and regularly charge to keep
an optimal condition.
16 60 .004 Disconnect and remove battery from watercraft
Subtract
10 50 .008 as explained in REMOVAL.
from the
4 40 .012
-1 30 .016
reading Check electrolyte level in each cell, add distilled
water up to upper level line.
EXAMPLE NO. 1 EXAMPLE NO. 2 CAUTION: Do not overfill.
TEMPERATURE ABOVE 21°C (70°F): TEMPERATURE ABOVE 21°C (70°F):
The battery must always be stored in fully charged
Hydrometer reading: 1.250 Hydrometer reading: 1.235
Electrolyte temperature: - 1°C (30°F) Electrolyte temperature: 38°C (100°F) condition. If required, charge until specific gravity
Subtract .016 Sp. Gr. Add .012 Sp. Gr. of 1.265 is obtained.
Corrected Sp. Gr. is 1.234 Corrected Sp. Gr. is 1.247
CAUTION: Battery electrolyte temperature must
not exceed 50°C (122°F). The casing should not
feel hot.
SMR2002-039_10_03A.FM 10-03-7
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 2
baking soda and water.
CAUTION: Do not allow cleaning solution to en-
ter battery.
Rinse battery with clear water and dry well using 3
a clean cloth.
1
Store battery in a cool dry place. Such conditions
reduce self-discharging and keep fluid evaporation
to a minimum. Keep battery away from dew, high
moisture and direct sunlight.
A17E0FB
During the storage period, recheck electrolyte level
and specific gravity readings at least every month. 1. Sealing tube removed
2. Battery electrolyte
If necessary, keep the battery at its upper level line 3. Upper level line
and near full charge as possible (trickle charge).
3. Allow the battery to stand for 30 minutes MIN-
Activation of a New Battery IMUM so that electrolyte soak through battery
cells.
 WARNING
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 seal-
ing tube.
CAUTION: Do not remove the sealing tube or 1
loosen battery caps unless activation is desired.
A17E0GA
NOTE: In case of accidental premature removal
1. 30 minutes
of caps or sealing tube, battery should be given a
full charge. 4. Readjust the electrolyte level to the UPPER LEVEL
Perform the following operations anytime a new line.
battery is to be installed.
1. Remove the sealing tube from the vent elbow.
 WARNING 1
Failure to remove the sealing tube could re-
sult in an explosion.
2. Remove caps and fill battery to UPPER LEVEL 2

line with electrolyte (specific gravity: 1.265 at
21°C (70°F)).
NOTE: This battery may fill slower than others
due to the anti-spill check ball design. A17E0RB
2. Upper level line
10-03-8 SMR2002-039_10_03A.FM
5. Connect a 2 A battery charger for 3 to 5 hours. 7. Test battery state of charge. Use a hydrometer.
3
1
2 - + 1
A17E0IA
Step 1 : Connect + lead to battery + post

Step 2 : Connect - lead to battery - post A17E0JA
Step 3 : Plug battery charger

1. Specific gravity 1.265
 WARNING 8. If electrolyte level has dropped after charging,

Gases given off by a battery being charged fill with distilled water to UPPER LEVEL line. Af-
are highly explosive. Always charge in a well ter water is added, continue charging for 1 to 2
ventilated area. Keep battery away from cig- hours to mix water with electrolyte.
arettes or open flames. Always turn battery 9. Reinstall caps and clean any electrolyte spillage
charger off prior to disconnecting cables. Oth- using a solution of baking soda and water.
erwise a spark will occur and battery might ex-
plode. Charging a Used Battery
CAUTION: If charging rate raises higher than
2.4 A reduce it immediately. If cell temperature
 WARNING
Never charge battery while installed in water-
rises higher than 50°C (122°F) or if the casing
craft.
feels hot, discontinue charging temporarily or
reduce the charging rate. For best results, battery should be charged when
6. Disconnect battery charger. the electrolyte and the plates are at room temper-
ature. A battery that is cold may not accept current
for several hours after charging begun.
1 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
2 - + 3 before charging.
 WARNING
Always charge battery in a well ventilated area.
A17E0IB
The time required to charge a battery will vary de-
Step 1 : Unplug battery charger pending on some factors such as:
Step 2 : Disconnect - lead
– Battery temperature: The charging time is in-
Step 3 : Disconnect + lead
creased as the temperature goes down. The
current accepted by a cold battery will remain
low. As the battery warms up, it will accept a
higher rate of charge.
SMR2002-039_10_03A.FM 10-03-9
– State of charge: Because the electrolyte is near- – Since the battery chargers vary in the amount
ly pure water in a completely discharged battery, of voltage and current they provide, the time
it cannot accept current as well as electrolyte. required for the battery to accept measurable
This is the reason the battery will not accept charger current might be up to approximately
current when the charging cycle first begins. As 10 hours or more.
the battery remains on the charger, the current – If the charging current is not up to a measurable
from the charger causes the electrolytic acid amount at the end of about 10 hours, the bat-
content to rise which makes the electrolyte a tery should be replaced.
better conductor and then, the battery will ac-
cept a higher charging rate. – If the charging current is measurable before the
end or at the end of about 10 hours, the battery
– Type of charger: Battery chargers vary in the is good and charging should be completed in
amount of voltage and current that they can the normal manner as specified in ACTIVATION
supply. Therefore, the time required for the bat- OF A NEW BATTERY.
tery to begin accepting measurable current will
also vary. – It is recommended that any battery recharged
by this procedure be load tested prior to return-
Charging a Very Flat or Completely Discharged ing it to service.
Battery
The battery charger should have an adjustable Battery Installation
charging rate. Variable adjustment is preferred,
but a unit which can be adjusted in small incre-  WARNING
ments is acceptable. Always connect battery cables exactly in the
The battery charger must be equipped with an am- specified order, RED positive cable first BLACK
meter capable of accurately measuring current of negative cable last.
less than 1 ampere.
Proceed as follows:
Unless this procedure is properly followed, a good
battery may be needlessly replaced. 1. Install battery in its emplacement.
– Measure the voltage at the battery posts with 2. Secure vent line to the battery and support. En-
an accurate voltmeter. If it is below 10 volts, the sure vent line is not kinked or obstructed.
battery will accept current at very low rate, in
term of milliamperes, because electrolyte is  WARNING
nearly pure water as explained above. It could Vent line must be free and open. Avoid skin con-
be some time before the charging rate increas- tact with electrolyte.
es. Such low current flow may not be detect-
able on some charger ammeters and the bat- 3. First connect RED positive cable.
tery will seem not to accept any charge. 4. Connect BLACK negative cable last.
– Exceptionally for this particular case, set the 5. Apply dielectric grease on battery posts.
charger to a high rate.
6. Verify cable routing and attachment.
NOTE: Some chargers have a polarity protection
feature which prevents charging unless the charg- RX Models
er leads are connected to the correct battery ter- Reinstall bilge vent tube.
minals. A completely discharged battery may not
have enough voltage to activate this circuitry, even GTI, GTI LE, GTX RFI and LRV DI Series
though the leads are connected properly. This will Reinstall seat support.
make it appear that the battery will not accept a
charge. Follow the charger manufacturer’s instruc-
tion on how to bypass or override this circuitry
so that the charger will turn on and charge a low-
voltage battery.
10-03-10 SMR2002-039_10_03A.FM
Subsection 04 (STARTING SYSTEM)
STARTING SYSTEM 0
717 Engine
6
7
8
10
11
2
4
22 Nm 3
(16 lbfft)
Loctite 13
243 5
Dielectric
5 Nm 12 grease
(44 lbfin)
17
22 Nm 14
(16 lbfft)
Loctite
271
Ground 15
cable
22 Nm 16
(16 lbfft)
F00H1PS Loctite 243
SMR2002-040_10_04A.FM 10-04-1
787 RFI Engine
6
7
8
10
11
2
4
3
5 Nm
(44 lbfin)
12 5
22 Nm
(16 lbfft)
13
17
Loctite
Loctite Dielectric 243
243 grease
16 22 Nm
(16 lbfft)
F15H01S
10-04-2 SMR2002-040_10_04A.FM
947 Engine
Dielectric
grease
Loctite 17
243
16 Ground
10 Nm cable
(89 lbfin)
Synthetic
grease
Synthetic
grease
10
18
11
19
2
5
3
F07H0TS
SMR2002-040_10_04A.FM 10-04-3
GENERAL MPEM
Causes of troubles are not necessarily related to If 2 short beeps are not heard when installing the
starter but may be due to a burnt fuse, faulty bat- safety lanyard, refer to DIGITALLY ENCODED SE-
tery, start/stop switch, safety lanyard switch, CURITY SYSTEM or ENGINE MANAGEMENT.
MPEM, solenoid, electrical cables or connections.
Engine Start/Stop Switch and Safety
Check these components before removing start- Lanyard Switch
er. Consult also the starting system troubleshoot-
ing table on next page for a general view of possi- Refer to IGNITION SYSTEM or ENGINE MANAGE-
ble problems. MENT.
 WARNING Solenoid
Short circuiting electric starter is always a dan- NOTE: Solenoid is located in the electrical box.
ger, therefore disconnect the battery ground Inspect connections and clean as necessary.
cable before carrying out any kind of mainte-
nance on starting system. Do not place tools Static Test: Continuity
on battery. With a multimeter, check primary winding resis-
tance. It should be approximately 5 ohms.
Fuse There should be no continuity between the posi-
tive posts of the solenoid.
Make sure 5 A fuse on MPEM is in good condition.
The solenoid may be the cause of a burnt fuse. If Dynamic Test
the solenoid checks good, one of the accessory Depress start/stop button and measure the volt-
may be defective. age on the solenoid positive posts with a multim-
eter.
Battery If there is no voltage and battery is in good condi-
To check battery condition, refer to CHARGING tion, replace the solenoid.
SYSTEM.
Electrical Cables or Connections
Check all connections, cables and wires. Tighten
any loose cables. Replace any chafed wires.
10-04-4 SMR2002-040_10_04A.FM
STARTING SYSTEM TROUBLESHOOTING

SYMPTOM CAUSE REMEDY
STARTER DOES NOT TURN. Burnt 5 A fuse on MPEM. Check wiring condition and replace fuse.
Poor contact of battery terminal(s). Clean and tighten terminal(s).
Poor battery ground cable connection. Clean and tighten.
Weak battery. Recharge or replace battery.
Poor contact of start/stop switch, Check connectors and clean contacts.
safety lanyard switch or solenoid. Check and replace defective parts.
Open circuit: start/stop switch or
Check and replace.
solenoid.
Refer to DIGITALLY ENCODED
Safety lanyard or MPEM. SECURITY SYSTEM or ENGINE
MANAGEMENT.
STARTER ENGAGES; Poor battery cable connections. Clean battery cable connections.
BUT DOES NOT CRANK
Poor contact of brush. Straighten commutator and brush.
THE ENGINE.
Burnt commutator. Turn commutator on a lathe.
Worn commutator segments. Undercut mica.
Shorted armature. Repair or replace armature.
Weak brush spring tension. Replace brush holder or spring.
Weak magnet. Replace yoke assembly.
Worn bushings. Replace clutch.
STARTER TURNS, BUT Worn clutch pinion gear. Replace clutch.
OVERRUNNING CLUTCH
Defective clutch. Replace clutch.
PINION DOES NOT MESH
WITH RING GEAR. Poor movement of clutch on splines. Clean and correct.
Worn clutch bushing. Replace clutch.
Worn ring gear. Replace ring gear.
STARTER MOTOR KEEPS Shorted solenoid winding. Replace solenoid.
RUNNING. Melted solenoid contacts. Replace solenoid.
Sticking or defective starter clutch. Lubricate or replace.
Presence of salt water in the electrical
Verify electrical box watertightness.
box which gives continuity.
SMR2002-040_10_04A.FM 10-04-5
STARTER REMOVAL STARTER DISASSEMBLY

Disconnect BLACK cable ground connection from 717 and 787 RFI Engines
battery. Before disassembling, trace index marks on yoke
no. 1 and clutch housing no. 10 to ease further
 WARNING assembly.
Always disconnect ground cable first and re-
connect last. 1
Disconnect RED cable connection from battery.

Remove the following parts:
– cables from starter
– screw no. 13 of starter rear support
– starter mount screws no. 16.
F01H0PA
947 Engine
TYPICAL
Disconnect starter cables and loosen Allen screws 1. Trace indexing marks
no. 16 retaining starter bracket to engine.
Remove starter support nuts no. 12 then through
3 2 bolts no. 5. Separate end frame no. 3 from yoke
assembly no. 1. Withdraw yoke assembly from ar-
mature no. 11.
Brush holder no. 2 can be removed from end frame
no. 3 by unscrewing nut retaining terminal.
Check that the radial play between the armature
shaft and end frame is not greater than 0.20 mm
(.008 in). Replace end frame if so.
Tap the pinion stop collar no. 7 using a screwdriv-
er. Remove circlip no. 6. Disassemble pinion stop
collar no. 7 and spring no. 8.
1
F06H35B 1 3
1. Positive starter cable
2. Negative starter cable
3. Allen screw
Remove bracket and starter.

NOTE: To remove the starter drive assembly, mag-
neto flywheel has to be removed. Refer to MAG- A03E04A
NETO SYSTEM and BOTTOM END. 1. Pinion stop collar

To check and replace the starter end bearing, refer
Turn clutch assembly no. 9 clockwise to remove
to BOTTOM END section.
it from armature assembly no. 11.
Pull housing from armature.
10-04-6 SMR2002-040_10_04A.FM
947 Engine
Locate index marks on yoke no. 1 and end covers
no. 3 and no. 10.
1
F06H1HA 1
F06H1FA
1. Thrust washers
1. Index marks Remove the other end cover no. 10 and gasket.
Loosen through bolts no. 5. Remove the three washers no. 18 from armature
shaft.
1
1
F06H1IA
F06H1GA 1. Washers
1. Through bolts Remove armature no. 11.

Remove end cover no. 3 and gasket on armature
shaft side.
Remove thrust washers no. 19 from armature shaft.
F06H1JA 1
1. Pull armature shaft
SMR2002-040_10_04A.FM 10-04-7
Release brush wires of yoke from brush holder no. 2. Remove brushes.
Remove brush holder no. 2. To remove bearing and seal in end cover, release
tabs of retainer.
F06H1KA
F06H1MA 1
1. Remove brush holder 1. Retainer
To remove brushes from yoke no. 1, loosen nut

and remove washers.
CLEANING
CAUTION: Yoke ass’y 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.
 WARNING
Always wear safety glasses when using com-
1 pressed air.
Remove dirt, oil or grease from commutator using

a clean cloth soaked in suitable solvent. Dry well
using a clean, dry cloth.
F06H1LA
Clean engine ring gear teeth and drive unit (clutch).
1. Loosen nut and remove washers 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.
10-04-8 SMR2002-040_10_04A.FM
PARTS INSPECTION Brush

Measure brush length. If less than 8.5 mm (.335 in),
Armature replace them.
NOTE: An ohmmeter may be used for the follow- NOTE: New brush length is 12 mm (.472 in).
ing testing procedures, except for the one con-
cerning shorted windings in armature.
Check commutator for roughness, burnt or scored
surface. If necessary, turn commutator on a lathe,
enough to resurface only. 2
1
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.
A03E05A
1. New
1 2. Wear limit, 8.5 mm (.335 in)
Overrunning Clutch
F01H0RA
Pinion of overrunning clutch should turn smoothly
1. Commutator undercut 0.20 mm (.008 in) in clockwise direction, and should not slip in a
counterclockwise direction. If defective, replace.
Check commutator out of round condition with V-
shaped blocks and an indicator. If commutator out Check pinion teeth for wear and damage. If defec-
of round is more than 0.40 mm (.016 in), commu- tive, replace.
tator should be turned on a lathe. NOTE: Always check engine ring gear teeth for
Check commutator outer diameter. If less than wear and damage. If defective replace ring gear.
27 mm (1.063 in), replace. Refer to MAGNETO.
STARTER ASSEMBLY
Reverse the order of disassembly to reassemble
starter. However, attention should be paid to the
following operations.
Prior to assembling, coat sliding surfaces on arma-
ture shaft splines, overrunning clutch and bushing
(717 engine) with G.E. Versilube G 341 M or ESSO
Beacon 325 lubricant or equivalent.
A03E06A 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.
Brush Holder
Slide stop collar no. 7 over circlip no. 6 and secure
Check brush holder for insulation using an ohm- in place by punching it at two or three places.
meter. Place one test probe on insulated brush
holder and the other test probe on brush holder
plate. If continuity is found, brush holder has to be
repaired or replaced.
SMR2002-040_10_04A.FM 10-04-9
2 3
A03E0EA F01H0TA
1. Armature shaft 1. Brush holder locating notch

2. Circlip
3. Pinion stop collar To ease end frame installation, retain brush holder
4. Punch
with a small screwdriver while installing end frame.
Yoke Assembly and Clutch Housing
Align previously traced indexing marks.
F01H0QA
TYPICAL 1
1. Align marks
Open brushes no. 4 and slide over commutator.

Align end frame locating notch with yoke locating F01H0UA
protrusion and properly sit brush holder no. 2 into

yoke no. 1. Step 1 : Retaining brush holder with a screwdriver
Step 2 : Align here
1 Align end frame notch with brush holder notch/
yoke protrusion.
CAUTION: Make sure end frame fits perfectly on
yoke.
F01H0SA
1. Locating protrusion is the higher one
10-04-10 SMR2002-040_10_04A.FM
947 Engine Screw and Teeth Washer

Install new O-rings and gaskets. Apply Loctite 271 (red) to screw.
Insert thrust washers no. 19 onto armature shaft. Connect BLACK negative cable to starter using flat
washer, teeth washer no. 15 and screw no. 14.
Torque screw to 22 N•m (16 lbf•ft). Apply dielectric
grease on terminal and screw.
F06H1HA 1
1. Thrust washers 2
Install the three washers no. 8 onto armature shaft. 3
1 4
When installing end covers no. 3 and no. 10 to 4
F01H1JC
yoke, align index marks.
717 ENGINE SHOWN
Apply Loctite 271 (red) on through bolts no. 5 and
Step 1: Torque nut to 6 N•m (53 lbf•in)
torque to 6 N•m (53 lbf•in). Step 2: Apply Loctite 271 on screw
Step 3: Torque screw to 22 N•m (16 lbf•ft)
STARTER INSTALLATION Step 4: Apply dielectric grease

procedure. However, pay particular attention to  WARNING
the following. Always connect RED positive cable first then
BLACK negative cable last. Whenever con-
Make sure that starter and engine mating surfaces
necting the RED positive cable to the starter
are free of debris. Serious trouble may arise if
motor make sure the battery cables are dis-
starter is not properly aligned.
connected to prevent electric shock.
717 Engine
947 Engine
Screw
Screw
Apply Loctite 243 (blue) on threads and torque start-
er screws no. 13 and no. 16 to 22 N•m (16 lbf•ft). Apply Loctite 243 (blue) to Allen screws no. 16 of
starter bracket and torque to 10 N•m (89 lbf•in).
Nut
Connect the RED positive cable to the starter and
torque nut no. 17 to 6 N•m (53 lbf•in). Apply di-
electric grease on terminal and nut.
SMR2002-040_10_04A.FM 10-04-11
Nut
Connect the RED positive cable to the starter and
torque nut no. 17 to 6 N•m (53 lbf•in). Apply di-
electric grease on terminal and nut.
3 2
F06H35B 1 3
GTX MODEL
1. Torque nut to 6 N•m (53 lbf•in), apply dielectric grease and install
protection cover
2. Negative BLACK cable
3. Apply Loctite 243 to threads and torque screw to 10 N•m
(89 lbf•in)
 WARNING
Always connect RED positive cable first then
BLACK negative cable last. Whenever con-
necting the RED positive cable to the starter
10-04-12 SMR2002-040_10_04A.FM
STARTER SPECIFICATION
Nominal output 0.6 kW
Voltage 12 V
Rated time 30 seconds
Rotation Counterclockwise (viewed from pinion side)
Weight Approx. 2 kg (4.4 lb)
No load 11.5 V 20 A max. 5500 RPM
Performance specification at 20°C (68°F) Load 8.5 V 170 A max. 2200 RPM
Stall 5V 350 A max. 0 RPM
Battery 12 V, 19 Ah
947 Engine
Voltage 12 V
Weight 1.7 kg (3.7 lb)
Performance specification at 20°C (68°F) Load 9V 120 A max. 5350 RPM
Stall 2.25 V 390 A max. 0 RPM
Battery 12 V, 19 Ah
SMR2002-040_10_04A.FM 10-04-13
Subsection 05 (INSTRUMENTS AND ACCESSORIES)
INSTRUMENTS AND ACCESSORIES 0

GENERAL 2 1 5
It is possible to activate the instruments when the
engine is not running.
Make sure the safety lanyard is removed, then de-
press the start/stop button.
The timer of the MPEM will maintain the gauge(s)
activated during a period of approximately 33 sec-
onds.
Information Center
NOTE: With the safety lanyard disconnected, in-
formation center can be activated for approxi-
mately 33 seconds by depressing the engine
start/stop button.
This is a LCD multifunction gauge. Different dis-
plays and functions can be activated using 2 but-
tons — MODE and SET — following specific se-
quences as described below.
F00L2CA 3 4
1. General display
2. Message/units display
3. Warning light
4. Fuel level display
5. VTS position indicator (if so equipped)
General Display
F00L2BA 1 2 The default display is the clock (or clock/compass
1. To change display mode if so equipped) unless another mode has been
2. To set or reset a function selected. See DISPLAY PRIORITIES below.
Resetting a Function Repeatedly pressing the MODE button scrolls the
following displays: Tachometer, speedometer, aver-
To reset a function (such as the chronometer, dis- age speed, trip meter, hourmeter, water tempera-
tance, etc.,) press and hold the SET button for 2 sec- ture, exterior temperature (if so equipped) and chro-
onds while in the appropriate mode. nometer.
The information center includes the following dis-
play areas.
F00L2BB 1
1. Press to change display mode
SMR2002-041_10_05A.FM 10-05-1
When you are satisfied with your choice, stop press- The warning light will blink at the same time.
ing the button.
Clock: Indicates the actual time in hours and min- Warning Light
utes (hh:mm). The red warning LED (Light-Emitting Diode) blinks
Clock/Compass (if so equipped): Displays the along with the message display to catch your at-
cardinal points to indicate the orientation of the tention.
watercraft.
Fuel Level Display
 WARNING Bar gauge continuously indicates the amount of
Use the compass as a guide only. Not to be fuel in the fuel tank while riding. A low-fuel condi-
used for navigation purposes. tion is also indicated when it occurs. See MES-
SAGE DISPLAY above.
Tachometer: Indicates the revolutions per minute
(RPM) of the engine. VTS Position Indicator (if so equipped)
Speedometer: Indicates the speed of watercraft The VTS position indicator shows the riding angle
in kilometers per hour (KPH) or miles per hour of the watercraft.
(MPH).
Average Speed: The information center approxi- 1 2 3
mately calculates and displays the average speed
(AV KPH or AV MPH) of the watercraft since the
last engine start.
Trip Meter: The information center approximately
calculates the distance based on the operation time
and the watercraft speed and displays the result in
kilometers (KM) or miles (MILES).
Hourmeter: Displays the time in hours of the wa-
tercraft usage.
Water Temperature: Displays the water temper-
ature (L TEMP) in degrees Celsius (°C) or Faren-
heit (°F).
Exterior Temperature (if so equipped): Displays
the exterior air temperature (E TEMP) in degrees
Celsius (°C) or Fahrenheit (°F).
Chronometer: Allows to measure an interval of
time in hours and minutes (hh:mm). F00L2DA
1. Position indicator
Message Display 2. Bow up
3. Bow down
The Information Center features a display area
that blinks a message whenever one of the follow- Display Priorities
ing circumstances occurs:
The clock, (clock/compass, if so equipped) is the
• compass error (COMPAS) default display mode. The default display is the
• maintenance (MAINT) one that appears when the information center is
• engine overheating (H-TEMP) first activated or displayed back after an alternate
display was chosen.
• low fuel (FUEL-LO)
The tachometer, speedometer and chronometer,
• low oil (OIL LOW) are the only other modes that may be chosen to
• low voltage (12 V LOW) replace the default display. When one of these is
• fuel injection system sensors and major compo- selected, it will become the default display until it
nents (DI models). is changed again.
Except for low fuel and low oil, which can be cor- When another display mode is chosen, the default
rected by refilling, refer to DIAGNOSTIC PROCE- display will be displayed back after 4 seconds.
DURES section when other messages occur.
10-05-2 SMR2002-041_10_05A.FM
As a self test, all LCD segments and the LED will English/Metric System
turn on for 3 seconds each time the information Allows to display the units in the metric system or
center is activated. in the SAE English system.
In the event of a warning message, the message
will blink and override the units display.
If more than one warning message occurs, the
blinking messages will scroll every 4 seconds.
Other Functions
The following describes how to select other avail-
able functions. F00L2BD 1
Language Option 1. Press TOGETHER and hold for 2 seconds
While in the clock/compass mode: Clock Adjustment
While in the clock/compass mode:
F00L2BC 1
1. Press and hold for 2 seconds F00L2BD 1
1. Press TOGETHER and hold for 2 seconds
F00L2BB 1
1. Repeatedly press F00L2BB 1
1. Repeatedly press to adjust HOURS
F00L2BC 1
1. Press to end F00L2BC 1
1. Repeatedly press to adjust MINUTES
SMR2002-041_10_05A.FM 10-05-3
NOTE: If maintenance message (MAINT) contin-

ues to blink, it indicates a fault with the fuel injec-
tion system on Di models. Refer to DIAGNOSTIC
PROCEDURES section.
INSPECTION
Air Temperature Sensor
F00L2BD 1
1. Press TOGETHER to end
GTX, GTX RFI and LRV DI Models
The temperature sensor is located in the storage
NOTE: If MODE and SET buttons are not pressed cover.
at the end, the default display will come back after
10 seconds and the time entered will remain. Remove the back panel of the storage cover to
access the temperature sensor.
Chronometer
While in the chronometer mode:
F00L2BC 1
1. Press to start or stop chronometer
F07H01A 1
1. Temperature sensor
To check if the temperature sensor is operational,

activate the Info Center and select the exterior
temperature mode.
F00L2BC 1
1. Press and hold for 2 seconds to reset
Use a heat gun to warm up the sensor. The tem-
perature should raise rapidly on the gauge.
Maintenance Information If not, replace the temperature sensor.
When the watercraft is due for a maintenance in-
spection, the message MAINT will blink. Water Temperature Sensor
To clear the warning message while it is blinking:
GTX, GTX RFI, LRV DI Models and RX Series
The water temperature sensor is integrated with
the speed sensor located on the ride plate.
To check if the water temperature sensor is oper-
ational, activate the Info Center and select the lake
temperature mode.
With a garden hose, spray the speed sensor with
F00L2BC 1 water. The temperature reading on the Info Center
1. Press and hold for 2 seconds to reset should adjust to the water temperature.
If not, replace the speed sensor.
10-05-4 SMR2002-041_10_05A.FM
Compass The BLACK wire is the ground.

GTX, GTX RFI and LRV DI Models The GRAY wire is the pulse signal from the multi-
purpose electronic module (MPEM).
The compass is located in the storage cover.
Remove the back panel of the storage cover to ac- Speed Sensor
cess the compass.
All Models except GTI
The speedometer gives a reading through a speed
sensor. Speed sensor is installed on riding plate. It
works with the water flow which turns a magnetic
paddle wheel that triggers an electronic pick-up
that in turn sends a speed signal to the speedom-
eter.
The paddle wheel is protected by the pick-up hous-
ing.
F07H02A 1
1. Compass
Remove the compass from the support.

Activate the Info Center. 1
Change the direction of the compass and keep it
horizontal (± 10°). There should be a change of 2
direction on the Info Center. F01H3VA
NOTE: To check the accuracy of the compass, you 1. Pick-up housing

2. Paddle wheel
can use a portable compass and point it in the
same direction. Compare the given directions, To check if the speed sensor is operational, dis-
they should be the same. connect the speed sensor connector housing
from inside bilge.
Tachometer Using an appropriate terminal remover (Snap-on
XP Models 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
F07H0KA
observed voltage should fluctuate between 5.5
and 8.5 Vdc.
The PURPLE wire is the 12 Vdc power source of the
tachometer.
SMR2002-041_10_05A.FM 10-05-5
Speedometer Adjust potentiometer to the resistance values as

per following chart to test the accuracy of the gauge.
All Models except GTI
NOTE: The gauge must be activated to obtain a
reading.
LOW FUEL
RESISTANCE FUEL LEVEL
LEVEL RED
(Ω) LCD GRAPHIC
LIGHT
0 + 2.2 FULL OFF
17.8 ± 2.2 7/8 OFF
27.8 ± 2.2 3/4 OFF
37.8 ± 2.2 5/8 OFF
47.8 ± 2.2 1/2 OFF
57.8 ± 2.2 3/8 OFF
F07H0LA
67.8 ± 2.2 1/4 OFF
TYPICAL
77.8 ± 2.2 1/8 ON
The PURPLE wire is the 12 Vdc power source of
89.0 ± 2.2 EMPTY ON
the speedometer.
The BLACK wire is the ground.
VTS
The PURPLE/YELLOW wire is the pulse signal
from the speed sensor. RX and RX DI
Disconnect the 2-circuit connector housing of the
Information Center Verification Information Center.
GTX, GTX RFI, LRV DI Models and RX Series Connect potentiometer test probes to the BROWN/
The PURPLE wire is the 12 Vdc power source of WHITE and BROWN/BLACK wires.
the Information Center. Adjust potentiometer to the resistance values as
The BLACK wire is the ground. per following chart to test the accuracy of the gauge.
The RED/PURPLE wire is the 12 Vdc from the bat- NOTE: The gauge must be activated to obtain a
tery. It is protected by a fuse on the MPEM; the reading.
fuse “MPEM” on the carburetor-equipped mod- RESISTANCE VTS LEVEL LCD
els and the fuse “ACC” fuse on DI models. (Ω) GRAPHIC
The accuracy of some features of the Information 167.3 ± 2.2 11/11 (UP)
Center can be checked with a potentiometer.
153.0 ± 2.2 10/11
Fuel Level 138.7 ± 2.2 9/11
Disconnect the 4-circuit connector housing of the 124.4 ± 2.2 8/11
Info Center.
110.1 ± 2.2 7/11
Using an appropriate terminal remover, remove
95.8 ± 2.2 6/11
the PINK wire from the tab housing.
81.5 ± 2.2 5/11
67.2 ± 2.2 4/11
Disconnect the 2-circuit connector housing which
contains a PURPLE and BLACK wires. 52.9 ± 2.2 3/11
Remove the BLACK wire from the receptacle hous- 38.6 ± 2.2 2/11
ing. 24.3 ± 2.2 1/11 (DOWN)
Connect potentiometer test probes to the PINK
and BLACK wires.
10-05-6 SMR2002-041_10_05A.FM
Water Temperature (L temp) (if so equipped) NOTE: The gauge must be activated to obtain a read-
Disconnect the 2-circuit connector housing of the ing.
Info Center which contains a BLACK/ORANGE RESISTANCE DISPLAY
and TAN/ORANGE wires. (Ω) TEMPERATURE (°C)
Connect potentiometer test probes to the BLACK/ 25590.1 5±2
ORANGE and TAN/ORANGE wires.
20005.8 10 ± 2
Adjust potentiometer to the resistance values as
15761.7 15 ± 2
12510.2 20 ± 2
reading. 10000.0 25 ± 2
8047.8 30 ± 2
RESISTANCE DISPLAY
(Ω) TEMPERATURE (°C) 6518.7 35 ± 2
25407.3 5±2
RESISTANCE DISPLAY
19911.1 10 ± 2 (Ω) TEMPERATURE (°F)
15718.0 15 ± 2 22919.8 45 ± 4
12495.0 20 ± 2 17491.7 55 ± 4
10000.0 25 ± 2 13487.5 65 ± 4
8054.9 30 ± 2 10501.5 75 ± 4
6528.3 35 ± 2 8252.0 85 ± 4
6518.7 95 ± 4
RESISTANCE DISPLAY
(Ω) TEMPERATURE (°F)
22799.0 45 ± 4 Fuel/Oil Gauge/Low Oil Warning Light
17262.0 55 ± 4 GTI, GTI LE and XP Models
13470.0 65 ± 4 The fuel gauge has a pointer which indicates fuel
10496.3 75 ± 4 level in the tank.
8264.4 85 ± 4 The low oil warning light is part of the gauge. It will
light when injection oil level is low.
6528.3 95 ± 4
Exterior Temperature (if so equipped)

Info Center which contains a TAN/WHITE and
BLACK/WHITE wires.
Connect potentiometer test probes to the TAN/
WHITE and BLACK/WHITE wires.
per following chart to test the accuracy of the
gauge.
F07H0OA
TYPICAL
SMR2002-041_10_05A.FM 10-05-7
Variable Trim Gauge

XP Models + 45° VTS
The trim gauge shows the riding angle of the wa-
tercraft.
0°
– 45° Bombardier
F01H0EA
If gauge is not within the specifications, replace it.
Fuel Baffle Pick Up Sender

F07H0PA All Models except RFI and DI Models
TYPICAL The baffle pick-up has an integrated fuel sender.
Accuracy of gauge can be checked with a potenti- To verify fuel sender, a resistance test should be
ometer. performed with a multimeter allowing the float to
– Disconnect 2-circuit connector housing of BROWN/ move up through a sequence.
BLACK and BROWN/WHITE wires of gauge.
1
– 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 read-
ing. 2
GAUGE NEEDLE
RESISTANCE (Ω)
POSITION
24.3 - 45°
42.2 3
60.1 F01F20A
78.9
1. Pick up tube
95.8 0° 2. Fuel sender
3. Baffle pick-up
113.7
131.6
149.4
167.3 + 45°
10-05-8 SMR2002-041_10_05A.FM
The resistance measured between PINK/BLACK RFI and DI Models

and PINK wires must be in accordance with fuel The fuel pick up system is part of the fuel pump
level (measured from under the flange) as speci- module mounted inside the fuel reservoir.
fied in the following charts.
The fuel level gauge sender is also mounted on this
FUEL LEVEL AND RESISTANCE module.
(GTI, GTI LE AND GTX)
FUEL LEVEL RESISTANCE
(mm) (Ω)
From 248.9 ± 5 and more 0 + 2.2
From 234.4 to 248.8 ± 5 17.8 ± 2.2
From 200.9 to 234.3 ± 5 27.8 ± 2.2
From 167.4 to 200.8 ± 5 37.8 ± 2.2
From 134.0 to 167.3 ± 5 47.8 ± 2.2
From 100.5 to 133.9 ± 5 57.8 ± 2.2
From 67.0 to 100.4 ± 5 67.8 ± 2.2
From 40.1 to 66.9 ± 5 77.8 ± 2.2
From 0 to 40.0 ± 5 89.8 ± 2.2
FUEL LEVEL AND RESISTANCE

F07F09A
(XP)
FUEL LEVEL RESISTANCE TYPICAL — FUEL LEVEL GAUGE SENDER MOUNTED ON FUEL
PUMP MODULE
(mm) (Ω)
From 325 ± 5 and more 0 + 2.2 Refer to ENGINE MANAGEMENT.
From 294 to 325 ± 5 17.8 ± 2.2
All Models
From 263 to 294 ± 5 27.8 ± 2.2
From 225 to263 ± 5 37.8 ± 2.2
Oil Sensor
From 190 to 225 ± 5 47.8 ± 2.2 The sensor sends the signal to the low-oil level
light in the fuel gauge or the LED in the Info Center.
From 149 to 190 ± 5 57.8 ± 2.2
From 93 to 149 ± 5 67.8 ± 2.2
From 41 to 93 ± 5 77.8 ± 2.2
From 0 to 41 ± 5 89.8 ± 2.2
F00H0LA 1
1. Oil sensor
SMR2002-041_10_05A.FM 10-05-9
The bottom of the sensor has a small reservoir To Reinstall Sensor:

with two small holes underneath to let the oil en- – Remove rubber seal from sensor.
ter inside and one at the top to let the air enter
allowing the oil to flow out. – Install seal in oil tank hole.
When there is enough oil inside the oil tank (and – Push sensor in seal.
therefore in the sensor reservoir), the sensor de- – Plug connector.
tects the liquid and the light DOES NOT turn on. NOTE: This sensor turns the LED to ON if the con-
When the oil level goes at critical LOW level inside nector has been forgotten unconnected even when
the oil tank (and therefore in sensor reservoir), the there is enough oil in tank.
sensor detects the absence of liquid and the light
TURNS ON. VTS Switch (if so equipped)
To check the oil sensor, unplug its connector and Always confirm first that the fuse is in good con-
pull sensor out of oil tank. dition.
Using a multimeter, check the continuity between Disconnect BLACK wire, BLUE/WHITE wire and
the BLUE and BLUE/BLACK terminals. GREEN/WHITE wire of VTS switch.
When sensor is out of oil tank and its reservoir is Using a multimeter, connect test probes to switch
empty, resistance must be infinite (open circuit). BLACK and BLUE/WHITE wires; then, connect test
NOTE: Wait about 15 - 20 seconds before taking probes to switch BLACK and GREEN/WHITE wires.
any reading to give the oil enough time to flow out Measure resistance; in both test it should be high
or inside sensor reservoir. when button is released and must be close to zero
Soak sensor in oil so that its reservoir fills up. Max- when activated.
imum resistance should be approximately 2 Ω
(closed circuit). VTS Motor (if so equipped)
Always confirm first that the fuse is in good con-
TEST CONDITION READING (Ω) dition.
Sensor OUT of oil ∞ (open circuit) The fuse is located on the MPEM module.
Sensor soaked IN oil 2 Ω max. (closed circuit) Motor condition can be checked with a multime-
ter. Install test probes on both BLUE/ORANGE and
GREEN/ORANGE wires. Measure resistance, it
should be close to 1.5 ohm.
1 If motor seems to jam and it has not reached the
end of its stroke, the following test could be per-
formed.
First remove motor, refer to VARIABLE TRIM SYS-
TEM. Then manually rotate worm to verify VTS
system actuating mechanism for free operation.
Connect motor through a 15 A fuse directly to the
battery.
2 Connect wires one way then reverse polarities to
F03H0BA verify motor rotation in both ways.
1. Measure resistance here If VTS actuating mechanism is correct and the mo-
2. Sensor reservoir
tor turns freely in both ways, VTS module could be
defective.
If VTS motor does not stop at the end of its stroke
while installed, the motor could be defective.
10-05-10 SMR2002-041_10_05A.FM
VTS Control Module (if so equipped)

It receives its current from the battery. It is protect-
ed by its own 7.5 A fuse, located on the MPEM
module.
Resistance Test
Disconnect BROWN/BLACK wire and BROWN/
WHITE wire of VTS control module.
Connect test probes of a multimeter to BROWN/
BLACK wire and BROWN/WHITE wire of VTS con-
trol module.
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 (Ω) NOZZLE POSITION
167 ± 1% UP
24 ± 1% DOWN
NOTE: If the VTS control module passes this resis-

tance test, it doesn’t mean it is in perfect condition.
SMR2002-041_10_05A.FM 10-05-11
Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM)
DIGITALLY ENCODED SECURITY

SYSTEM 0
NOTE: For RFI and DI models, refer to ENGINE
MANAGEMENT section.
GENERAL
The Digitally Encoded Security System (DESS)
features an anti-start protection against unautho-
rized use of the watercraft.
switch.
The safety lanyard cap has a magnet and a ROM
chip. The chip has a unique digital code.
The DESS circuitry in the watercraft MPEM is ac-
tivated at the factory. Therefore, a safety lanyard
must be programmed to start the engine.
NOTE: Actually, it is the memory of the MPEM
which is programmed to recognize the digital code
of the safety lanyard cap. This is achieved with the
VCK (P/N 529 035 676) or with the MPEM pro-
grammer (P/N 529 035 718). Refer to Guide to pro-
gram a safety lanyard.
The system is quite flexible. Up to eight safety lan-
yards 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 self-
diagnostic modes.
SMR2002-042_10_06A.FM 10-06-1

It is self-activated when the safety lanyard cap is being installed on the watercraft switch. It gives imme-
diate monitoring. Some codes may occur only when pressing the start/stop button. Refer to the following
chart.
SIGNAL CAUSE REMEDY
2 short beeps • Safety lanyard is • Ignition is authorized, engine can be started

recognized by the MPEM. normally.
(while installing
safety lanyard on • Good contact between
watercraft switch) safety lanyard cap and
DESS post.
• Bad connection between • Remove and replace the safety lanyard on the
safety lanyard cap and switch until 2 short beeps are heard to indicate the
switch. system is ready to allow engine starting.
• Unprogrammed or • Use the safety lanyard that has been programmed

1 long beep defective safety lanyard. for the watercraft. If it does not work, check safety
(while installing lanyard condition with the programmer. Replace
safety lanyard on safety lanyard if reported defective. If it still does not
work, enable advanced diagnostic mode to obtain
watercraft switch or more details about the failure.
when pressing
start/stop button) • Salt water or dirt in safety • Clean safety lanyard cap to remove dirt or salt water.
lanyard cap.
• Improper operation of • Enable advanced diagnostic mode to obtain more

MPEM or defective wiring detail about the failure.
harness.
4 long beeps • Low battery voltage. • Check battery connections and battery condition.
(while installing • Recharge or replace battery.
safety lanyard on
DESS post)

(memory).
Continuous beep • Engine overheating. • Refer to TROUBLESHOOTING CHART.
10-06-2 SMR2002-042_10_06A.FM

1. Remove safety lanyard cap from watercraft switch.
3. Install safety lanyard on watercraft switch.
SIGNAL CAUSE REMEDY
• No safety lanyard has ever been • Use programmer and program a safety
1 long and programmed in watercraft MPEM. lanyard. This code can occur only
when you receive a new MPEM from
1 short beeps the factory and no key has ever been
programmed.
• MPEM can not read the digital code of • Check safety lanyard cap condition
the safety lanyard cap or the magnet is with the MPEM programmer. Replace
defective. safety lanyard if reported defective.
2 short beeps
• Mixed wires at safety lanyard switch • Check switch wiring harness.
• Wrong safety lanyard or bad • Use the safety lanyard that has been
connection of the DESS wires. programmed for the watercraft. If the
2 long beeps problem is not resolved, check safety
programmer. Replace safety lanyard if
reported defective.
• Wiring harness of DESS switch is • Check wiring harness and safety
3 short beeps
grounded or there is a short circuit. lanyard switch.
If you need to listen again the coded beeps, remove safety lanyard and repeat the procedure to activate
SMR2002-042_10_06A.FM 10-06-3
Section 11 PROPULSION SYSTEM
TABLE OF CONTENTS 0
JET PUMP .............................................................................................................................. 11-02-1
GENERAL ........................................................................................................................... 11-02-3
JET PUMP INSPECTION ON WATERCRAFT.................................................................... 11-02-3
REMOVAL........................................................................................................................... 11-02-6
DISASSEMBLY................................................................................................................... 11-02-8
CLEANING ......................................................................................................................... 11-02-11
ASSEMBLY......................................................................................................................... 11-02-13
PUMP PRESSURIZATION ................................................................................................. 11-02-21
INSTALLATION .................................................................................................................. 11-02-21
DRIVE SYSTEM ..................................................................................................................... 11-03-1

GENERAL ........................................................................................................................... 11-03-3
REMOVAL........................................................................................................................... 11-03-3
INSPECTION ...................................................................................................................... 11-03-7
ASSEMBLY......................................................................................................................... 11-03-8
INSTALLATION .................................................................................................................. 11-03-10
LUBRICATION.................................................................................................................... 11-03-12
REVERSE SYSTEM................................................................................................................ 11-04-1

DISASSEMBLY................................................................................................................... 11-04-2
INSPECTION ...................................................................................................................... 11-04-3
ASSEMBLY ........................................................................................................................ 11-04-3
ADJUSTMENT ................................................................................................................... 11-04-4
DISASSEMBLY................................................................................................................... 11-04-8
INSPECTION ...................................................................................................................... 11-04-9
ASSEMBLY......................................................................................................................... 11-04-9
ADJUSTMENT ................................................................................................................... 11-04-9
VARIABLE TRIM SYSTEM .................................................................................................... 11-05-1

GENERAL ........................................................................................................................... 11-05-3
REMOVAL........................................................................................................................... 11-05-3
DISASSEMBLY................................................................................................................... 11-05-4
INSPECTION ...................................................................................................................... 11-05-4
ASSEMBLY......................................................................................................................... 11-05-4
INSTALLATION .................................................................................................................. 11-05-5
ADJUSTMENT ................................................................................................................... 11-05-6
SMR2002-052_11_01ATOC.FM 11-01-1
Subsection 02 (JET PUMP)
JET PUMP 0
GTX RFI Models
3
2
38
1
31
Loctite
518
40 29
41
25 30
31 Nm
(23 lbfft)
Loctite
518
7.5 Nm
(66 lbfin)
Synthetic 26
30 grease Loctite
243 42
32
33 Loctite 36 Loctite
243 35 518 20 Nm
28 (15 lbfft)
34 21
115 Nm 37
(85 lbfft)
3 Nm 23
(27 lbfin) 22
13
Pipe sealant
24
10 7 Nm
(62 lbfin)
9 Loctite 39
243 21 Nm
11 (16 lbfft)
4 42 20
9 Nm
(80 lbfin)
12
11
9 Nm
(80 lbfin)
F15J03S
SMR2002-043_11_02A.FM 11-02-1
All Models except GTX RFI
Loctite
454 1
6 Nm 3
(53 lbfin)
31
40
41
25 31 Nm 2
(23 lbfft) Loctite
518
Loctite
518 38
Synthetic 29
30
36 grease
34 35
Loctite
30 7.5 Nm
32 37 518 (66 lbfin)
33 Loctite
Loctite 243 243 42
21
6 Nm 115 Nm 28 3 Nm
(53 lbfin) (85 lbfft) (27 lbfin) 20 Nm
(15 lbfft)
27 26
24
Pipe
sealant
Loctite
2.5 Nm 15 243
(22 lbfin) 16 42
39
2.5 Nm 6 21 Nm 20
(22 lbfin) (16 lbfft)
19 14 7
2.5 Nm
(22 lbfin) 13
18 2.5 Nm
13 (22 lbfin)
5
20 Nm
(15 lbfft)
4
17
20 Nm 8
(15 lbfft)
F12J01S
11-02-2 SMR2002-043_11_02A.FM
GENERAL WATERCRAFT IMPELLER

MATERIAL PITCH
MODEL P/N
4
Progressive
Stainless
XP 271 000 920 pitch
3 steel
15° - 21°
Progressive
2 Stainless
5 GTI 271 001 297 pitch
steel
9° - 20°
1
Progressive
Stainless
GTI LE 271 001 297 pitch
steel
9° - 20°
6
Progressive
Stainless
F00J0SA
GTX 271 001 128 pitch
steel
15° - 21°
1. Nozzle
2. Venturi Progressive
3. Housing Stainless
4. Wear ring GTX RFI 271 001 024 pitch
steel
5. Impeller 12° - 25°
6. Stator
Progressive
Stainless
Impeller Identification LRV DI 271 000 920 pitch
steel
15° - 21°
To identify the impellers refer to the following il-
lustration and chart. Progressive
Stainless
RX DI 271 000 920 pitch
steel
15° - 21°
Progressive
Stainless
RX 271 000 920 pitch
steel
15° - 21°
1
JET PUMP INSPECTION ON
WATERCRAFT
To work on watercraft, securely install it on a stand.
Thus, if access is needed to water inlet area, it will
be easy to slide underneath watercraft.
A lift kit (P/N 295 100 044) can be used to install
F02J0VA
watercraft on a stand.
1. Stamped part number
SMR2002-043_11_02A.FM 11-02-3
Using a feeler gauge with 30 cm (12 in) blades,

measure clearance between impeller blade tip and
wear ring. Measure each blade at its center. Clear-
ance should not exceed 1.0 mm (.040 in). If clear-
ance is greater, disassemble jet pump and inspect
impeller and wear ring. Renew worn parts.
1
1
F01J42A 2
TYPICAL
1. Lift kit
2. Work stand
Impeller Condition
Condition of impeller no. 1, boot no. 2 and ring
no. 3 can be quickly checked from underneath of
the watercraft. Remove grate and look through
water inlet opening.
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. F01J0FA 1
Clearance can be checked from water inlet open- TYPICAL — MEASURING FROM VENTURI SIDE
ing or from venturi side. However, the last method 1. Feeler gauge
requires more work.
To check clearance from water inlet side, remove
inlet grate.
To check clearance from venturi side, remove ven-
turi/nozzle assembly as described in OIL INSPEC-
TION in this subsection.
11-02-4 SMR2002-043_11_02A.FM
Oil Inspection Oil Replacement

Remove: Remove venturi as described in OIL INSPECTION.
– reverse gate cable Remove 3 screws retaining cover.
– VTS rod (if so equippped)
– steering cable
– screws no. 10 retaining venturi to the housing.
Pull venturi.
Remove plug from cover.
F02J0TB 1
TYPICAL
1. Screws
Using a fiber hammer, gently tap cover to release

it from housing cover.
1 Thoroughly clean reservoir and inside of cover
F01J5IA
with a solvent. Check O-ring condition. Replace as
TYPICAL necessary.
1. Remove plug
Apply a thin layer of Loctite 518 on mating surface
Check oil level, it should be at bottom of hole of cover and reinstall it with its O-ring.
threads. Apply Loctite 243 on threads and torque screws to
If oil level is low, check impeller shaft housing for 7 N•m (62 lbf•in) on the XP and GTX RFI models
leaks. A pressure test must be performed. See and 4 N•m (35 lbf•in) on the other models.
PUMP PRESSURIZATION in this subsection. Remove plug from cover.
To check oil condition, insert a wire through oil lev- Pour oil through hole until oil reaches the bottom
el hole then withdraw. A whitish oil indicates wa- of hole threads. Use SEA-DOO JET PUMP SYN-
ter contamination. THETIC OIL (P/N 293 600 011) only. Oil will drain
This may involve defective impeller shaft seal slowly into center area of housing, wait a few min-
and/or O-ring of housing cover. Jet pump unit should utes and readjust oil level.
be overhauled to replace seal. CAUTION: This is a synthetic oil. Do not mix
If everything is correct, apply Loctite pipe sealant with mineral based oil. Do not mix oil brands.
(P/N 293 800 018) on plug threads and reinstall it Apply Loctite pipe sealant (P/N 293 800 018) on
on cover. Properly reinstall removed parts. plug threads and reinstall it on cover.
NOTE: The plug threads are perpendicular to the NOTE: The plug threads are perpendicular to the
impeller shaft. impeller shaft.
Properly reinstall removed parts.
SMR2002-043_11_02A.FM 11-02-5
REMOVAL
Reverse Gate (if so equipped)
To remove reverse gate no. 4, put shift lever in
reverse position.
Unscrew pivot bolt no. 5 retaining connecting rod
no. 6 and pivot support no. 7.
1
F07J08B 4 3 2 1
1. Bolt
2. Cable end
3. Cable lever
4. Lock nut
Unscrew and remove 2 Allen screws no. 11 retaining

reverse gate to support no. 12 and remove reverse
gate.
Pivot Support
F16J04A 2
Remove reverse gate.
1. Pivot bolt
2. Reverse gate retaining bolt (each side) Unscrew pivot support bolts no. 13.
Remove screws no. 8. 1 4 2
GTX RFI Models
Put shift lever in reverse position.
Disconnect reverse cable from reverse gate. Re-
move lock nut no. 9 and bolt no. 10 retaining cable
end to cable lever.
F16J05B 3
1. Pivot bolts
2. Pivot support
3. Reverse gate
4. Pivot support bolt
Withdraw pivot support.
11-02-6 SMR2002-043_11_02A.FM
Connecting Rod Nozzle

Remove: All Models except GTX RFI and XP
– reverse gate Disconnect steering cable from jet pump nozzle
– pivot bolt no. 14. no. 20.
Withdraw connecting rod. Remove:
– reverse gate
Pivot Triangle
– spring
Remove:
– pivot arm bolts no. 18 retaining pivot arm and
– reverse gate VTS ring (if so equipped) to nozzle.
– connecting rod Remove nozzle.
– pivot triangle bolts no. 15.
GTX RFI Models
Withdraw pivot triangle no. 16.
Disconnect steering cable from jet pump nozzle.
Pivot Arm Remove 2 retaining screws no. 21, 2 sleeves
no. 22, 2 washers no. 23.
Remove:
– reverse gate 3 2
– connecting rod
– reverse cable
– spring no. 17
– pivot arm bolts no. 18. Take note of bushing
size for reinstallation.
Withdraw pivot arm no. 19. 1
F01J3BE 3 2
TYPICAL
1. Screw
2. Washers
3. Sleeve
Remove nozzle.
F16J06A 2 3 1
1. Pivot bolts (each side)
2. Spring
3. Pivot arm
SMR2002-043_11_02A.FM 11-02-7
XP Models
1
Disconnect ball joint of VTS link rod.
Loosen 2 screws each side of trim ring.
F02J0TA 1
1. Remove screws
F01J5FA 1
1. Remove screws Jet Pump Housing
Remove nozzle. Remove:
– nozzle
Venturi – venturi.
Remove: Loosen 4 hexagonal nuts no. 24 and remove flat
– reverse gate (if so equipped) washers and lock washers from jet pump housing.
– nozzle Remove jet pump with a wiggle movement.
– pivot arm (if so equipped). CAUTION: When removing pump unit, a shim
could have been installed between hull and
Remove 4 retaining screws no. 39 and withdraw
pump housing. Be sure to reinstall it otherwise
venturi no. 24.
engine and jet pump alignment will be altered.
It’s possible to remove the venturi without remov-
NOTE: After jet pump removal, if drive shaft re-
ing the reverse gate and the nozzle, see the fol-
mains in the PTO flywheel (except XP), simply pull
lowing instructions.
it out. If drive shaft is seized in the PTO flywheel,
Disconnect: refer to DRIVE SYSTEM.
– steering cable
– VTS link rod (if so equipped) DISASSEMBLY
– reverse cable (if so equipped). NOTE: Whenever removing a part, visually check
Remove 4 retaining screws no. 39 and withdraw for damage such as: corrosion, crack, split, break,
venturi no. 24. porosity, cavitation, deformation, distortion, heat-
ing discoloration, wear pattern, missing plating,
missing or broken needles in needle bearing, wa-
ter damage diagnosed by black-colored spots on
metal parts, etc. Renew any damaged part. As a
quick check, manually feel clearance and end play,
where applicable, to detect excessive wear.
11-02-8 SMR2002-043_11_02A.FM
Cover
With pump assembly in horizontal position, remove
3 retaining screws no. 26.
Place container under cover no. 27 to catch oil.
it from jet pump housing.
Impeller 1
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 1
1. Shaft holder
Insert special tool in impeller splines.
Heat impeller shaft end with a propane torch to 1

approximately 150°C (300°F) to break the Loctite
bond before to remove impeller. Do not heat im-
peller directly.
Install shaft holder in a vice.
F00J08A
1. Impeller remover tool
SMR2002-043_11_02A.FM 11-02-9
Rotate impeller remover tool counterclockwise After cutting ring, insert a screwdriver blade be-
and unscrew completely impeller. tween jet pump housing and ring outside diameter.
CAUTION: Never use any impact wrench to loos- Push ring so that it can collapse internally.
en impeller. Pull ring out.
To remove impeller, apply a rotating movement
and pull at same time. Slide impeller out of hous- Impeller Shaft
ing. Remove tool from impeller. Remove shaft holder tool.
Wear Ring Remove impeller shaft no. 28 with thrust washer
and thrust bearing.
NOTE: On the models with the large pump (947
engines), remove the screws retaining wear ring Seal and Needle Bearing
in the jet pump housing.
Remove seal no. 29 and bearings no. 30 at the
Place jet pump housing in a vise with soft jaws. It same time using bearing/seal remover tool (P/N
is best to clamp housing using a lower ear. 295 000 144).
Cut wear ring at two places.
CAUTION: When cutting ring, be careful not to
damage jet pump housing.
NOTE: Wear ring can be cut using a jigsaw, a small
grinder or a low clearance hacksaw such as Snap-
on HS3 or equivalent.
F01J11A
Insert bearing remover then press tool using a ar-

bor press until seal and bearings are out. However,
care should be taken not to damage bearing jour-
nals.
F01J0VA
1
TYPICAL
F00J0MA
1. Bearing/seal remover tool
NOTE: It is always recommended to renew both

bearings, even if only one bearing needs to be re-
F01J0WA
placed.
TYPICAL
1. Snap-on HS3
11-02-10 SMR2002-043_11_02A.FM
CLEANING PARTS INSPECTION

All Models Impeller
Thoroughly clean jet pump housing by applying Loc-
Visually inspect impeller splines. Check for wear or
tite Stripper (P/N 293 110 004). Allow it some time
deformation. Renew parts if damaged.
to dissolve the old dried Loctite (10 to 15 minutes).
NOTE: Check also PTO flywheel and drive shaft
 WARNING condition. Refer to BOTTOM END and DRIVE SYS-
TEM.
Technician should wear gloves when using
this cleaning product. Examine impeller in wear ring for distortion.
Check if blade tips are blunted round, chipped or
CAUTION: DO NOT use Loctite Stripper on wear broken. Such impeller is unbalanced and will vi-
ring since it will cause irreparable damage to it. brate and damage wear ring, impeller shaft, shaft
Wipe Loctite Stripper with a clean cloth. seal or bearings. Renew if damaged.
Make sure surface is cleaned and dried of Loctite
1
Stripper.
Sealant on the jet pump housing can be removed
with a wire brush (disc) mounted on a drill or a
scraper.
Properly clean all threads.
Remove all O-rings and clean parts in a solvent.
Carefully check water passages and oil passages.
Blow low pressure compressed air through them
and make sure they are clear.
F02J0VB
1. Replaced if blunted round or damaged

1
Check impeller for cavitation damage, deep scratch-
es or any other damage.
F01J13A
2
TYPICAL
1. Water passages
2. Oil passages
Brush and clean impeller shaft threads, impeller

and drive shaft splines with Loctite Parts Cleaner
(P/N 413 711 809) or equivalent. Free threads and
splines from any residue. F02J0UA
CAUTION: Be careful not to damage impeller 1. Check for cavitation, deep scratches or other damage
shaft diameter.
SMR2002-043_11_02A.FM 11-02-11
Wear Ring To check both bearings, proceed the same way

with other shaft end. Position gauge tip on diam-
Check wear ring no. 31 for deep scratches, irreg-
eter, close to flats on shaft.
ular surface or any apparent damage.
If impeller/wear ring clearance is too large and im-
peller is in good shape, renew wear ring. 1
Needle Bearing and Impeller Shaft

WEAR
Inspect needle bearings no. 30 and their contact
surface. Check for scoring, pitting, chipping or oth-
er evidence of wear.
With your finger nail, feel contact surface of seal.
If any irregular surface is found, renew impeller
shaft no. 28.
Install bearings, then install impeller shaft and ro-
tate it. Make sure it turns smoothly. F01J19A 2
RADIAL PLAY TYPICAL — MEASURING IMPELLER SHAFT RADIAL PLAY
1. Dial gauge
Radial play is critical for jet pump unit life span. 2. Measure close to flats at shaft end
Radial play of impeller shaft is checked with shaft Excessive play can come either from worn bear-
in housing, without impeller. ings or impeller shaft or damaged jet pump hous-
Retain housing in a soft jaw vise making sure not ing bearing surfaces.
to damage housing lug. Measuring shaft diameter will determine the de-
Set a dial gauge and position its tip onto shaft end, fective parts.
close to end of threads. Using a micrometer, measure diameter on bearing
Move shaft end up and down. Difference between contact surfaces. Minimum shaft diameter should
highest and lowest dial gauge reading is radial be 22.24 mm (.876 in).
play.
1
Maximum permissible radial play is 0.05 mm (.002 in).
F01J1AA
1. Inspect for wear at the bearing pilot

2. Radial bearing raceway
F01J18A 2 NOTE: If shaft is to be replaced, it is recommend-

ed to replace both bearings at the same time. In
TYPICAL — MEASURING IMPELLER SHAFT RADIAL PLAY addition, it is suggested to replace thrust bearing
1. Dial gauge and thrust washer.
2. Measure close to threads at shaft end
11-02-12 SMR2002-043_11_02A.FM
Thrust Washer and Thrust Bearing Seal

Visually inspect thrust washer no. 32, thrust bear- Carefully inspect seal lips. Make sure that lips are
ing no. 33 and their contact surface. Check for not worn, distorted, cracked or show signs of any
scoring, pitting, flaking, discoloration or other evi- other damage. Replace after 150 hours even if it
dence of wear. For best inspection, use a 7X mag- seems good.
nifying glass to check wear pattern.
1
ASSEMBLY
2
3
Wear Ring
These models are equipped with large pumps. It
is important that the screws retaining wear ring to
housing are installed on this models.
F01J52A
TYPICAL
1. Worn roller (trunnion worn on end roller)
2. Good roller (cylindrical shape)
3. Look for scoring on retainer
NOTE: When replacing either washer or bearing,

it is recommended to renew both. F08J06A
Anti-Rattle Pusher
Check for melted plastic around metal pad. If so,
replace it.
F08J07A
All Models
To install ring in housing, use a square steel plate
F08J05A
of approximately 180 × 180 mm × 6 mm thick (7 ×
Check for excessive wear of pad. 7 in × 1/4 in) and a press.
SMR2002-043_11_02A.FM 11-02-13
Manually engage ring in housing making sure it is Seal and Needle Bearing
equally inserted all around. Press ring until it seats
into bottom of housing. GTX RFI Models
Bearings no. 30 and seal no. 29 will be properly
installed in housing using bearing/seal installer
tool (P/N 295 000 107).
F01J4KA 2
BEARING/SEAL INSTALLER TOOL
1. Seal side
2. Bearing side
2
F01J5DA Bearing no. 30 and seal no. 29 on impeller side will
1. Seal lip
be properly installed in housing using bearing/seal
2. Press wear ring installer tool (P/N 295 000 107).
If a press is not readily available, a piece of wood 1
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. F01J4KA 2
1. Seal side
2. Bearing side
For the bearing on venturi side use inner bearing

installer tool (P/N 529 035 609).
2
1
F08B01A
F01J5EA CAUTION: Failure to use this tool will cause ma-

1. Piece of wood
jor damage to the pump.
2. Seal lip facing upward
3. Wear ring
NOTE: Do not forget, install retaining screws on

large pump models.
11-02-14 SMR2002-043_11_02A.FM
Impeller Side CAUTION: These tools have been designed to

properly position bearings and seal, thus pro-
All Models
viding space for lubrication purposes. The tool
Stamped end of bearings (showing identification flanges allow this. If a different pusher type is
markings) must be located toward outside of hous- being used, components must be properly po-
ing. sitioned as follows.
Properly insert bearing on tool. Using an arbor Bearing on impeller side must be 1.5 to 2.5 mm
press only, push tool until tool flange contacts (.060 - .100 in) inside reservoir measured from seal
housing. seat. Refer to following illustration.
1
F01J5YA
F01J1HA
1. Seal seat
2. Stamped end of bearing
1. Stamped end this side A. 1.5 - 2.5 mm (.060 - .100 in)
CAUTION: Never hammer the bearing into its Apply Loctite 518 (P/N 293 800 038) to seal hous-
housing. ing, all around outer diameter and on seal seat.
Properly insert seal on tool.
NOTE: Apply synthetic grease on tool to ease seal
insetion.
Install seal with the spring toward the outside.
F01J1KA 1
F00J0ZA
1. Spring of seal this side
1. Press on tool until it stops
2. Bearing
SMR2002-043_11_02A.FM 11-02-15
CAUTION: Prevent sealant from contacting any Properly insert bearing on tool. Using an arbor
needles of bearing. press only, push tool until tool flange contacts
Push on tool end with a press until tool flange con- housing.
tacts housing.
F01J1HA
F00J0CA 1 1. Stamped end this side
1. Press on tool until it stops CAUTION: Never hammer the bearing into its hous-
Apply synthetic grease (P/N 293 550 010) between ing.
seal lips.
F01J1MA
1. Loctite 518 all around and behind

2. Spring of seal lip this side
F16J09A
Venturi Side
GTX RFI Models
CAUTION: These tools have been designed to
Use the same procedure than impeller side. properly position bearing, thus providing space
for lubrication purposes. The tool flanges allow
this. If a different pusher type is being used,
Stamped end of bearings (showing identification components must be properly positioned as fol-
markings) must be located toward outside of hous- lows.
ing.
11-02-16 SMR2002-043_11_02A.FM
Bearing on venturi side must be 2 to 4 mm (.080 -

.157 in) inside reservoir measured from thrust
washer seat. Refer to following illustration.
F00J0EA 1
1. Thrust bearing on top of thrust washer
F01J5YB
1. Thrust washer seat Impeller Shaft

A. 2 - 4 mm (.080 - .157 in) To prevent seal lip damage when inserting impel-
ler shaft, use impeller shaft guide (P/N 295 000
Thrust Washer 002).
Position jet pump housing with the stator vanes
on top.
Insert thrust washer no. 32 in the stator seat.
F01J1OA
Insert tool onto shaft end then carefully install

shaft in jet pump housing.
F00J0DA 1
1. Thrust washer properly installed in stator seat
Thrust Bearing
Apply SEA-DOO JET PUMP SYNTHETIC OIL (P/N
293 600 011) on both sides of thrust bearing.
Position thrust bearing no. 33 on thrust washer
no. 32. F00J0FA 1 2
1. Impeller shaft
2. Impeller shaft guide
SMR2002-043_11_02A.FM 11-02-17
NOTE: If jet pump housing rest against a table,

raise it slightly to allow complete shaft insertion
with the shaft guide.
Remove shaft guide.
Impeller
Apply Loctite primer N (P/N 293 600 012) on threads
of impeller shaft no. 28. Allow to dry for 2 min-
utes. 1
NOTE: Loctite primer is used to reduce Loctite

243 curing time and to activate stainless steel and
aluminum surfaces for better bonding action. If ap-
plied, complete curing time is 6 hours, if primer is
not used, allow 24 hours for curing time.
Apply Loctite 243 (blue) to shaft threads.
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 im-
peller and push so that it slides on impeller shaft
threads. Carefully engage threads making sure
they are well aligned.
Install impeller remover/installer tool into impeller
splines and tighten.
F00J0GA 1
1. Apply Loctite 243 (blue) on threads

secure impeller shaft holder tool (P/N 295 000 082)
to housing.
Install shaft holder tool in a vice.
F00J08A
1. Impeller remover/installer tool
CAUTION: Make sure thrust washer and bear-

ing are not wedged in shaft groove. To check,
manually pull and push jet pump housing, some
axial play must be felt.
Torque impeller to 115 N•m (85 lbf•ft) then remove
tools.
CAUTION: Never use any impact wrench to tight-
en impeller.
11-02-18 SMR2002-043_11_02A.FM
Apply synthetic grease (P/N 293 550 010) on im-

peller splines.
Insert a new boot no. 2 and ring no. 3 to impeller.
F00J0WA
Apply synthetic grease in the center hole of the

cover.
Install pusher no. 36 into cover. Place the flat side
in front of slider tab.
F00J10A 1
1. Boot and ring
Anti-Rattle System
Install spring no. 34 on slider no. 35.
F00J0XA
F00J0VA 2 1
Install O-ring no. 37 to cover. Apply Loctite 518 on
1. Spring O-ring.
2. Slider
Install cover to jet pump housing making sure to
Insert slider and spring into cover. properly position filler plug on top side. Do not
NOTE: Align the longer slider tab with hole. torque yet, keep a small gap.
Insert a pencil or any other plastic tool in the hole
and push on the slider tab.
CAUTION: Do not use a metal tool to push the
tab. It is possible to damage the inner threads.
Hold tab and torque screws.
Remove pencil or tool to release locking mecha-
nism.
SMR2002-043_11_02A.FM 11-02-19
Check if the mechanism worked properly. Push Venturi

tab with the pencil or tool; if there is a small play
If needed, install new O-rings no. 38 around bailer
the installation is correct. If not, redo the proce-
passages.
dure.
Verify if the impeller is rotating freely.
Add oil.
Oil Fill
NOTE: It is highly recommended to perform a leak-
age test prior adding the oil. See PUMP PRESSUR-
IZATION in this subsection.
Place housing horizontally as in its operating posi-
tion so that filler plug is located on top. Remove
filler plug from cover. Pour SEA-DOO JET PUMP
SYNTHETIC OIL (P/N 293 600 011) in reservoir un-
til oil comes level with bottom of hole. Let oil drain
into housing and after a few minutes add more oil
until it is level with bottom of filler hole. F00J0KA 1
CAUTION: This is a synthetic oil. Do not mix 1. O-rings
with mineral based oil. Do not mix oil brands.
Apply Loctite 518 (Gasket Eliminator) on mating
NOTE: When filling reservoir, oil must be poured surface.
into cover quite slowly to allow complete housing
fill. Position venturi no. 24 with bailer passages on
top.
Apply Loctite pipe sealant (P/N 293 800 018) on
plug threads and reinstall it on cover. Apply Loctite 243 (blue) on threads of screws
no. 39.
NOTE: The plug threads are perpendicular to the
impeller shaft. Install screws no. 39, lock washers and flat wash-
ers then torque to 21 N•m (16 lbf•ft).
F00J0JA 1
TYPICAL
1. Pour oil slowly until it is level with bottom of filler hole F02J0TA 1
1. Torque screws to 21 N•m (16 lbf•ft)
11-02-20 SMR2002-043_11_02A.FM
O-Rings – Disconnect pump gauge tester and remove fit-

ting.
Install O-rings no. 38 around bailer passages or make
sure they are in place if they were not removed. – Check oil level. Refill as necessary.
– Apply Loctite Pipe sealant (P/N 293 800 018) to
PUMP PRESSURIZATION threads of filler plug then secure it in cover.
Whenever doing any type of repair on jet pump, a NOTE: The plug threads are perpendicular to the
pressure test should be done to check for leakage. impeller shaft.
Proceed as follows:
INSTALLATION
– Remove drain plug from cover.
– Apply Loctite Pipe sealant on threads of fitting Jet Pump Housing
tool (P/N 295 000 086) then secure on cover. Generously apply synthetic grease on drive shaft
– Connect pump gauge tester (P/N 529 021 800) splines.
to fitting. Make sure rubber damper is on drive shaft end.
– Pressurize pump to a maximum of 70 kPa (10 PSI). Install jet pump. If necessary, wiggle jet pump to
engage drive shaft splines in impeller.
CAUTION: Some watercraft require a shim be-
tween hull and pump; if shim has been re-
moved at pump removal, be sure to reinstall it,
otherwise engine alignment will be altered.
Apply Loctite 243 (blue) on stud threads of jet
pump housing.
Install flat washers no. 40, lock washers no. 41
and nuts no. 25. Tighten nuts of jet pump housing
in a criss-cross sequence and torque to 31 N•m
(23 lbf•ft).
NOTE: Slightly lubricate wear ring with
BOMBARDIER LUBE lubricant to minimize friction
F00J0LA during initial start.
– Pump must maintain this pressure for at least Nozzle

10 minutes.
GTX RFI Models
CAUTION: Repair any leak, failure to correct a
leak will lead to premature wear of pump com- Insert bushings no. 42 in nozzle no. 20, position-
ponents. ing their flanges from inside of nozzle.
NOTE: If there is a pressure drop spray soapy wa- Insert sleeves no. 22 in bushings no. 42.
ter around cover. If there are no bubbles, impeller Install nozzle on venturi no. 24; position its steer-
shaft, impeller shaft seal, or jet pump housing is ing arm on RH side. Apply Loctite 243 (blue) on
leaking through porosity and has to be replaced. screw threads (or use new screws with pre-ap-
Jet pump unit has to be disassembled. If jet pump plied threadlocker). Install screws no. 21 and wash-
has been overhauled, the impeller shaft seal ers no. 23 then torque to 20 N•m (15 lbf•ft).
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.
SMR2002-043_11_02A.FM 11-02-21
XP Models
1 Install nozzle/trim ring assembly.
Torque screws to 20 N•m (15 lbf•ft).
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
2 jet pump is on right side and trim arm is above
venturi.
1
F01J3BA
TYPICAL
1. Washers
 WARNING
Screws must be torqued as specified.
F01J5FA 1
Pivot Triangle (if so equipped) 1. Torque screws to 20 N•m (15 lbf•ft)
Install head bolts toward inside.
NOTE: Make sure the pivot triangle turn freely. Steering Cable
Refer to section, STEERING SYSTEM.
Reverse Gate (if so equipped)
Install reverse gate with spacer and washer. Trim System
Torque to 20 N•m (15 lbf•ft). Refer to VARIABLE TRIM SYSTEM.
NOTE: When installing the reverse gate, pay at-
tention to position its lever behind the reverse Reverse Cable
gate support stopper. Refer to REVERSE SYSTEM.
1
F07J07A
1. Stopper
11-02-22 SMR2002-043_11_02A.FM
Subsection 03 (DRIVE SYSTEM)
DRIVE SYSTEM 0
2
3
4
5
6
7
8
2 Nm
9 (18 lbfin)
10
13
11 2 Nm
(18 lbfin)
Synthetic
grease
12
Synthetic
grease
13
F02I09S
SMR2002-044_11_03A.FM 11-03-1
XP Models
23 1
Loctite
243
Synthetic
grease
Loctite
243
20
18
24 23 Synthetic
19 grease
22 Nm
(16 lbfft)
22 Nm Loctite
(16 lbfft) 243
Loctite
243
22 Nm
(16 lbfft) 22
Loctite
5 518 Synthetic
6
7 grease
8 Loctite Loctite
9 271 518
10
11 15
10 Nm 21
(89 lbfin) 17
2 Nm 16
(18 lbfin) 15
12 14
Right Stuff
sealant
31 Nm Synthetic
(23 lbfft) grease Synthetic
grease
13
Right Stuff
sealant
Loctite
518 31 Nm
F08J04T (23 lbfft) Loctite 243
11-03-2 SMR2002-044_11_03A.FM
GENERAL
Jet pump must be removed to replace any com-
ponents of the drive system. Refer to JET PUMP
for removal procedure.
REMOVAL
PTO Flywheel Guard
Remove seat(s).
Remove vent tube support or seat support.
Remove plastic wing nuts retaining PTO flywheel
guard no. 1 to engine support.
Detach PTO flywheel guard from engine and with- 1
F01J2AA
draw from bilge.
TYPICAL
XP Models 1. Closing hooks
Open engine compartment cover. – Squeeze pliers to draw hooks together and dis-
Remove storage basket. engage windows from locking hooks.
Remove vent tubes from PTO flywheel guard.
Large Clamp
Unfasten large clamp of PTO flywheel boot no. 3
as follows:
– Use pliers (P/N 295 000 069).
F01J29A 1
TYPICAL
F01J0GA 1. Locking hooks
– Insert pointed tips of pliers in closing hooks. Small Clamp

Unfasten small clamp of PTO flywheel boot as fol-
lows:
SMR2002-044_11_03A.FM 11-03-3
– Use pliers (P/N 295 000 054). All Models except XP

Drive Shaft
Simply pull out drive shaft.
NOTE: If the drive shaft is jammed into PTO fly-
wheel, make the following tool and use it in con-
junction with the jet pump housing remover (P/N
295 000 113) to withdraw drive shaft.
F01B1TA
Raw Material:
– 1 aluminum alloy square of 51 mm (2 in) x 305 mm
– To open clamp, place flat side of plier on clamp (12 in).
embossment, squeeze and twist plier. – 2 aluminum rods of 28.5 mm (1-1/8 in) dia. x
30 mm (1-3/16 in).
2 1 I
J
C
A
B
D
E
4 3
H
5 D
6 F F
F02J0PA
F01I05A G
Circlip and Floating Ring 1. Use ball end mill for radius. This section of the slot should be
NOTE: On XP models, open rear access cover to 38 mm (1-15/32 in) deep
2. Drill 25 mm (1 in) hole in center to remove material
reach boot no. 10 and floating ring no. 6. 3. Weld all around
4. Drill 9 mm (11/32 in) hole
Hold floating ring no. 6 and compress boot no. 10; 5. Drill through 9 mm (11/32 in)
then, pull out circlip no. 5 from drive shaft groove. 6. Drill and tap 6 mm (1/4 in) holes
A. 305 mm (12 in)
B. 105 mm (4-1/8 in)
1 2 C. 16 mm (5/8 in)
D. 51 mm (2 in)
E. 36 mm (1-25/64 in)
F. 22 mm (7/8 in)
G. 17 mm (43/64 in)
H. 19 mm (3/4 in)
I. 35 mm (1-3/8 in)
J. 20.3 mm ± .18 mm (.800 in ± .007 in)
F06I06A
TYPICAL
1. Push floating ring
2. Remove circlip
11-03-4 SMR2002-044_11_03A.FM
Mount on drive shaft puller the jet pump housing Pull rear drive shaft until coupler no. 19 is disen-
remover; then, install assembly on drive shaft us- gage from splines.
ing screws.
1
F01I06A 3
TYPICAL
1. Jet pump housing remover F08I04A 1
2. Drive shaft puller
3. Screws 1. Pull drive shaft to disengage coupler from splines
CAUTION: Be careful not to damage hull rear Remove rear drive shaft.
section or engine rubber mounts. Remove coupler no. 19.
XP Models Front Drive Shaft

Rear Drive Shaft Remove PTO flywheel guard no. 1.
Remove rear access panel. Remove bolts, lock nuts and sleeves from sup-
port.
Remove protective plate no. 18.
F08I04B 1
F08I03A 1
1. Remove bolts, lock nuts and sleeves
1. Remove protective plate
SMR2002-044_11_03A.FM 11-03-5
Loosen bolts and lock nuts retaining the lower sup- Loosen gear clamp retaining the outer boot of the
port of the shock absorber. shock absorber.
F08Q01A 1 F08L12A 1
TYPICAL 1. Loosen gear clamp
1. Remove bolts and lock nuts
Tilt seat.
Loosen 4 screws and remove bottom cover of Remove front drive shaft.
seat.
Seal Carrier of Mid Bearing
To remove the seal carrier from support, loosen
the 6 nuts no. 21.
1
F08L11A 1
1. Remove cover
F05I05A
1. Nut (6)
11-03-6 SMR2002-044_11_03A.FM
Bearing no. 16 and seals no. 15 can be easily re- Excessive deflection could cause vibration and
moved using the bearing/seal remover tool (P/N damage to drive shaft splines, impeller, flywheel
295 000 144). 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).
F01J11A
NOTE: The same tool is used for bearing and seals

removal of jet pump.
Properly support seal carrier housing no. 17 when
removing seals and bearing.
Remove bushings from alignment washer no. 22.
1
All Models
Boot
Loosen gear clamp no. 11 holding boot, then care-
fully pull boot and carbon ring no. 8 from hull in-
F01J15A 2
sert.
MEASURING DRIVE SHAFT DEFLECTION
Carbon Ring 1. Dial gauge
2. V-blocks
Loosen gear clamp no. 9 then pull carbon ring from
boot no. 10. Damper
Visually inspect shape of dampers no. 13 for de-
INSPECTION formation or other damage.
All Models Floating Ring and O-Ring
Drive Shaft Inspect condition of O-rings no. 7 and floating ring
Inspect condition of drive shaft and PTO flywheel contact surface.
splines (except XP models).
1
Inspect condition of groove.
With your finger nail, feel machined surface of
drive shaft. If any irregular surface is found, renew
drive shaft.
F01I0FA 1 2 3 F01I0GA
1. O-rings
1. Surface condition
2. Floating ring contact surface
2. Groove condition
3. Splines condition
SMR2002-044_11_03A.FM 11-03-7
Boot Slide floating ring far enough forward in order to

release it from carbon ring.
Inspect the condition of boot. If there is any dam-
age or evidence of wear, replace it. Measure boot free length.
To verify the preload of the boot no. 10, proceed Subtract the installed length measurement from
as follows: the free length measurement. A difference of 4 mm
to 12 mm (5/32 in to 15/32 in) should be obtained.
NOTE: To verify the boot preload and free length,
jet pump and drive shaft must be installed. If the length is less than 4 mm (5/32 in), install a
spacer (P/N 293 250 017) between boot and thru
Measure boot length when normally installed on
hull fitting.
drive shaft. Ensure circlip no. 5 is properly in-
stalled into groove. 1
F00J04B
F00J03A 1 A
1. Spacer
1. Boot
A. Measure here NOTE: Drive shaft must be removed to install spacer.
Push floating ring to compress boot; then, remove
circlip out of drive shaft groove. XP Models
1 2
Inspect seal carrier needle bearing no. 16. Check
parts for scoring, pitting, chipping or other evi-
dence of wear.
Inspect seals no. 15 for deterioration or excessive
wear. Replace if necessary.
ASSEMBLY
XP Models
Properly support seal carrier housing no. 17 when
installing seals and bearing.
F06I06A
CAUTION: Ensure to install stamped end of bear-
2. Remove circlip ing (showing identification markings) first on
tool. Never hammer the bearing into its housing.
11-03-8 SMR2002-044_11_03A.FM
Install bearing no. 16 with the bearing/seal install-

er tool (P/N 295 000 107).
2
1
3 3
F01J2FA 4
F01J51A 1. Double-lip seal toward engine
2. Double-lip seal with protector toward jet pump
1. Press bearing in its housing 3. Raised edge of lip outwards
4. Seal carrier
NOTE: Bearing can also be installed with the same
Apply Loctite 518 all around seals outside diameter.
driver used at disassembly. Center bearing in longi-
tudinal axis of housing. 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
F01J2TA
1. Push bearing centered in its housing
Install double-lip seal no. 15 with protector toward

jet pump.
On both seals no. 15, raised edge of lip must be F01J1YA
located outwards of seal carrier. TYPICAL
Pack seals and bearing with synthetic grease (P/N

293 550 010).
SMR2002-044_11_03A.FM 11-03-9
INSTALLATION Carefully slide shaft through support plate and seal

carrier. Insert adapter end into PTO flywheel.
NOTE: Ensure the mid bearing is loosened.
procedure. However, pay particular attention to
the following.
XP Models
NOTE: Do not reinstall bushings into alignment
washer no. 22.
Properly index alignment washers no. 22 together.
Install seal carrier and hand tighten nuts no. 21.
NOTE: Apply Loctite 243 (blue) on studs.
Align the seal carrier using the following tools:
– support plate kit (P/N 529 035 506)
F05I08A 1 2
NOTE: Use plate (P/N 529 035 507) for the 155.6 mm
(6-1/8 in) jet pump. TYPICAL
1. Alignment tool
2. Seal carrier
Place grease fitting on the top and torque seal car-

rier 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 6
8 11
F00B0FA 1 2
3 4
1. Plate (P/N 529 035 507)
2. Support (P/N 529 035 511)
10 9
– alignment shaft (P/N 295 000 141).
5 2
F05I0EB 12 7
Step 1 : Torque to 3 N•m (26 lbf•in) as per sequence

F00B0GA 1 Step 2 : Torque to 10 N•m (88 lbf•in) as per sequence
1. Alignment shaft
Install support plate at rear of watercraft.
11-03-10 SMR2002-044_11_03A.FM
Front Drive Shaft Coupler and Damper NOTE: Make sure to install floating ring before in-
serting the drive shaft in the PTO flywheel.
Make sure to install dampers into drive shaft cou-
pler at both ends. While holding jet pump, guide and engage drive
shaft splines in PTO flywheel. Rotate shaft to
properly index splines. Make sure boot is well po-
sitioned over shaft end.
All Models
Circlip
Push the floating ring to compress the boot. Insert
the circlip no. 5 in the drive shaft groove.
1 2
2 1
F08I07A
SAME COUPLER AND DAMPER AT BOTH ENDS

1. Damper
2. Drive shaft coupler
Front Drive Shaft

Install front drive shaft no. 20.
Rear Drive Shaft

F06I06A
Install damper no. 13 to rear drive shaft no. 12.
Install drive shaft and jet pump at the same time. 2. Insert circlip in the groove
Insert drive shaft through carbon ring no. 8 and Slide the floating ring onto the circlip.
floating ring no. 6.
Insert drive shaft through seal carrier no. 14 and All Models except XP
into the coupler assembly. Be careful not to dam-
age seals. Large Clamp
CAUTION: When sliding the drive shaft through Secure large clamp no. 2 as follows:
seal carrier, the double lip seal can be folded over. – Use pliers (P/N 295 000 069) as for removal.
This would cause a seal carrier bearing failure.
– Manually engage holding hook in large window.
Reinstall protective plate no. 18. Apply Loctite This is a pre-clamping position only.
243 (blue) on bolts and torque lock nuts to 10 N•m
(88 lbf•in). 1

Drive Shaft and Dampers
Install dampers no. 13 on drive shaft no. 12.
NOTE: Make sure dampers were not left in PTO
flywheel or impeller.
Install drive shaft and jet pump at the same time.
F01J23A 2
Insert drive shaft through carbon ring no. 8 and
floating ring no. 6. PRE-CLAMPING POSITION
1. Holding hook
2. Large window
SMR2002-044_11_03A.FM 11-03-11
– Insert pointed tips of pliers first in closing hooks. Small Clamp

To secure small clamp no. 4, place notch side of
plier on clamp embossment and squeeze plier.
1
F01J2BA 1
TYPICAL F02J0PB
1. Closing hooks
1. Squeeze plier
– Squeeze pliers. When both large and small win-
dows are directly over the 2 locking hooks, LUBRICATION
press those windows down to engage hooks in
windows. PTO Flywheel
NOTE: At installation, clamp tail should be in op- All Models except XP
posite direction of engine rotation. Using a grease gun, carefully lubricate PTO fly-
wheel with synthetic grease (P/N 293 550 010),
1 until boot is just beginning to expand. At this point,
immediately stop greasing.
F01J23B 2
1. Engine rotation (counterclockwise)
2. Tail in opposite direction
F01I0BB
11-03-12 SMR2002-044_11_03A.FM

XP Models
Using a grease gun, lubricate seal carrier of mid
bearing with synthetic grease (P/N 293 550 010).
F05I09A 1
TYPICAL
1. Grease fitting
SMR2002-044_11_03A.FM 11-03-13
Subsection 04 (REVERSE SYSTEM)
REVERSE SYSTEM 0
GTX RFI and LRV DI Models
Synthetic grease 15 19 3 Nm (27 lbfin)

Loctite 243 3.5 Nm
16 (31 lbfin)
11 Loctite 243
2.5 Nm 20
(22 lbfin) 13
23
12
18 Silicone
6 Nm sealant
(53 lbfin) 17
3 Nm
(27 lbfin)
Loctite
243
14
7 Nm (62 lbfin) 2 4 Nm
21 (35 lbfin)
2.5 Nm
(22 lbfin) 5
3
10 Nm
(89 lbfin)
Loctite 243
4
6 6 Nm
(53 lbfin)
9 Nm
(80 lbfin)
7
8 1
10 9
4 9 Nm
5 Nm (80 lbfin)
22 (44 lbfin)
F07J0TS
SMR2002-045_11_04A.FM 11-04-1
DISASSEMBLY Reverse Gate Support

Unscrew 4 bolts which retain reverse gate support
Reverse Gate no. 10 to venturi.
Put shift lever in reverse position. Remove reverse gate support from venturi.
Disconnect reverse cable from reverse gate no. 1.
Remove lock nut no. 3 and bolt no. 2 retaining cable 2 1 2
end no. 21 to cable lever no. 5.
F07J02A 2 2
1. Reverse gate support
2. Remove bolts
F07J08B 4 3 2 1 Interior Lever

1. Bolt Remove glove box to have access to the shifting
2. Cable end lever mechanism.
3. Cable lever
4. Lock nut
Unscrew and remove 2 Allen screws no. 4 retain-

ing reverse gate to support no. 10 and remove re-
verse gate.
Cable Lever
Remove Allen screw no. 6 and detach cable lever
from reverse gate.
Pawl Lock and Spring

To remove pawl lock no. 7 and spring no. 8 re-
move roll pin no. 9.
F07L1FA 1
1. Remove glove box
11-04-2 SMR2002-045_11_04A.FM
Remove bolt no. 12 and lock nut no. 13 retaining ASSEMBLY

reverse cable end to interior lever no. 11.
1 2 bly procedures. However, pay particular attention
to the following.
CAUTION: Apply all specified torques and ser-
vice products as per main illustration.
Spring
Make sure to properly install spring no. 15 into in-
terior lever no. 11 as per following illustration.
F07J03A
1. Reverse cable
2. Interior lever
From outside of body, unscrew bolt no. 14 retain-

ing the shift lever no. 20.
1 2
F07J05A 1
1. Spring
Interior Lever and Shift Lever

Install the interior lever no. 11 in a rotating move-
ment. Engage properly the interior lever tabs in the
shift lever slots.
1 2
F07J04A
1. Bolt
2. Shift lever
Remove the interior lever no. 11 and spring no. 15.
Reverse Cable Support

Unscrew bolts no. 18 and remove retaining block
no. 17. Detach adjustment nut no. 23 from reverse
cable support no. 16.
Remove 3 bolts no. 19 retaining reverse cable sup-
port no. 16 to body.
F07J04B
Remove reverse cable support.
1. Shift lever
2. Interior lever tabs
INSPECTION
Make sure the shift lever action is smooth and pre-
Visually inspect parts for wear or cracks. Replace cise. Forward, neutral and reverse positions should be
parts as required. easy to select with a detent position between each.
SMR2002-045_11_04A.FM 11-04-3
Spring and Pawl Lock Reverse Cable

Make sure spring no. 8 is properly installed. One Install reverse cable to cable lever as per following
end of the spring is hooked in the pawl lock no. 7 illustration.
and the other end is retained by the stopper lock
nut.
2
3
F07J08A 5 4 3 4 2 1
F07J06A
1. Bolt
2. Ball joint
1. Pawl lock
3. Cable lever
2. Spring
4. Flat washer
3. Stopper lock nut
5. Lock nut
Reverse Gate CAUTION: Ensure cable ball joint is parallel to

When installing the reverse gate, pay attention to cable lever (90° ± 5°) to minimize tension on ca-
position its lever behind the reverse gate support ble. Adjust as required.
stopper.
ADJUSTMENT
1
Put shift lever in forward position.
Pull shift lever approximately 50 mm (2 in) and
push it back slowly in forward position.
 WARNING
When adjusting reverse cable, assure that le-
ver is well engaged into the spring slot.
The pawl lock no. 7 should be engaged in the an-

chor no. 22.
F07J07A
1. Stopper
11-04-4 SMR2002-045_11_04A.FM
If not, adjust reverse cable. Loosen 2 bolts no. 18

at reverse cable support no. 16. Turn adjustment
nut no. 23 as required.
3
2
F07J09A
1. Reverse cable support

2. Loosen bolts
3. Adjustment nut
When adjustment is completed, there should be

gap of 0 to 5 mm (0 to 3/16 in) between handle and
left cover.
F07J0AA
A. 0 to 5 mm (0 to 3/16 in)
All models except GTX RFI and LRV DI

To remove reverse gate, refer to JET PUMP section.
SMR2002-045_11_04A.FM 11-04-5
GTI, GT I LE, RX and RX DI Models
Synthetic
grease
7
Loctite 2 Nm
243 (18 lbfin)
2.5 Nm
9 (22 lbfin)
Silicone
sealant
2.5 Nm 3
(22 lbfin)
7
Loctite 2 Nm 2
243 (18 lbfin)
5 3.3 Nm
(29 lbfin)
10 6
4 9
4 Nm Loctite 2 Nm
(35 lbfin) 243 (18 lbfin)
8
10 Nm
(89 lbfin)
2
2.5 Nm
(22 lbfin)
1 7 Nm
(62 lbfin)
F16J0BT
11-04-6 SMR2002-045_11_04A.FM
GTX Models
Synthetic
Grease
5 Loctite 243 7
Loctite 296
10 3.5 Nm
(31 lbfin) 3 Nm
(27 lbfin)
2.5 Nm
(22 lbfin)
3
11
2 1 Nm
(9 lbfin)
3 Nm
(27 lbfin)
4 Nm
(35 lbfin) 6
9
Loctite 243
4
2.5 Nm
10 Nm (22 lbfin)
(89 lbfin)
7 Nm
(62 lbfin)
1
F02J12S
SMR2002-045_11_04A.FM 11-04-7
DISASSEMBLY
GTX, GTI, GTI LE, RX and RX DI Models
Reverse Gate
To remove reverse gate, refer to JET PUMP section.
Reverse Cable
Unscrew bolt no. 1, washers and the elastic stop
nut retaining reverse cable no. 2 on pivot arm.
1 2
F16J0DA 2 1
1. Reverse cable
2. Interior lever
Shift Lever
Unscrew the shift lever retaining bolt no. 4, wash-
er and nut.
Disengage the shift lever slots from interior lever
tabs, then remove the shift lever no. 5.
GTI, GTI LE, RX and RX DI Models
F16J0CA
1. Reverse cable
2. Pivot arm
Unscrew the cable lock then remove the half rings.

Remove the glove box. Refer to HULL/BODY.
On the interior lever no. 3, unscrew the elastic stop
nut and the washer retaining the reverse cable.
Remove the bracket no. 6.
NOTE: Before removing reverse cable from hull,
note cable routing for reinstallation.
Interior Lever
Detach the reverse cable from interior lever no. 3.
Unscrew the shift lever retaining bolt no. 4, wash-
er and nut, then remove interior lever.
F16J0EA 1
1. Shift lever retaining bolt
11-04-8 SMR2002-045_11_04A.FM
1 2 Handle Housing
Remove:
– shift lever
– interior lever
– reverse cable support
– bolts no. 9.
Then, remove handle housing no. 10.
INSPECTION
Visually inspect parts for wear or cracks. Replace all
defective parts.
F07J04B
1. Bolt ASSEMBLY
2. Interior lever tabs
Reverse Cable Support bly procedures. However pay particular attention
to the following.
Remove:
– shift lever Interior Lever
– interior lever Apply synthetic grease on the interior lever pivot
– bracket no. 6 and in the reverse cable support hole.
Install the interior lever in a rotating movement.
All Models except RFI Engage properly the interior lever tabs in the shift
lever slots.
cise. Forward and reverse positions should be easy
to select with a detent position between each.
Reverse Gate
Refer to JET PUMP section.
Reinstall glove box.
ADJUSTMENT
F16J0FA 2 1  WARNING
1. Bracket When adjusting reverse cable, assure that le-
2. Reverse cable
– bolts no. 7.
Place reverse gate in the up position.
Withdraw reverse cable support no. 8.
Turn the joint at the end of reverse cable and place
the hole in pivot arm and joint face to face.
Secure with bolt, washers, spacer and elastic stop
nut. Torque to 7 N•m (62 lbf•in).
SMR2002-045_11_04A.FM 11-04-9
Subsection 05 (VARIABLE TRIM SYSTEM)
VARIABLE TRIM SYSTEM 0

RX and RX DI Models
12
7 Nm
(62 lbfin)
11
Synthetic
grease
Dielectric
7 grease
6
8
9
Loctite Synthetic
Primer N grease
2
3 7 Nm
5 Nm (62 lbfin)
(44 lbfin) 4
2
5
7 Nm
10 (62 lbfin) Loctite
13 Primer N Loctite
243
14 3 Nm
(27 lbfin)
1
20 Nm
(15 lbfft)
20 Nm
F16J01U (15 lbfft)
SMR2002-046_11_05A.FM 11-05-1
XP Models
12
7 Nm
(62 lbfin)
11
Synthetic Dielectric
grease grease
7 8
6
9
Loctite
Primer N Synthetic
10 grease
5
2
4
3 5 Nm
(44 lbfin)
2
Loctite
Primer N
Loctite
243
1 13 10 Nm
(89 lbfin)
14
15 7 Nm
(62 lbfin)
16
2.5 Nm
(23 lbfin) 20 Nm
(15 lbfft)
20 Nm
(15 lbfft)
20 Nm
F08J10S
(15 lbfft)
11-05-2 SMR2002-046_11_05A.FM
GENERAL 1 2 4 3
To test VTS control module, motor or switch, refer
to INSTRUMENTS AND ACCESSORIES.
To have access to VTS module, remove seat (ex-
cept XP).
NOTE: On XP models, open rear access cover.
REMOVAL
All Models
Remove nut no. 14 and bolt no. 13 retaining VTS
rod no. 1 to sliding shaft no. 10.
Remove clamps no. 2.
Remove boot no. 3. F06J01E
XP MODELS
1 3 4 2 1. VTS rod
2. Bolt
3. Lock nut
4. Rubber boot
RX and RX DI Models
Disconnect:
– steering cable
– reverse cable.
Unscrew the pivot arm bolts (one on each side).
Move the reverse pivot arm backwards.
All Models
To loosen nut no. 4, use VTS socket tool (P/N 295
000 133).
F16J0AA
RX AND RX DI MODELS
1. VTS rod
2. Bolt
3. Lock nut
4. Rubber boot
F01B2PA
Remove sealing washer no. 5.

All Models
Disconnect wiring harnesses.
Pull out VTS assembly no. 6 from bilge.
SMR2002-046_11_05A.FM 11-05-3
DISASSEMBLY INSPECTION
Cover Boot
Remove VTS cover no. 7 by pressing on tabs. Make sure boot no. 3 is in good condition. If it is
cracked or teared, replace boot.
1
Worm
Inspect threads and splines of worm no. 9 for
wear. If worm replacement is necessary, renew
also sliding shaft.
F01J1WA 1
1. Press tabs to remove cover
Motor
Disconnect wires from motor no. 8.
Remove retaining nuts no. 11. F01J25A 1
1. Inspect threads and splines
1
ASSEMBLY
to the following.
Motor, Worm and Sliding Shaft

Apply synthetic grease to worm.
Screw worm no. 9 to sliding shaft no. 10.
Mesh worm splines to gear of motor.
F01J1XA 2
1. Remove nuts
2. Disconnect wires
Pull on motor to remove it.
Worm and Sliding Shaft

Simply pull on worm no. 9 and sliding shaft no. 10 F01J2PA
1
in order to remove them.
1. Mesh worm spline to gear of motor
11-05-4 SMR2002-046_11_05A.FM
Install motor no. 8, worm and sliding shaft in VTS Apply Loctite Primer N (P/N 293 800 041) to threads
housing. of VTS housing, and to nut no. 4.
Apply Loctite 243 (blue) to nut no. 4.
Install nut with sealing washer and torque to
7 N•m (62 lbf•in) using the VTS socket tool.
Apply synthetic grease to sliding shaft.
Boot and Clamps

Install rubber boot no. 3 over sliding shaft and se-
cure with clamps.
VTS Rod
RX and RX DI Models
Install:
F01J2GA
– pivot arm
Tighten nuts no. 11 to 7 N•m (62 Ibf•in). – reverse cable
Connect wires of motor. – steering cable
CAUTION: Make sure wire color codes match. – boot with clamps.
Install cover no. 7. Slide the VTS rod onto the sliding shaft end using
bolt no. 13 and nut no. 14. Torque nut to 7 N•m
NOTE: Make sure seal no. 12 is in place. (62 lbf•in).
INSTALLATION XP Models
Position boot on sliding shaft and secure it with
Installation is essentially the reverse of removal clamps.
procedures. However pay particular attention to
the following. Install ball joint on LEFT side of sliding shaft no. 10
using bolt no. 13, washers no. 15 and nut no. 14.
Nut and Sealing Washer Torque nut to 10 N•m (88 lbf•in).
Place sealing washer no. 5 on nut no. 4. Make 2 1 3
sure seal lips are facing toward hull.
F06J01C
F01J2LA
1 2 TYPICAL
1. Washers
1. Seal lips facing hull 2. Bolt
2. Nut 3. Lock nut
SMR2002-046_11_05A.FM 11-05-5
ADJUSTMENT
RX and RX DI Models
On these models, no adjustment is required.
XP Models
Push on VTS button up position until motor stops.
When the nozzle is up (8°), nozzle edge must not
interfere with venturi (there should be a gap of
1 mm (.039 in)).
NOTE: Activate timer to be able to position VTS.
8°
2
F01J3IA
1. No interference
2. Nozzle up
If an adjustment is necessary, loosen jam nut no. 16

of VTS rod no. 1. Turn adjustment nut of VTS rod
to obtain the desired gap between trim ring and
venturi.
1
F06J01A
TYPICAL
1. Turn adjustment nut of VTS rod
Tighten jam nut of VTS rod to 2.5 N•m (23 lbf•in)

when adjustment is completed.
11-05-6 SMR2002-046_11_05A.FM
Section 12 STEERING SYSTEM
TABLE OF CONTENTS 0
STEERING SYSTEM .............................................................................................................. 12-02-1
DISASSEMBLY................................................................................................................... 12-02-2
ASSEMBLY......................................................................................................................... 12-02-4
DISASSEMBLY .................................................................................................................. 12-02-7
ASSEMBLY......................................................................................................................... 12-02-10
OFF-POWER ASSISTED STEERING SYSTEM (O.P.A.S.)................................................ 12-02-12
GENERAL ........................................................................................................................................... 12-02-13
SIDE VANE ......................................................................................................................... 12-02-13
CYLINDER SUPPORT ASSEMBLY ................................................................................... 12-02-14
TIE ROD .............................................................................................................................. 12-02-15
SEALED TUBE ................................................................................................................... 12-02-16
FILTER ................................................................................................................................ 12-02-16
VALVE................................................................................................................................. 12-02-16
WATER HOSE .................................................................................................................... 12-02-17
CROSS SUPPORT PLATE ................................................................................................. 12-02-17
ALIGNMENT .......................................................................................................................... 12-03-1
SMR2002-052_12_01ATOC.FM 12-01-1
Subsection 02 (STEERING SYSTEM)
STEERING SYSTEM 0
7 Nm
(62 lbfin)
4 20
21
2
3 23 6
1 5 6
26 Nm
Loctite 243 (19 lbfft)
10 Nm
(89 lbfin) 5
5 Nm
(44 lbfin)
22
4 Nm
(35 lbfin) 12
14
4
Synthetic
grease
Loctite 243
13 Nm 13
(115 lbfin)
8
Carburetor-equipped 18
7
engines 16
11 6 Nm
15 (53 lbfin)
Loctite 243 6 Nm

3 Nm 17
(26 lbfin)
2.5 Nm 2.5 Nm
10 19
9
6 Nm Loctite
(53 lbfin) 243
24
10 Nm
26 25 (88 lbfin)
27
F07K11S
SMR2002-047_12_02A.FM 12-02-1
DISASSEMBLY Remove 2 screws no. 20 and flat washers no. 21

each side of cover.
Handle Grip and Grip Insert
To remove handle grip no. 1, pull out cap no. 2 and
remove screw no. 3.
Pull out grip and remove grip insert from handlebar
no. 22.
NOTE: Verify grip insert for damage.
Steering Cover
Remove grips no. 1. F07K0JA 1
Loosen set screws no. 5 of handlebar housings 1. Remove screws
no. 6.
Remove cover.
1
Cable Support
Loosen bolts no. 9 and remove retaining block
no. 10.
F00K01A
1. Set screw
Remove 4 screws no. 7.

2
F01K18C
1. Retaining block
F00K02A 1
TYPICAL
1. Cover
2. Screws
12-02-2 SMR2002-047_12_02A.FM
Loosen bolts no. 11 each side of steering support Steering Support

no. 12.
1 2 Cut locking tie securing wiring harness boot.
F07K02A
1. Steering support
2. Bolt F07K04A 1 2
1. Boot
1 2 2. Locking tie
Disconnect the throttle and choke cables from car-

buretor levers.
Disconnect the wiring harnesses leading out of
steering stem and cut locking tie.
1 2
F07K03A
1. Steering support
2. Bolts
Remove cable support no. 8.
F07K05A
ALL OTHER MODELS EXCEPT XP

1. Tie rap
2. Connectors
SMR2002-047_12_02A.FM 12-02-3
Disconnect the steering cable from the steering Steering Stem Arm and Support
stem arm no. 15.
Loosen bolts no. 17 retaining steering stem arm
no. 15 to support no. 16.
1 2
1
2
F07K06A
F07K08A 2
1. Steering stem arm
2. Steering cable 1. Steering stem arm
2. Bolts
Loosen bolts no. 11 retaining cable support no. 8
to steering support no. 12. Remove steering stem arm and support.
Loosen bolts no. 13 and lock nuts no. 14. Steering Cable
Disconnect steering cable no. 24 from steering
stem arm no. 15.
Remove retaining block no. 10.
Disconnect ball joint no. 19 from jet pump nozzle.
Remove ball joint no. 19 and jam nut from cable.
1 Loosen nut no. 25, then remove half rings no. 26
2 and O-ring no. 27.
NOTE: To loosen nut, use steering cable tool (P/N
295 000 145).
Remove steering cable from watercraft.
3
2
ASSEMBLY
3 Assembly is essentially the reverse of disassem-
F07K07A
bly procedures. However, pay particular attention
1. Steering support to the following.
2. Bolts
3. Lock nuts CAUTION: Apply all specified torques and ser-
vice products as per main illustration at the be-
Remove steering support no. 12 with handlebar, ginning of this subsection.
wiring harnesses and cables.
12-02-4 SMR2002-047_12_02A.FM

When installing the grip insert no. 21 in the han-
dlebar no. 22, ensure that it is properly inserted in
the slot at the end of the handlebar tubing. 2
2
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 N•m
(53 lbf•in).
Ball Joint
F02K0JA 1 Secure the steering cable ball joint no. 19 to the
1. Grip insert nozzle as per following illustrations.
Install grip no. 1 on handlebar no. 22 matching it CAUTION: Ensure the ball joint is parallel (± 5°)
to the hexagonal form on the grip insert. to the nozzle arm.
Install flat washer no. 23 and screw no. 3. All Models except XP
Torque screw to 7 N•m (62 lbf•in).
Install cap no. 2.
1 3 5
F02K0KA
2 4
1. Grip insert
2. Grip
3. Flat washer
4. Screw. Torque to 7 N•m (62 lbf•in)
5. Cap
F06K01A 1 2
CAUTION: Ensure to install flat washer other-
wise screw will damage grip end. TYPICAL
1. Ball joint on top of steering arm
2. Torque nut to 7 N•m (62 lbf•in)
Steering Stem Arm and Support
Position steering stem arm no. 15 and support STEERING ALIGNMENT
no. 16 onto steering stem. For steering alignment procedure, refer to ALIGN-
MENT.
 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.
SMR2002-047_12_02A.FM 12-02-5
XP Models
Loctite 243
10 Nm
(89 lbfin) 6
9
1 Nm
4 Nm (9 lbfin)
(35 lbfin)
7 Nm
(62 lbfin)
4
18 8 1 Nm
(9 lbfin)
2
13 Nm 3 Nm 3
(10 lbfft) (27 lbfin) 7
1
Synthetic 5 26 Nm
13 grease (19 lbfft)
7 Nm
(62 lbfin) 7
Engine 10
cover Loctite Loctite
243 28
243
Loctite 2.5 Nm
243 14
(22 lbfin) 12
17
Loctite Synthetic
243 Loctite grease
20 6 Nm 243 7 Nm
(53 lbfin) (62 lbfin) 7 Nm
(62 lbfin)
19 15 21
2.5 Nm
(22 lbfin)
16
24 23 22
Engine
cover 11
6 Nm
(53 lbfin) 10 Nm
(89 lbfin)
27 26 25
F08K0QS
12-02-6 SMR2002-047_12_02A.FM
DISASSEMBLY Remove 2 screws no. 9 and flat washers each

side of cover.
To remove handle grip no. 1, pull out cap no. 2
from grip end and remove screw no. 3 and washer
no. 4.
Pull out grip and remove grip insert from handle-
bar.
NOTE: Verify grip insert no. 5 for damage.
Steering Cover F07K0JA 1

To remove the steering cover no. 6, loosen set 1. Remove screws
screws no. 7 of handlebar housing.
Detach upper and lower section of cover from
1 steering.
1
F00K01A
1. Set screws
Remove 4 screws no. 8 and washers. F07K0KA 2

1. Upper section
2 2. Lower section
F00K02A 1
TYPICAL
1. Cover
2. Screws
SMR2002-047_12_02A.FM 12-02-7
Lever Remove link rod no. 12.

Open engine compartment cover.
Remove the top section of the engine cover by
loosening the 10 Allen screws located inside the
cover.
1 1
F08K06A
1. Remove link rod
1 1 Remove bolt no. 13 and washer retaining lever

no. 10 to steering support no. 18.
F08L0KB
1. Loosen Allen screws
Lift the top section of the engine cover and discon-

nect wiring harnesses.
Remove the top section of the engine compart-
ment cover.
Disconnect steering cable no. 11 from lever no. 10.
F08K07A
1. Remove bolt and washer
F08K05A 1
1. Disconnect steering cable
12-02-8 SMR2002-047_12_02A.FM
Steering Stem Arm and Support

Loosen bolts no. 17 retaining steering stem arm
no. 15 and support no. 16.
F08K0AA
1. Remove support and steering stem arm

F08K08A 1
1. Loosen bolts
Steering Stem
Loosen nuts and bolts retaining steering support Disconnect wiring harnesses, choke and throttle
no. 18. cables from engine.
Remove steering stem no. 14.
Steering Cable
Remove glove box.
Disconnect steering cable no. 11 at lever no. 10.
1 1
F08K09A
1. Loosen nuts and bolts
Lift steering support no. 18 and slightly pullback

steering stem no. 14 in order to remove the sup-
port no. 16 and steering stem arm no. 15.
F08K05A 1
1. Disconnect steering cable
SMR2002-047_12_02A.FM 12-02-9
Unscrew bolts from retaining block no. 20 to re-

move steering cable from cable support no. 19.
F08K0MA
1. Apply synthetic grease
F08K0KA 1 2 Steering Stem Arm and Support

1. Cable support Position steering stem arm no. 15 and support
2. Remove M6 bolts
no. 16 onto steering stem no. 14.
Disconnect ball joint no. 21 of steering cable from
jet pump nozzle.  WARNING
Remove ball joint no. 21, jam nut no. 22 and boots Make sure integrated flat keys of steering
no. 23 and no. 24. stem arm and support are properly seated in
steering stem keyways.
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 Handle Grip and Grip Insert
295 000 145). When installing the grip insert no. 5 in the handle-
Remove steering cable from watercraft. bar no. 28, ensure that it is properly inserted in the
slot at the end of the handlebar tubing.
ASSEMBLY
bly procedure. However, pay particular attention
to the following.
Lever
Prior installing lever no. 10, apply synthetic grease to
pivot.
Steering Stem
Apply synthetic grease to front and rear thrust
bearing surface.
F02K0JA 1
1. Grip insert
12-02-10 SMR2002-047_12_02A.FM
Install flat washer no. 4 and screw no. 3.

 WARNING
Correct torque must be strictly followed.
1 3 5
F02K0KA
2 4
1. Grip insert
2. Grip
3. Flat washer
4. Torque screw to 7 N•m (62 lbf•in)
5. Cap
CAUTION: Ensure to install flat washer other-

wise screw will damage grip end.
Ball Joint
Secure the steering cable ball joint no. 21 to the
nozzle as per following illustration.
CAUTION: Ensure the ball joint is parallel (± 5°)
to the nozzle arm.
F06K01A 1 2
TYPICAL
1. Ball joint on top of steering arm
2. Torque nut to 7 N•m (62 lbf•in)
STEERING ALIGNMENT
For steering alignment procedure, refer to ALIGN-
MENT.
SMR2002-047_12_02A.FM 12-02-11
OFF-POWER ASSISTED STEERING SYSTEM (O.P.A.S.)
12
19
13 10
1.2 Nm 9
18 (10 lbfin) 11
14 21
Body 12 2.2 Nm
17 36 24
15 25 (19 lbfin)
20
16
22
35
1.7 Nm 5.5 Nm
26 (49 lbfin)
(15 lbfin)
33 Hull
4.5 Nm 26
(40 lbfin) 10 2.2 Nm
1.2 Nm 36 34 (19 lbfin)
(10 lbfin) 31
32 1.7 Nm
9 24 12 (15 lbfin)
2.2 Nm
(19 lbfin) 25 30
23
11 Hull
22 21 27
29
5.5 Nm Hull
(49 lbfin) 2.2 Nm 28 2.2 Nm
8
29 28 6 7 Nm
8 7 (62 lbfin)
23 Hull 1
5
4
6 7
27 3
7 Nm 20 Nm
F18K0KS
(62 lbfin) 2 (15 lbfft)
12-02-12 SMR2002-047_12_02A.FM
GENERAL When throttle is released and engine RPM drops,

the side vanes are automatically lowered thus as-
The Off-Power Assisted Steering (O.P.A.S.) system sisting steering control.
uses a dual side vanes design that assists the water-
craft steering in deceleration, to redirect watercraft
path when steering is turned after throttle has been
released or engine stopped.
The side vanes on the rear sides of the hull, turn as
the steering is turned to assist the watercraft turning.
At first, carefully experiment turning with this system.
F18K01A 1
1. Side vane in lower position
F18K03A 1 1
SIDE VANE
1. Side vanes turn following steering movement
When engine is running at approximately 75% or Disassembly

more RPM, the side vanes are automatically raised Removal procedure for RH and LH side vane no. 9
to upper position since they are not required at that is same.
vehicle speed range.
Turn the steering for removal of tie rod retaining
Between 30% and 75% engine RPM, side vanes screw.
are gradually raised from lower position to upper
Remove tie rod retaining screw no. 10 and socket
position.
screw no. 11.
F18K0LA 3 4
F18K02A 1 1. Tie rod screw
1. Side vane in upper position 2. Side vane
3. Cylinder support assembly
4. Tie rod retaining stabilizer
SMR2002-047_12_02A.FM 12-02-13
CYLINDER SUPPORT ASSEMBLY

Disassembly
1
Removal procedure for RH and LH cylinder sup-
port assembly is same.
Remove side vane as mentioned above.
Unscrew bottom nut using O.P.A.S. cylinder nut
wrench (P/N 529 035 840).
F18K0MA
1. Socket screw
Lift shaft while holding top of side vane.

Pull side vane out. 2
Adjustment 1
Put the steering in straight ahead position. 3
Measure the portion of tie rod stabilizing fitting
no. 21 exceeding from cylinder support. F18K0NA 4
The exceeding distance of tie rod stabilizing fitting 1. Bottom nut
no. 21 from the cylinder support should be 42 ± 1 mm 2. Cylinder support
3. Pivot rod
(1.65 ± .04 in). 4. O.P.A.S. cylinder nut wrench
Remove cylinder assembly out of cylinder support.
F18K0OA 4 3 2 1
A 1. Pivot rod
2. Cylinder cap assembly
3. Piston
F18K0ZA
4. Spring
A. 42 ± 1 mm (1.65 ± .04 in)
Unscrew tie rod stabilizing fitting no. 21 from tie
Assembly rod no. 23.
Unscrew 4 socket screws no. 22.
Assembly is the reverse process of disassembly.
Torque tie rod retaining screw no. 10 to 4.5 N•m
(40 lbf•in).
Torque socket screw no. 11 to 2.2 N•m (19 lbf•in).
12-02-14 SMR2002-047_12_02A.FM
– Socket screws no. 22 should be turned 2-3

turns by hand before tightening with tool.
– Replace the cylinder seal ring whenever servic-
ing.
1 1
TIE ROD
Disassembly
Removal procedure for RH and LH tie rod is same.
Remove side vane and cylinder support assembly
F18K0PA as mentioned above.
1. Socket screws Remove O.P.A.S. “U” lever screw no. 2, flat
washer no. 3, bushing no. 4 and venturi bushing
Remove oetiker clamp no. 25 to remove water
no. 5 from nozzle.
hose no. 26 from the cylinder support no. 12.
Remove jet pump (refer PROPULSION SYSTEM).
Remove screw no. 6 and washers no. 7 to remove
“U” lever no. 1 from tie rod connecting levers no. 8.
4
3
F18K0QA 3 1 2
1. Oetiker clamp
2. Water hose
3. Cylinder support F18K0RA 2 1
1. “U” lever screw
Assembly 2. Screw
3. Tie rod connecting lever
Assembly is the reverse process of disassembly, 4. Tie rod
make sure of the following when doing assembly: Pull tie rod out from jet pump side.
– Always discard old threaded cover rod no. 14 Unscrew lever from the tie rod.
and replace with new one.
Assembly
Torque screw no. 6 to 7 N•m (62 lbf•in).
Torque O.P.A.S. “U” lever screw no. 2 to 20 N•m
F18K0YA 1 (177 lbf•in).
1. Replace threaded cover Torque socket screw no. 11 to 2.2 N•m (19 lbf•in).
– Check pivot rod no. 13 for cracks or scratches.
Replace pivot road, if necessary.
SMR2002-047_12_02A.FM 12-02-15
SEALED TUBE Assembly

Disassembly
Apply silicone grease on the screws before installing.
Removal procedure for RH and LH sealed tube
Torque Phillips screws no. 28 to 2.2 N•m (19 lbf•in).
no. 27 is same.
Remove side van, cylinder housing assembly and FILTER
O.P.A.S. “U” lever as mentioned above.
Remove jet pump (refer PROPULSION SYSTEM). For removal and installation procedure refer to
PROPULSION SYSTEM.
Remove Phillips screws no. 28 and remove rod
grommet no. 29. O.P.A.S. filter is part of plastic elbow no. 30.
Check for cleanness. Replace or clean it as neces-
sary.
VALVE
Disassembly
1 Remove O.P.A.S. “U” lever screw no. 2, flat
washer no. 3, bushing no. 4 and venturi bushing
no. 5 from nozzle.
Remove jet pump, filter and formed hose no. 32
(refer PROPULSION SYSTEM).
Remove gear clamps no. 35 to remove water hos-
F18K0SA 2 es no. 26 from valve.
1. Phillips screws
2. Rod grommet
Pull sealed tube out with tie rod from inside of

bilge towards jet pump side.
2
F18K0UA 3
1. Gear clamps
2. Valve
3. Water hoses
F18K0TA 1 2
1. Sealed tube
2. Tie rod
12-02-16 SMR2002-047_12_02A.FM
Unscrew bottom nut of valve no. 33 using WATER HOSE

O.P.A.S. cylinder nut wrench (P/N 529 035 840).
Disassembly
Removal procedure for RH and LH water hose is
same.
as mentioned above.
Remove gear clamps no. 35 to remove water
hose no. 26 from valve.
Pull out the water hose no. 26 from exterior.
Assembly
Assembly is the reverse process of disassembly,
F18K0VA 1 2 make sure of the following when doing assembly:
1. O.P.A.S. cylinder nut wrench
– Water hose must be installed from the out side
2. Valve to the inside of hull by turning it, oriented to-
wards valve.
Remove 2 Phillips screws no. 34 from valve collar.
Tighten gear clamps no. 35 manually to 1.7 N•m
1 (15 lbf•in).
CROSS SUPPORT PLATE

Disassembly
For LH Side Cross Support Plate
Remove Gooseneck pipe, exhaust pipe and LH
muffle (refer to EXHAUST SYSTEM).
For RH Side Cross Support Plate
Remove RH muffle (refer to EXHAUST SYSTEM).
For RH and LH Cross Support Plates
F18K0WA Remove side vane and cylinder support assembly
1. Phillips screws
as mentioned above.
Unscrew the screw no. 24.
Remove valve downwards from pump tunnel.
Assembly
make sure of the following when doing assembly:
1
– Check for cracks on formed hose no. 32,
change if necessary.
– Make sure that valve must be installed in the
right position.
Tighten gear clamps no. 31 manually to 1.7 N•m F18K0XA
(15 lbf•in).
1. Remove screw
SMR2002-047_12_02A.FM 12-02-17
Remove cross support plate no. 36 from the in-

side of bilge.
Assembly
– Check for cracks and deterioration of screw
threads on cross support plate, change if nec-
essary.
– Apply silicone sealant on cross support plate
when servicing or changing.
1 1
F18K10A
1. Apply silicone sealant
Torque screw no. 24 to 1.2 N•m (10 lbf•in).
12-02-18 SMR2002-047_12_02A.FM
Subsection 03 (ALIGNMENT)
ALIGNMENT 0
Position handlebar in straight ahead position by Loosen 2 bolts retaining block at cable support.
measuring each side the distance from handlebar Turn adjustment nut as required.
grip end to floorboard.
1
F01K07A
3
TYPICAL
1. Measuring handlebar grip end/floorboard distance 2
F01K18A
Check jet pump nozzle position by placing a
straight edge on nozzle outer end. Measure the ALL MODELS EXCEPT XP
distance on each side of the straight edge. It must 1. Retaining block
2. Adjustment nut
be equalled. 3. Loosen bolts
XP Models
To have access to the cable adjustment nut, open
upper storage compartment cover and remove
storage basket.
F01J5ZA
TYPICAL
1. Measure the distance on each side of the straight edge
If necessary, steering alignment adjustment should

be performed at steering cable support.
All Models except XP F01H6WA 1
Open storage compartment cover and remove bas- 1. Remove storage basket
ket (if so equipped).
SMR2002-047_12_03A.FM 12-03-1
F08K03B
TYPICAL — XP MODELS
1. Support
2. Adjustment nut
3. Loosen bolts
All Models
After adjustment, torque retaining block bolts to
6 N•m (53 Ibf•in).
CAUTION: Verify when the handlebar is turned
completely to the left or right side, that there is
no interference with venturi or VTS ring.
12-03-2 SMR2002-047_12_03A.FM
Section 13 SUSPENSION
TABLE OF CONTENTS 0
DIRECT ACTION SUSPENSION............................................................................................ 13-02-1
REMOVAL .......................................................................................................................... 13-02-2
INSPECTION ...................................................................................................................... 13-02-3
ASSEMBLY......................................................................................................................... 13-02-3
SMR2002-052_13_01ATOC.FM 13-01-1
Subsection 02 (DIRECT ACTION SUSPENSION)
DIRECT ACTION SUSPENSION 0

XP Model
10
5 Nm 2
(44 lbfin) 11
34 Nm
(25 lbfft)
3
13
12
5 34 Nm
1 7 (25 lbfft)
4
6
8 10 Nm
(89 lbfin)
Loctite
243
10 Nm
(89 lbfin)
Loctite
243
F08Q02T
SMR2002-048_13_02A.FM 13-02-1
REMOVAL Remove rear access panel from body.

Loosen lower gear clamp no. 4, then push inner
Shock Absorber boot no. 5 upward.
Loosen 4 screws and remove bottom cover of seat.
F08I03B 1
F08L11A 1 1. Loosen gear clamp
1. Remove cover Remove bolt no. 6 and lock nut no. 7 from shock
Loosen gear clamp no. 2 of outer boot no. 3, then absorber lower support no. 8.
pull outer boot downward.
F08Q03A 1 2
F08L12A 1 1. Bolt
2. Lock nut
13-02-2 SMR2002-048_13_02A.FM
Tilt seat upward. Install shock absorber/coil spring assembly in

Loosen upper gear clamp no. 9 of inner boot no. 5. spring compressor tool.
F08L13A 1
1. Loosen gear clamp F05L0NA
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
Boot
Inspect condition of boots. If there is any tear, re-
new boot(s).
Shock Absorber
Inspect shock absorber for wear. Extend and com-
press the piston several times over its entire
stroke; it should move smoothly and with uniform
resistance.
F08Q04A 1 2 Pay attention to the following conditions that will
1. Bolt denote a defective shock absorber:
2. Lock nut
– A skip or a hang back when reversing stroke at
Remove shock absorber/coil spring assembly. mid travel.
– Seizing or binding condition except at extreme
Outer Boot end of either stroke.
Pull outer boot to remove it from body. – Oil leakage.
– A gurgling noise, after completing one full com-
Coil Spring pression and extension stroke.
Install spring compressor tool (P/N 529 027 100) Renew if any defects are present.
in a vise.
 WARNING ASSEMBLY
Do not attempt to dismantle a spring without Assembly is essentially the reverse of disassem-
using the proper tool. bly procedure. Refer to the main illustration at the
beginning of this subsection for torque specifica-
tions and service products to be used.
SMR2002-048_13_02A.FM 13-02-3
Section 14 HULL/BODY
TABLE OF CONTENTS 0
ADJUSTMENT AND REPAIR ................................................................................................ 14-02-1
GLOVE BOX ....................................................................................................................... 14-02-19
SEAT ADJUSTMENT......................................................................................................... 14-02-20
STORAGE COMPARTMENT INNER SHELL ..................................................................... 14-02-21
STORAGE COMPARTMENT COVER ADJUSTMENT ...................................................... 14-02-21
ACCESS PANEL ADJUSTMENT ....................................................................................... 14-02-22
MIRROR.............................................................................................................................. 14-02-23
INLET GRATE ..................................................................................................................... 14-02-23
RIDING PLATE.................................................................................................................... 14-02-23
JET PUMP SUPPORT ........................................................................................................ 14-02-25
DEFLECTOR ....................................................................................................................... 14-02-26
DRAIN PLUG INSTALLATION ........................................................................................... 14-02-27
SEAT REMOVAL ................................................................................................................ 14-02-27
SEAT COVER REPLACEMENT .......................................................................................... 14-02-29
BUMPER REPLACEMENT ................................................................................................. 14-02-29
SPONSON REPLACEMENT .............................................................................................. 14-02-29
ENGINE COMPARTMENT COVER REMOVAL ................................................................. 14-02-30
DECALS REPLACEMENT .................................................................................................. 14-02-30
HULL AND BODY REPAIR ................................................................................................. 14-02-31
TOOLS AND MATERIALS LIST ......................................................................................... 14-02-34
THRU-HULL FITTING INSTALLATION ............................................................................. 14-02-34
SMR2002-052_14_01ATOC.FM 14-01-1
Subsection 02 (ADJUSTMENT AND REPAIR)
ADJUSTMENT AND REPAIR 0

GTI and GTI LE Models (bow)
Loctite 8 Nm
271 (71 lbfin)
Loctite
5 Nm 271
(44 lbfin)
6 Nm
(53 lbfin)
Silicone
Loctite sealant
271
15 Nm Silicone
(133 lbfin) sealant
Loctite
271
Body
F17L0RS
SMR2002-049_14_02A.FM 14-02-1
GTI and GTI LE Models (stern)
Loctite
271
13
15 Nm
(133 lbfin)
Loctite
271
Silicone
sealant
Loctite
243
Silicone
sealant
2.2 Nm
4 4 (19 lbfin)
5
5
14
15 Silicone
sealant
12 12
F17L0ST 12 12
14-02-2 SMR2002-049_14_02A.FM
GTI and GTI LE Models (cover)
GTI LE
Loctite
243
5 Nm
(44 lbfin)
Loctite
243
3 Nm
(26 lbfin)
F17L0TT
SMR2002-049_14_02A.FM 14-02-3
GTI and GTI LE Models (seats)
F17L0US
14-02-4 SMR2002-049_14_02A.FM
RX Series (bow)
Loctite 8 Nm
271 (71 lbfin)
Loctite
271
5 Nm
(44 lbfin)
6 Nm
(53 lbfin)
Silicone
Loctite sealant
271 Silicone
15 Nm sealant
(133 lbfin)
Loctite
271
Body
F16L0WS
SMR2002-049_14_02A.FM 14-02-5
RX Series (stern)
Loctite 271
13
12
Loctite
243
4 4
14
5 5
Loctite 271
12 Silicone
12 12 sealant 15 Nm
(133 lbfin)
Silicone
sealant
15 2.2 Nm
F16L0ST
(19 lbfin)
14-02-6 SMR2002-049_14_02A.FM
RX Series (cover)
Loctite
243
5 Nm
(44 lbfin)
Loctite
243
3 Nm
(26 lbfin)
F16L03S
SMR2002-049_14_02A.FM 14-02-7
RX Series (seat)
F16L04S
14-02-8 SMR2002-049_14_02A.FM
GTX, GTX RFI and LRV DI (bow)
Loctite
243
5 Nm 5 Nm
8 Nm
(71 lbfin)
3 Loctite
243
Loctite
243
5 Nm
(44 lbfin)
10
8 Nm
(71 lbfin)
Loctite
271
Loctite
243
Silicone
sealant 10
8 5 Nm
7 (44 lbfin)
Body
Loctite Silicone
271 sealant
6 Right
side
only 15 Nm
(133 lbfin)
F07L2DS
SMR2002-049_14_02A.FM 14-02-9
GTX, GTX RFI and LRV DI (stern)
13
12 8 Nm
(71 lbfin)
15 Nm
(133 lbfin)
Loctite
271
8 Nm
(71 lbfin) Silicone
sealant
Silicone
sealant
4 4 15
5 5 2.2 Nm
(19 lbfin)
12 12
14
F07L2FT 12
14-02-10 SMR2002-049_14_02A.FM
GTX, GTX RFI and LRV DI (cover)
8 Nm
1.4 Nm (71 lbfin)
(12 lbfin)
0.8 Nm
(7 lbfin)
Loctite
243
Loctite
243 5 Nm
(44 lbfin)
5 Nm
(44 lbfin)
8 Nm
(71 lbfin)
Loctite
243
3 Nm
(26 lbfin)
Loctite
243
5 Nm
F07L1MT
(44 lbfin)
SMR2002-049_14_02A.FM 14-02-11
GTX, GTX RFI and LRV DI (seat)
5 Nm
4 Nm (44 lbfin)
(35 lbfin)
Loctite 243
5 Nm
F07L1NT (44 lbfin)
14-02-12 SMR2002-049_14_02A.FM
XP Models (bow)
Loctite
243
Silicone 8 10
sealant 7
Loctite
6 243
Silicone
sealant
15 Nm
(11 lbfft)
Body
Loctite
271
F08L1JT
SMR2002-049_14_02A.FM 14-02-13
XP Models (stern)
3
Loctite 243
Body
5 Nm 3
12
13
Body
5 Nm
(44 lbfin)
Body
4 Silicone
sealant
14
5 5
Silicone
sealant 15 2.2 Nm
12 (19 lbfin)
F08L1RT
14-02-14 SMR2002-049_14_02A.FM
XP Models (seat)
4 Nm
(35 lbfin)
Loctite 243
15 Nm Loctite
(11 lbfft) 243
17
13 Nm
(10 lbfft)
24
5 Nm
(44 lbfin) Synthetic
grease
23
22
Loctite 271
3 Nm
21 (27 lbfin)
20
19
3 Nm
18 (27 lbfin)
F08L16T
SMR2002-049_14_02A.FM 14-02-15
XP Models (suspension and engine cover)
4 Nm
(35 lbfin) Loctite
243
Loctite 4 Nm
243 (35 lbfin)
Loctite
243
8 Nm
(71 lbfin)
Loctite
243
Loctite
648
Loctite
243
8 Nm 4 Nm
F08L1KT
14-02-16 SMR2002-049_14_02A.FM
XP Models (front cover)
Loctite
271
3 Nm
(27 lbfin)
Engine
cover
2 Nm
(18 lbfin)
F08L18S
SMR2002-049_14_02A.FM 14-02-17
XP Models (rear cover)
Loctite
243
Loctite
243
22 Nm
(16 lbfft)
4 Nm
(35 lbfin)
Loctite 243
4 Nm
(35 lbfin)
F08L19T
14-02-18 SMR2002-049_14_02A.FM
GLOVE BOX GTI, GTI LE and RX Series

Open front storage cover and remove the access
GTX, GTX RFI and LRV DI
panel.
Open the glove box cover then unscrew the four
Detach the latch retaining vent tube to bracket.
screws.
Pull the glove box out of body.
GTI, GTI LE and RX Series
Removal
Remove handle from shift lever.
F17L0OA 1
1. Unlatch

Pull vent tube out.
F16L07A 1 From the engine compartment, insert a hand
1. Unscrew through the vent tube hole and press glove box
lock tabs to release.
Unscrew retaining screws then remove side pan-
els.
F16L0AA 1
F16L08A 1 1. Insert your hand here to release the lock tabs
1. Unscrew
SMR2002-049_14_02A.FM 14-02-19
From front storage compartment, pull glove box

out. 1
2 A
F06L03A
F16L0BA 1 GTX, GTX RFI AND LRV DI — REAR SEAT

1. Lock tabs 1. Lock pin
2. Adjustment nut (apply Loctite 243). Torque to 5 N•m (44 lbf•in)
A. 33.5 ± 1 mm (1-5/16 ± 3/64 in)
Installation
Reverse the removal procedure. 1
SEAT ADJUSTMENT
A
Seat Retainer
NOTE: Apply Loctite 243 on threads of lock pin 2
when the adjustment is required or when the lock
pin is removed then reinstalled. The threads on
new lock pin are coated with a self-locking prod-
uct, do not apply Loctite 243 on threads.
1
F17L0PA
GTI AND GTI LE MODELS — FRONT SEAT

1. Lock pin
A. 34 ± 1 mm (1-11/32 ± 3/64 in)
A
2
F07L08A
GTX, GTX RFI AND LRV DI — FRONT SEAT

1. Lock pin
2. Adjustment nut (Loctite 243). Torque to 5 N•m (44 lbf•in)
A. 39 ± 1 mm (1-35/64 ± 3/64 in)
14-02-20 SMR2002-049_14_02A.FM
Gently pull on large end (rear end) and pull apart

1 towards the small end (front). See illustration.
2
2
F16L05A 1
1. Gently pull starting this end
2. Finish with this end
F17L0QA
For installation, proceed as follows:
GTI AND GTI LE MODELS — REAR SEAT
1. Lock pin • Sand both inner and outer shells in area to be
2. Adjustment nut (apply Loctite 243). Torque to 5 N•m (44 lbf•in) glued (except GTI).
A. 34 ± 1 mm (1-11/32 ± 3/64 in)
• Clean to remove any dust with isopropylic alco-
hol. Let dry.
1
• Apply a 2 mm (3/32 in) bead of Loctite 454.
• Reinstall inner shell with its retaining screws.
• Tighten screws starting with the one at the
A small end (front) and finish with rear end. Care-
fully hand tighten.
2
STORAGE COMPARTMENT
COVER ADJUSTMENT
NOTE: Apply Loctite 243 on threads of lock pin
F16L0TA
RX AND RX DI MODELS new lock pin are coated with a self-locking prod-
1. Lock pin uct, do not apply Loctite 243 on threads.
A. 39 ± 1 mm (1-35/64 ± 3/64 in)
STORAGE COMPARTMENT
INNER SHELL
To remove inner shell, proceed as follows:
CAUTION: Failure to follow this order may lead
to damaging inner plastic studs.
SMR2002-049_14_02A.FM 14-02-21
All Models NOTE: Some models have a floating type lock pin.
Adjust lock pin no. 3 as per following specifica- It is normal to have a front and aft play of the lock
tions: pin. To adjust, tighten lock pin until any vertical play
is eliminated. Make sure a front and aft play re-
1 mains when pressing by hands.
A
2
F06L04A F08L1AA
FIXED TYPE LOCK PIN XP MODELS

1. Lock pin (apply Loctite 243) 1. Lock pin. Torque to 4 N•m (35 lbf•in)
2. Adjustment nut. Torque to 5 N•m (44 lbf•in) A. 13.4 mm (17/32 in)
A. 34 ± 1 mm (1-11/32 ± 3/64 in)
ACCESS PANEL ADJUSTMENT
1
XP Models
Adjust lock pin no. 3 of access panel as per follow-
ing specifications:
A
1
2
2 A
F16L0UA 3
FLOATING TYPE
1. Lock pin (apply Loctite 243)
2. Rubber washer
3. Lock nut. Torque to 5 N•m (44 lbf•in) 3
A. 39.2 ± 1 mm (1-35/64 ± 3/64 in)
F08L1BA
1. Lock pin
2. Adjustment nut (Loctite 243)
3. Lock nut. Torque to 5 N•m (44 lbf•in)
A. 39 ± 1 mm (1-17/32 ± 3/64 in)
14-02-22 SMR2002-049_14_02A.FM
Adjust bolts no. 16 of access panel arms as per

following specifications:
3
F05L0VA 1
2
1. Lock nut. Torque to 22 N•m (16 lbf•ft)
A. 20 ± 1 mm (25/32 ± 3/64 in)
MIRROR
GTI LE and RX Series F16L06A
Place the mirror frame in hot water to “soften” the

material to allow mirror installation in its frame.
RIDING PLATE
INLET GRATE Removal
All Models
Removal and Installation
Remove inlet grate.
Loosen screws and remove inlet grate.
Remove jet pump. Refer to JET PUMP.
NOTE: An impact screwdriver should be used to
loosen tight screws. Remove the speed sensor from the riding plate (if
applicable).
GTX, GTX RFI and LRV DI Loosen riding plate screws.
When reinstalling inlet grate, apply Loctite 271 on NOTE: An impact screwdriver should be used to
threads and torque screws to 11 N•m (8 lbf•ft). loosen tight screws.
GTI, GTI LE, XP and RX Series Using a low height hydraulic bottle jack and 2 steel
When reinstalling inlet grate, apply Loctite 271 on plates, pry out riding plate.
threads.
Follow this sequence referring to the illustration:
Hand tighten screw numbers ➀, ➁ then ➂.
Torque screw numbers ➀ and ➁ to 11 N•m (97
lbf•in).
Torque screw number ➂ to 26 N•m (19 lbf•ft).
SMR2002-049_14_02A.FM 14-02-23
6 4
82
F05J03A 2 1 71
TYPICAL
1. Hydraulic bottle jack
2. Steel plates
Cleaning
Scrape off all excess of sealant from riding plate
and hull. F08L1TA 5 3
Clean hull surface with acetone based solvent to GTI, GTI LE, LRV DI RX AND RX DI MODELS
eliminate grease, dust and any residue of sealant.
NOTE: Apply Loctite The Right Stuff Gasket as in-
dicated by the shaded area.
Installation
All Models 4 6
Apply Loctite The Right Stuff Gasket as indicated
by the shaded areas in the next illustrations. Fol-
low also the torquing sequence as shown in the 82
same illustrations.
71
3 5
F08L1SA
XP MODELS
14-02-24 SMR2002-049_14_02A.FM

1 3
21
82 F05K02A 1
TYPICAL
1. Unscrew nut
Remove ball joint, boot, nut, half rings and O-rings

from reverse cable (GTI, GTI LE, RX series, GTX,
6 4 GTX RFI and LRV DI).
F07L2MA
Remove boot and nut from VTS sliding shaft (RX

GTX MODELS
series and XP models).
NOTE: Apply Loctite The Right Stuff Gasket as in- Disconnect water supply hose, water return hose
dicated by the shaded area. and bailer hoses.
Remove nuts, lock washers and flat washers re-
4 6 taining jet pump support.
82
71
3 5
F15L04A
GTX RFI MODELS

dicated by the shaded area. F07L0AA 1
TYPICAL
JET PUMP SUPPORT 1. Remove nuts
Removal Using a heat gun, heat jet pump support until it is

possible to pull it.
NOTE: Shims may have been installed between
Remove inlet grate and riding plate. support and body. Do not remove these shims,
Remove ball joint, boot, nut, half rings and O-rings otherwise jet pump alignment will be altered.
from steering cable.
SMR2002-049_14_02A.FM 14-02-25
Installation
by the shaded areas in the next illustrations. Fol-
low also the torquing sequence as shown in the 1 2
same illustrations.
1 2
3 4
4 Nm
(35 lbfin) F12L0GA
LRV DI MODELS
3
4
DEFLECTOR
F15L05A
GTX, GTX RFI and LRV DI

GTX RFI MODELS
Removal
1 2 Using a heat gun, heat deflector and pry it using a
piece of wood.
Installation
by the shaded area in the following illustrations.
3 4
F07L2LA
GTX MODELS
1 2
F12L0JA
GTX AND LRV DI MODELS
3 4
F08L1OA
GTI , GTI LE, RX, RX DI AND XP MODELS
14-02-26 SMR2002-049_14_02A.FM
SEAT REMOVAL
XP Models
Loosen 4 screws and remove bottom cover no. 17
of seat.
F07L2NA
GTX RFI MODELS
DRAIN PLUG INSTALLATION

Refer to the following illustration to install drain plug F08L11A 1
no. 15.
1. Remove cover
Loosen gear clamp of outer boot; then, pull outer

boot downward.
3
2 1
F00L2RA
1. Drain plug
2. Silicone sealant (P/N 293 800 086) around the middle hole and in
the screw holes
3. Torque screws to 2.2 N•m (19 lbf•in)
F08L12A 1
SMR2002-049_14_02A.FM 14-02-27
Loosen gear clamp of inner boot; then, pull boot

downward.
F08L1EA
1
1. Loosen screws of eyelet
F08L13A 1
Remove cup no. 21 on each side of seat.
1. Gear clamp
Loosen nut no. 23 on each side of seat.
Remove bolt and lock nut from shock absorber up-
per support. 1
F08L1FA
F08Q04A 1 2 1. Loosen nut
1. Bolt Tilt seat.

2. Lock nut
Loosen screws no. 24 on each side of seat retain-
Remove protective caps no. 18 and loosen screws ing the side covers.
no. 19 to remove eyelet no. 20 on each side of Lower seat.
seat.
Remove side covers.
Pull seat frame out of pivots.
Remove seat.
Seat installation is essentially the reverse of re-
moval procedure. Refer to the main illustration of
seat at the beginning of this subsection for proper
torque specifications and service products to be
used.
14-02-28 SMR2002-049_14_02A.FM
SEAT COVER REPLACEMENT 1 2

Install staples with an electric tacker such as Ar-
row tacker no. ETN-50 or with a manual tacker
such as Arrow tacker no. T-50.
NOTE: For an easier installation, it’s highly recom-
mended to use an electric tacker.
Ensure that the seat rest firmly against a hard sur-
face such as a piece of wood. This is done to get
the staples completely pushed in place. F07L2JA 4 3
TYPICAL
1. Front bumper
2. Corner bumper
3. Straight section
4. Bow section
4. Slide bumper rail no. 4 under front bumper

no. 13.
5. Using a 4.80 mm (3/16 in) drill bit, drill first hole
through bumper rail no. 4 at front of bow sec-
tion. Use locating mark as a guide. Then install
a rivet no. 12.
CAUTION: When drilling, be careful not to dam-
age bumper rail and/or hull.
6. Position bumper rail no. 4 properly onto body
and cut excess length if necessary.
7. Slide bumper rail no. 4 in corner bumper no. 14.
8. Using hole positions previously marked on
1 body, drill holes in bumper rail no. 4 and install
rivets no. 12.
F01L3YA 2 9. Install trim no. 5 using soapy water.
TYPICAL 10. Repeat procedure for the other side.
1. Piece of wood
2. ETN-50 (electric) or T-50 (manual)
SPONSON REPLACEMENT
After cover installation cut all around the excess
of material. RX Series
Remove retaining screw from rear of sponson.
BUMPER REPLACEMENT Pull sponson out.
1. Remove trim no. 5 from side bumper rail no. 4. At installation, apply Loctite 271 (red) on screw
2. Drill pop rivets no. 12 to remove side bumper rail threads and on sponson nut. Torque screw to 6
no. 4. N•m (53 lbf•in).
3. Mark hole positions on body straight and bow
sections.  WARNING
Recommended torques and use of Loctite
must be strictly followed.
SMR2002-049_14_02A.FM 14-02-29
Other Models Disconnect the gas assist cylinder.

Remove seat (access cover for the XP models). Remove engine compartment cover.
Remove seat support (GTI, GTI LE, GTX, GTX RFI Engine cover installation is essentially the reverse
and LRV DI). of removal procedure. Refer to the main illustra-
Remove muffler. tion of engine cover at the beginning of this sub-
section for proper torque specifications and ser-
Remove battery. vice products to be used.
From inside bilge, remove lock nuts no. 10 using a
10 mm deep socket with an extension. DECALS REPLACEMENT
Remove sponsons no. 6. Clean any residues of
sealant adhesive on hull. Removal
Install gaskets no. 7 on new sponsons no. 6. Using a heat gun warm up one end of decal for a
Apply silicone sealant (P/N 293 800 086) around few seconds until decal can roll off when rubbing
sponson studs. with your finger.
Apply Loctite 243 (blue) on sponson studs. Pull decal slowly and when necessary apply more
heat to ease removal on the area that has to be
Install sponsons no. 6 on hull. peeled off.
From inside bilge, first insert flat washers no. 8 If decal tears while pulling off, it has to be heated
over sponson studs. Secure with lock nuts no. 10. for a few seconds longer. If decal tends to stretch
Tighten to 5 N•m (44 lbf•in). while pulling off, stop heating and wait a few sec-
NOTE: To ease flat washer and lock washer instal- onds to let it cool, then peel it off.
lation, use a flexible 4-claw Snap-on pick-up tool.
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.
F01P09A DECALS HAVING A PROTECTIVE FILM ON
BACK SIDE ONLY
Reinstall removed parts.
These decals usually contain written information
Clean hull and sponsons of any sealant adhesive (ex.: warning) and are used on gelcoat or metal.
surplus.
Clean surface with a good solvent such as ACRYLI-
 WARNING CLEAN DX 330 from PPG or equivalent (refer to
manufacturer instructions).
must be strictly followed. Using a pencil and the decal as a template, mark
the area where decal will be located.
Remove half of the decal back protective film and
ENGINE COMPARTMENT COVER align decal with marks. Start sticking it from center
REMOVAL and remove the other half of the film to stick it
completely. Carefully squeegee decal beginning at
XP Models center and working outward using, firm, short,
Disconnect throttle and choke cables at carburetor overlapping strokes.
linkage.
DECALS HAVING A PROTECTIVE FILM ON
Disconnect wiring harnesses of start/stop button, BOTH SIDES
monitoring beeper, safety lanyard switch and
These decals usually contain graphics and are used
gauges.
on gelcoat or plastic.
Loosen bolts and nuts of hinge from watercraft
body.
14-02-30 SMR2002-049_14_02A.FM
INSTALLATION ON GELCOAT The body and hull of the Sea-Doo are constructed
Clean surface with a good solvent such as ACRYLI- of chopped fiberglass, saturated with resin. It is
CLEAN DX 330 from PPG or equivalent (refer to sprayed on the layer of gelcoat along with pieces
manufacturer instructions). of fiberglass mat, cloth and woven rowing which
are added at required areas. This type of construc-
For best result apply an activator (P/N 293 530 tion is very accommodating for high quality re-
036) to prepare the surface using a clean cloth. pairs. With patience, the proper techniques and
After a few seconds, when the activator evapo- materials, a damaged area can be restored to an
rates, the surface is ready. original finish.
Using a pencil and the decal as a template mark NOTE: Fiberglass repair kit is available through au-
the area where decal will be located. tomotive or marine suppliers. Gelcoat repair kits
For better adhesion a dry application is recom- are available directly to GELCOTE INTERNATION-
mended, however, to ease decal installation a mild AL LTD.
solution of soapy water can be sprayed over sur-
face where decal will be installed.  WARNING
Remove back protective film from decal and align Protect skin, wear gloves when in contact with
decal with marks. When well aligned squeegee resin, hardeners and gelcoat. A barrier skin
decal beginning at center and working outward us- cream may also be used. Do not expose area
ing firm, short, overlapping strokes. to open flame or lit cigarette. Some of the ma-
Remove front protective film once decal has ad- terials are flammable. Protect eyes, wear safety
hered to hull. glasses when grinding, sanding or spraying.
Use a dust mask when sanding or grinding.
INSTALLATION ON PLASTIC When spraying wear a respirator or paint
(storage cover) mask. Always read warning labels on products.
Clean surface with isopropyl alcohol.
Using a pencil and the decal as a template, mark Air Bubbles
Possible cause:
Apply an activator (P/N 293 530 036) to prepare the
– Air pocket trapped between layers of laminate
surface using a clean cloth. After a few seconds,
and gelcoat.
when the activator evaporates, the surface is ready.
CAUTION: Do not use soapy water to locate de- PREPARATION OF SURFACE
cal on plastic parts. Remove all of the damaged gelcoat surrounding
Remove back protective film from decal and care- the air bubble with a putty knife or preferably a
fully align decal with marks. When well aligned carbide grinding tip. Make sure all loose and weak
squeegee decal beginning at center and working areas are completely removed. Sand a small area
outward using firm, short, overlapping strokes. of the gelcoat surface with 220-grit sandpaper. If
needed, sand the cavity itself. These areas must
Remove front protective film once decal has ad- have a rough surface to allow the gelcoat putty to
hered. bond properly.
HULL AND BODY REPAIR FILLING THE CAVITY

The prepared surface must be cleaned with ace-
General tone on a cloth. Use a gelcoat repair kit. Follow the
mixing instructions in the kit when preparing the
Gelcoat is the smooth and durable cosmetic finish
gelcoat putty.
which coats the fiberglass hull and body of a Sea-
Doo watercraft. It also provides a protective barri-
er against water and sun. It consists of a mixture
of resin, pigment (coloring), fillers, monomers and
catalyst which is sprayed into the mold.
SMR2002-049_14_02A.FM 14-02-31
Carefully mix the required amount while making PREPARING THE SURFACES
sure there are no air bubbles in the mixture. With
Small Fractures
a putty knife, fill the repair area and cover with
plastic film. Curing time may depend on tempera- Open the cracks up with a sharp triangular can
ture, amount of putty and percentage of catalyst. opener or preferably a carbide tipped die grinder.
After 2 hours, press lightly on the surface with fin- The V groove will provide a good bonding area for
gers to test the hardness. When the area becomes the gelcoat. With 220-grit sandpaper, sand the
hard, remove the plastic film. sides of the notched out areas.
SANDING Numerous Fractures
Begin block sanding the patch with 320-grit sand- Using a grinder with a 24-grit disk, remove the
paper until you come close to the original surface. gelcoat. Sand the area edge with 220-grit sandpa-
Remove dust with a water soaked cloth and con- per.
tinue sanding with a 400-grit wet paper. Finish wet FILLING THE REPAIR AREA
sanding with a 600-grit to remove deeper scratch-
es. If needed you can wet sand with finer grit pa- Small Fractures
per such as 1000-grit. Refer to the same procedure as in the Air Bubbles.
BUFFING AND WAXING Numerous Fractures Over Large Surface:
Buff the surface using a heavy duty polisher with Prepare the area for spray application of liquid
a buffing pad. Make sure the pad is free of dirt or gelcoat. Wipe down the surface with acetone.
you may damage the gelcoat. Carefully begin buff- Mask the area off to protect the watercraft from
ing with a white medium compound. Finish off us- overspray.
ing a fine compound. While buffing, pay close at-
Mix the needed quantity of gelcoat and catalyst
tention to avoid overheating the surface.
according to suppliers recommendations. The
gelcoat can be thinned with acetone up to 10%. If
Blisters it needs more consistency you can add cabosil.
Possible causes: Make sure that the air supply is free of oil, dirt and
– Insert catalyst. water.
– Improper catalyst/gelcoat ratio. Test spray the gelcoat mixture on paper to verify
A blister is a visible bump on the watercraft surface its consistency and pattern. You may have to apply
that may not necessarily come right through the 5 or 6 coats to cover the area properly. Overlap
gelcoat layer. In the case of only a few blisters, follow each coat further than the last, leaving at least 30
the same repair procedure as for air bubbles. If they seconds between passes. Avoid trying to coat the
are numerous and in close concentration, spray liquid surface with only a few heavy coats, this will not
gelcoat to achieve proper repair. This procedure is allow the gelcoat to dry properly.
covered in Minor Gelcoat Fractures. Apply a coat of polyvinyl alcohol to seal off the air
and protect the gelcoat surface from dust. PVA
Minor Gelcoat Fractures speeds up the curing process because gelcoat will
Possible causes: not cure properly when exposed to air.
– Flexing of fiberglass laminate. SANDING
– Gelcoat thickness. Wash the polyvinyl alcohol off with water. De-
pending on the size of the area repaired, you can
– Direct result of impact.
either block sand as per previous procedure or you
In case of fractures which have not penetrated may use an air sander. Sand the surface down with
past the gelcoat layer, the repair concerns the progressively finer grits of sandpaper until the de-
gelcoat only. If flex cracking or impact are evident, sired finish is achieved.
then additional reinforcement may be necessary.
This subject will be covered in Compound Frac-
tures.
14-02-32 SMR2002-049_14_02A.FM
BUFFING AND WAXING PATCHING THE REPAIR AREA

Buff the surface using a heavy duty polisher with Outside
a buffing pad. Make sure the pad is free of dirt or
The outside should be done first. Wipe clean the
you may damage the gelcoat. Carefully begin buff-
area with acetone on a cloth, then mask off area.
ing with a white medium compound. Finish off us-
For a small crack use an epoxy filler in the same
ing a fine compound. While buffing, pay close at-
way you would use gelcoat repair putty. When lay-
ing up a larger area you will use mat, cloth and
fiberglass resin and hardener. Use a clean contain-
Compound Fractures er to mix the resin, mix only what you will need.
Possible causes: Follow the recommended catalyst ratio.
– Thickness of fiberglass laminate. Using a clean paintbrush, brush the mixed resin on
– Direct result of impact. the surface. Place the smallest piece of mat over
the fracture and then wet out the mat. Follow with
Compound fractures are those that have gone the remaining pieces of mat and final layer of
past the gelcoated surface and in through the lay- cloth. While wetting the pieces make sure you
ers of fiberglass laminate. Two types of repairs work the air bubbles out and saturate all the pieces
have to be performed. The first is to restore the evenly. Try to work quickly, you may only have 15
structural integrity of the damaged area. Fracture or 20 minutes. You may clean the brush with ace-
types can vary from a simple crack to a large hole. tone.
Usually, fiberglass reinforcement becomes neces-
sary, especially if the fracture can be attributed to Wait until the repair has hardened before moving
weakness. The final part of the repair is the on to the interior repair. If the size of the opening
gelcoating, which cannot be done until the interior is too large for the pieces to maintain the proper
and exterior laminate surfaces have been repaired. shape, you will have to use a backing support. It is
a shaped piece of cardboard that fits flush to the
Outside interior surface and has a plastic layer on the repair
Remove the damaged gelcoat and fiberglass with side. It is held in place by tape or a support.
a 24-grit disk using a power sander. Grind outward Inside
at least 2 inches from the fracture to allow the
patch to bond to strong material. Cut enough piec- Wipe down the area with acetone on a cloth. Ap-
es of fiberglass mat necessary to build up the area. ply the same procedure as for outside repair when
The pieces should be cut so they overlap each oth- laminating the alternating pieces of fiberglass ma-
er by at least a half inch. For a smoother finish, the terial. If a backing support was used, remove it
last layer should be fiberglass cloth. If the fracture before starting the repair. After the area has hard-
is small enough all you may have to do is fill the ened, remove sharp edges of material from sur-
area with an epoxy filler. face. If required paint the surface.
Inside SANDING
For the interior repair, you can grind more. This will Outside
allow for more fiberglass material which will This surface will have to be prepared for applica-
strengthen the area. If the fracture opening is too tion of gelcoat. The size of the area will determine
large after surface preparation, you may need a the gelcoating procedure to be used. Refer to the
backing support to cover the opening. Cut alternat- repair procedure for minor gelcoat fractures.
ing pieces of fiberglass mat and cloth in overlap-
ping sizes. BUFFING AND WAXING
Refer to the buffing and waxing for Minor Gelcoat
Fractures.
SMR2002-049_14_02A.FM 14-02-33
TOOLS AND MATERIALS LIST THRU-HULL FITTING

INSTALLATION
Tools
For hull insert repair proceed as follows:
– safety glasses
Cut plastic hull insert flush with hull using a saw.
– air mask
– white cloths
– sanding block 1
– putty knife
– plastic film
– stirring stick
– cover sheets (for Sea-Doo)
– scissors
– buffing pad
– heavy-duty polisher
– power sander
F01L2UA 2
– paint brush
1. Hull
– plastic container (mixing) 2. Plastic hull insert
– spray gun Mix epoxy glue (3M-05895), follow manufacturer

– plastic squeegee. instructions.
Apply epoxy glue on aluminum insert (P/N 292 000
Materials 075) knurled surface and on plastic insert inner
– fiberglass mat bore.
– fiberglass cloth CAUTION: If you notice any clearance between
plastic insert and aluminum insert, fill gap with
– polyester resin epoxy glue to obtain good adhesion of alumi-
– cardboard num insert.
– masking tape 1
– sandpaper (100-grit, 220-grit, 320-grit, 400-grit,
600-grit, 1000-grit)
– 24-grit sanding disks
– gelcoat putty
– liquid gelcoat
– acetone
– cabosil
– epoxy filler
– medium compound (white)
– fine compound (white) 2
F01L2VA
– wax.
1. Knurled surface
2. Inner bore
14-02-34 SMR2002-049_14_02A.FM
Install aluminum insert into plastic hull insert.

NOTE: Align aluminum insert as much as possible
with PTO flywheel.
1
F01L2WA
1. Aluminum insert
NOTE: The epoxy glue curing time is 30 minutes.
SMR2002-049_14_02A.FM 14-02-35
Section 15 TECHNICAL DATA
Subsection 01 (GTI AND GTI LE MODELS)
GTI AND GTI LE MODELS 0

ENGINE GTI GTI LE
Engine type BOMBARDIER-ROTAX 717
Induction type Rotary valve
Type Water cooled, water injected
Water injection fitting
3.5 mm (.139 in)
Exhaust system (head)
3.5 mm (.139 in)
(cone)
Starting system Electric start
Fuel/oil mixture VROI (Variable Rate Oil Injection)
Lubrication Oil injection pump Gear driven
Oil injection type BOMBARDIER-ROTAX (mineral based)
Number of cylinders 2
Standard 82 mm (3.228 in)
Bore First oversize 82.25 mm (3.238 in)
Second oversize 82.50 mm (3.248 in)
Stroke 68 mm (2.677 in)
Displacement 718.2 cm³ (43.81 in³)
Corrected compression ratio 6.2: 1
Cylinder head volume 42.4 ± 0.4 cc
Cylinder head warpage (maximum) 0.05 mm (.002 in)
Piston ring type and quantity 1 semi-trapez — 1 rectangular
New 0.25 - 0.40 mm (.010 - .016 in)
Ring end gap
Wear limit 1.00 mm (.039 in)
Ring/piston groove New 0.025 - 0.070 mm (.001 - .003 in)
clearance Wear limit 0.2 mm (.008 in)
Piston/cylinder New (minimum) 0.10 mm (.0039 in)
wall clearance Wear limit 0.20 mm (.008 in)
Cylinder taper (maximum) 0.10 mm (.004 in)
Cylinder out of round (maximum) 0.080 mm (.003 in)
Connecting rod big end New 0.311 - 0.677 mm (.012 - .027 in)
axial play Wear limit 1.2 mm (.047 in)
Crankshaft deflection MAG: 0.050 mm (.002 in); PTO: 0.030 mm (.001 in)
Opening 147° ± 5 BTDC
Rotary valve timing
Closing 65.5° ± 5 ATDC
Rotary valve duration 159°
Rotary valve/cover clearance 0.25 - 0.35 mm (.010 - .014 in)
Connecting rod/ New 0.020 - 0.033 mm (.0008 - .0013 in)
crankshaft pin radial
piston pin radial clearance Wear limit 0.015 mm (.00059 in)
ADDITIONAL INFORMATION:
SMR2002-050_15_01A.FM 15-01-1
ELECTRICAL GTI GTI LE

Magneto generator output 160 W @ 6000 RPM
Ignition system type Digital CDI
Make and type NGK BR8ES
Spark plug
Gap 0.4 - 0.5 mm (.016 - .020 in)
mm (in) 2.59 (.102)
Ignition timing (BTDC)
Degrees 20° ± 1.5 ➀
Generating coil 40 - 76 Ω
Battery charging coil 0.05 - 0.6 Ω
Primary 0.34 - 0.62 Ω
Ignition coil
Secondary 9 - 15 kΩ
Engine rev limiter setting 7100 ± 50 RPM
Battery 12 V, 19 A•h (Yuasa/Exide)
MPEM 5A
Fuse Main electrical system 15 A
Charging system 15 A
ADDITIONAL INFORMATION: ➀ Engine cold @ 6000 RPM.
CARBURETION GTI GTI LE

Type Mikuni BN-40i diaphragm, fuel accelerator pump
Carburetor
Quantity 1
Main jet 167.5
Pilot jet 75
Spring 130 g (4.6 oz) 115 g (4.1 oz)
Low-speed screw 1 turn ± 1/4
High-speed screw 0
Adjustment
Idle speed (in water) 1500 ± 100 RPM
Idle speed (out of water) 3000 RPM
Type Regular unleaded gasoline
Fuel
Minimum octane no. 87
Fuel return line orifice 0.8 mm (.031 in)
COOLING GTI GTI LE

Type Open circuit — Direct flow from jet propulsion unit
Thermostat Not applicable
Monitoring beeper setting 86 - 94°C (187 - 201°F)
15-01-2 SMR2002-050_15_01A.FM
PROPULSION GTI GTI LE

Propulsion system BOMBARDIER Formula Pump
Jet pump type Axial flow single stage
Impeller rotation (seen from rear) Counterclockwise
Transmission Direct drive
Coupling type Crown splines
SEA-DOO JET PUMP SYNTHETIC
Oil type
POLYOLESTER OIL 75W90 GL5
Steering nozzle pivoting angle 20°
Minimum required water level 90 cm (35 in)
Drive shaft deflection (maximum) 0.5 mm (.020 in)
Impeller outside diameter 155.3 mm (6.114 in)
Impeller/wear ring New 0.0 - 0.4 mm (.000 - .016 in)
Impeller shaft end play (new) 0
Impeller shaft radial play 0.05 mm (.002 in)
Impeller pitch/material Progressive pitch/stainless steel
ADDITIONAL INFORMATION: Do not mix different brands or oil types.
DIMENSIONS GTI GTI LE

Number of passenger (driver included) 3
Overall length 307 cm (121 in)
Overall width 120 cm (47 in)
Overall height 104 cm (41 in)
Dry weight 272 kg (600 lb)
Load limit (passenger and 10 kg (22 lb) luggage) 243 kg (536 lb)
CAPACITIES GTI GTI LE

Fuel tank (including reserve) 56.5 L (15 U.S. gal)
Fuel tank reserve 11.4 L (3 U.S. gal)
Oil injection reservoir 6 L (1.6 U.S. gal)
Jet pump impeller shaft Capacity 115 mL (3.88 U.S. oz)
reservoir Oil level height Up to plug
SMR2002-050_15_01A.FM 15-01-3
MATERIALS GTI GTI LE

Hull Composite
Inlet grate Aluminum
Impeller housing/stator/venturi/nozzle Plastic/plastic/aluminum/aluminum
Air intake silencer Thermoplastic
Flame arrester Multi-layer wire screen
Steering padding Thermoplastic
Fuel tank Polyethylene
Oil injection reservoir Polyethylene
Seat Polyurethane foam
PERFORMANCE GTI GTI LE

Estimated pump power 25.2 kW (34 HP)
Maximum fuel consumption at wide open throttle 33.5 L/h (8.8 U.S. gal/h)
Cruising time at full Fuel tank without reserve 1.21 hour
throttle Fuel tank reserve 21 minutes
15-01-4 SMR2002-050_15_01A.FM
Subsection 02 (GTX RFI MODEL)
GTX RFI MODEL 0

ENGINE GTX RFI
Induction type Rotary valve
Type Water cooled, water injected with regulator
Water injection fitting (head) 3.5 mm (.139 in)
Exhaust system Water injection fitting (cone) Not applicable
(muffler) 3.5 mm (.139 in)
Exhaust valve Rotax Adjustable Variable Exhaust (RAVE)
Lubrication Oil injection pump Direct driven
Oil injection type BOMBARDIER Formula XP-S II (synthetic)
Second oversize Not applicable
Stroke 74 mm (2.91 in)
Displacement 781.6 cm³ (47.7 in³)
Cylinder head warpage (maximum) 0.05 mm (.002 in)
Piston ring type and quantity 1 semi-trapez — 1 rectangular
New 0.40 - 0.55 mm (.016 - .022 in)
Ring end gap
New 0.025 - 0.070 mm (.001 - .003 in)
Ring/piston groove
Piston/ New (minimum) 0.13 mm (.005 in)
cylinder wall clearance Wear limit 0.22 mm (.009 in)
Opening 147° ± 5° BTDC
Rotary valve timing
Closing 63.5° ± 5° ATDC
Rotary valve duration 159°
Rotary valve/cover clearance 0.25 - 0.35 mm (.010 - .014 in)
piston pin radial
SMR2002-050_15_02A.FM 15-02-1
ELECTRICAL SYSTEM GTX RFI

Ignition system type Digital, inductive type
Spark plug
Gap 0.4 - 0.5 mm (.016 - .020 in)
mm (in) 1.02 (.040)
Degrees 12°± 1.0 (fixed timing mode at any RPM)
Battery charging coil 0.1 Ω - 1 Ω
Primary 0.3 Ω ± 0.6 Ω
Ignition coil
Secondary Not applicable
MPEM 5A
Main electrical system 20 A
Fuses Battery 15 A
VTS Not applicable
Info center 1A
Fuel pump 10 A
FUEL SYSTEM GTX RFI

Rotax Fuel Injection, semi-direct,
Fuel injection type single throttle body (56 mm)
Throttle Position Sensor (TPS) 1.6 kΩ - 2.4 kΩ (terminals 1-2)
710 Ω - 1380 Ω (terminals 2-3)
Crankshaft Position Sensor (CPS) 774 Ω - 946 Ω
Air Temperature Sensor (ATS) 2.280 kΩ - 2.74 kΩ
Water Temperature Sensor (WTS) 2.280 kΩ - 2.74 kΩ
Air Pressure Sensor (APS) 3.4 kΩ and 8.2 kΩ (terminals 9-2)
2.4 kΩ and 8.2 kΩ (terminals 1-2)
RAVE solenoid 30 Ω
Fuel injector 2.4Ω ± 0.1 Ω
Fuel
COOLING GTX RFI

15-02-2 SMR2002-050_15_02A.FM
PROPULSION GTX RFI

Oil type
DIMENSIONS GTX RFI

Number of passenger (driver incl.) 3
CAPACITIES GTX RFI

Fuel tank reserve (from low level signal) 11.4 L (3 U.S. gal)
SMR2002-050_15_02A.FM 15-02-3
MATERIALS GTX RFI

Hull Composite
Impeller housing/stator/venturi/nozzle Plastic/plastic/plastic/aluminum
Flame arrester Multi-layer wire screen
PERFORMANCE GTX RFI

Estimated pump output 30.6 kW (41 HP)
Maximum fuel consumption at wide open throttle 41.5 L/h (11 U.S. gal/h)
Cruising time at full Fuel tank without reserve 1 hour 5 minutes
15-02-4 SMR2002-050_15_02A.FM
Subsection 03 (XP MODEL)
XP MODEL 0
ENGINE XP
Induction type Reed valve
3.5 mm (.139 in)
(head)
Exhaust system Water injection fitting
Not applicable
(cone)
3.5 mm (.139 in)
(muffler)
Stroke 78.20 mm (3.079 in)
Displacement 951.2 cm³ (58 in³)
Cylinder head warpage (maximum) 0.10 mm (.0039 in) total
Piston ring type and quantity 2 semi-trapez
New 0.45 - 0.60 mm (.018 - .024 in)
Ring end gap
New 0.048 - 0.075 mm (.002 - .003 in)
Ring piston groove
Piston/cylinder wall New (minimum) 0.09 mm (.0035 in)
Opening Not applicable
Rotary valve timing
Closing Not applicable
Rotary valve duration Not applicable
Rotary valve/cover clearance Not applicable
Connecting rod/crankshaft New 0.017 - 0.034 mm (.0006 - .0013 in)
pin radial clearance Wear limit 0.050 mm (.002 in)
SMR2002-050_15_03A.FM 15-03-1
ELECTRICAL XP
Ignition system type Digital DC-CDI
Spark plug
Gap 0.4 - 0.5 mm (.016 - .020 in)
mm (in) 2.99 (.118)
Degrees 20° ± 1 @ 3500 RPM
Battery charging coil 0.1 - 1 Ω
Trigger coil 190 - 300 Ω
Primary 0.33 - 0.62 Ω
Ignition coil
Secondary 8.4 - 15.6 k Ω
MPEM 5A
Fuses Charging system 15 A
VTS system 7.5 A
Bilge pump 3A
CARBURETION XP
Type Mikuni BN-46i (diaphragm), fuel accelerator pump
Carburetor
Quantity 2
Main jet MAG and PTO: 162.5
Pilot jet 75
Spring 95 g
Low-speed screw 1-1/2 turn ± 1/4
High-speed screw 0
Adjustment
Fuel
Fuel return line orifice MAG and PTO: 0.8 mm (.031 in)
COOLING XP
15-03-2 SMR2002-050_15_03A.FM
PROPULSION XP
Coupling type Split FR and RR rubber coupling
Oil type
DIMENSIONS XP
CAPACITIES XP
Fuel tank (including reserve) 54 L (14 U.S. gal)
Fuel tank reserve 10 L (2.6 U.S. gal)
SMR2002-050_15_03A.FM 15-03-3
MATERIALS XP
Hull Composite
Flame arrester Tubular wire screen
PERFORMANCE XP
Estimated pump output 53.1 kW (71.1 HP)
Maximum fuel consumption at wide open throttle 55 L/h (14.5 U.S. gal/h)
Cruising time at full Fuel tank without reserve 48 minutes
15-03-4 SMR2002-050_15_03A.FM
Subsection 04 (RX DI MODEL)
RX DI MODEL 0
RX DI RX DI
ENGINE
(5591/5592) (5583/5584/5585/5586)
Engine type Bombardier-Rotax 947 DI Bombardier-Rotax 947 DI LE
3.5 mm (.139 in)
(head)
Not applicable
(cone)
3 mm (.118 in)
(muffler)
Stroke 78.20 mm (3.079 in)
Corrected compression ratio 6.1: 1 6.0: 1
Cylinder head volume 51.4 ± 0.6 cc 50.76 ± 0.6 cc
New 0.55 - 0.70 mm (.022 - .028 in)
Ring end gap
New 0.044 - 0.089 mm (.002 - .004 in)
Ring piston groove
MAG side: 0.050 mm (.002 in);
Crankshaft deflection
PTO side: 0.030 mm (.001 in)
Rotary valve timing
SMR2002-050_15_04A.FM 15-04-1
RX DI RX DI
ENGINE
(5591/5592) (5583/5584/5585/5586)
New
Connecting rod/piston 0.001 - 0.014 mm (.000039 - .00055 in)
pin radial clearanceWear limit 0.017 mm (.00067 in)
Type Piston
Displacement 43 cm³ (2.6 in³)
Air compressor Drive Balancing shaft
Intake side Reed valves
Exhaust side Reed valves
RX DI RX DI
ELECTRICAL
(5591/5592) (5583/5580/5581/5582)
Ignition system type Digital inductive
Make and type NGK ZFR4F
Spark plug
Gap 1.1 mm (.04 in)
5.39 mm (.212 in) (direct) measured
mm (in) through direct injector hole 7.87 (.310) (indirect)
Ignition timing (BTDC) measured through spark plug hole
Degrees 27° ± 1.5 @ 1450 RPM
Generating coil Not applicable
Trigger coil Not applicable
Primary 0.45 - 0.55 Ω
Ignition coil
Secondary 6.84 - 10.2 k Ω without high tension leads
MPEM Not applicable
VTS system 7.5 A
Fuses
Battery 25 A
Info center 2A
Fuel pump 15 A
Injection 15 A
15-04-2 SMR2002-050_15_04A.FM
RX DI RX DI
FUEL SYSTEM
(5591/5592) (5583/5580/5581/5582)
Fuel injection type Orbital Direct Fuel Injection, twin throttle body (46 mm)
Throttle Position Sensor (TPS) 1.6 kΩ - 2.4 kΩ (terminals 3-4)
710 Ω - 1380 Ω (terminals 4-11)
Manifold Air Temperature Sensor (MATS) 2.280 kΩ - 2.74 kΩ
Exhaust Gas Temperature Sensor (EGT) 2.280 kΩ - 2.74 kΩ
Manifold Air Pressure Sensor (MAPS)
Knock sensor (KS) 5 MΩ
Fuel injector 1.7 Ω - 1.9 Ω
Direct injector 1.0 Ω - 1.6 Ω
Premium unleaded Regular unleaded
Type gasoline gasoline
Fuel
Minimum octane no. 91 87
Fuel return line orifice Not applicable
COOLING RX DI RX DI
(5591/5592) (5583/5580/5581/5582)
Monitoring beeper setting 86 - 94°C (187 - 201°F) 75 - 80°C (167 - 176°F)
SMR2002-050_15_04A.FM 15-04-3
RX DI RX DI
PROPULSION
(5591/5592) (5583/5580/5581/5582)
Propulsion system BOMBARDIER Formula pump
Oil type
Impeller/ New 0.0 - 0.4 mm (.000 - .016 in)
wear ring clearance Wear limit 1.00 mm (.040 in)
RX DI RX DI
DIMENSIONS
(5591/5592) (5583/5580/5581/5582)
RX DI RX DI
CAPACITIES
(5591/5592) (5583/5580/5581/5582)
Fuel tank reserve 9.8 L (2.6 U.S. gal) from low level signal
Capacity
Jet pump impeller shaft 115 mL (3.88 U.S. oz)
15-04-4 SMR2002-050_15_04A.FM
RX DI RX DI
MATERIALS
(5591/5592) (5583/5580/5581/5582)
Hull Composite
RX DI RX DI
PERFORMANCE
(5591/5592) (5583/5580/5581/5582)
Estimated pump output 50.2 kW (67 HP)
Cruising time at full Fuel tank without reserve 1 hour
SMR2002-050_15_04A.FM 15-04-5
Subsection 05 (LRV DI MODEL)
LRV DI MODEL 0
ENGINE LRV DI
Engine type BOMBARDIER-ROTAX 947 DI LE
Exhaust system
Water injection fitting (cone) Not applicable
Water injection fitting (muffler) 3 mm (.118 in)
Stroke 78.20 mm (3.079 in)
New 0.55 - 0.7 mm
Ring end gap (.022 - .028 in)
Ring/piston groove New 0.044 - 0.089 mm (.002 - .004 in)
Connecting rod big New 0.390 - 0.737 mm (.015 - .029 in)
end axial play Wear limit 1.2 mm (.047 in)
MAG side: 0.050 mm (.002 in);
Crankshaft deflection PTO side: 0.030 mm (.001 in)
Rotary valve timing
SMR2002-050_15_05A.FM 15-05-1
ENGINE LRV DI
piston pin radial
Type Piston
ELECTRICAL LRV DI
Ignition system type Digital Inductive
Spark plug
Gap 1.1 mm (.04 in)
5.39 mm (.212 in) (direct) measured
mm (in) through direct injector hole 7.87 (.310) (indirect)
Ignition timing (BTDC) measured through spark plug hole
Degrees 27° ± 1.5 @ 1450 RPM
Primary 0.45 - 0.55 Ω
Ignition coil
Secondary 6.84 - 10.2 kΩ without high tension leads
VTS system Not applicable
Fuses Battery 25 A
Info center 2A
Fuel pump 15 A
Injection 15 A
15-05-2 SMR2002-050_15_05A.FM
FUEL SYSTEM LRV DI

Fuel injection type Orbital Direct Fuel Injection, twin throttle body
(46 mm (1.81 in))
1.6 kΩ - 2.4 kΩ (terminals 3-4)
Throttle Position Sensor (TPS)
710 Ω - 1380 Ω (terminals 4-11)
Manifold Air Temperature Sensor (MATS) 2.280 kΩ - 2.74 kΩ
Exhaust Gas Temperature Sensor (EGT) 2.280 kΩ - 2.74 kΩ
Manifold Air Pressure Sensor (MAPS) 2.4 kΩ and 8.2 kΩ (terminals 1-2)
Knock Sensor (KS) 5 MΩ
Fuel injector 1.7 Ω - 1.9 Ω
Direct injector 1.0 Ω - 1.6 Ω
Fuel
Fuel return line orifice Not applicable
COOLING LRV DI
SMR2002-050_15_05A.FM 15-05-3
PROPULSION LRV DI
Oil type POLYOLESTER OIL 75W90 GL5
Impeller shaft side play 0.05 mm (.002 in)
DIMENSIONS LRV DI
Overall height 108 cm (42.5 in)
CAPACITIES LRV DI
Fuel tank (including reserve) 95 L (25 U.S. gal)
Fuel tank reserve 19 L (5.0 U.S. gal) (from low level signal)
15-05-4 SMR2002-050_15_05A.FM
MATERIALS LRV DI
Hull Composite
PERFORMANCE LRV DI
Estimated pump power 50.2 kW (67.3 HP)
Fuel tank without reserve 1 hour
Cruising time at full
throttle Fuel tank reserve
(from low level signal) 12 minutes
SMR2002-050_15_05A.FM 15-05-5
Subsection 06 (GTX AND RX MODELS)
GTX AND RX MODELS 0

ENGINE GTX RX
3.5 mm (.139 in) 3 mm (.118 in)
(head)
Not applicable
(cone)
3.5 mm (.139 in)
(muffler)
Stroke 78.20 mm (3.079 in)
New 0.45 - 0.60 mm (.018 - .024 in)
Ring end gap
New 0.048 - 0.075 mm (.002 - .003 in)
Ring piston groove
New (minimum) 0.09 mm (.0035 in)
Piston/cylinder wall clearance
New 0.390 - 0.737 mm (.015 - .029 in)
Connecting rod big end axial play
Crankshaft deflection MAG side: 0.050 mm (.002 in); PTO side: 0.030 mm (.001 in)
Rotary valve timing
crankshaft pin radial clearance Wear limit 0.050 mm (.002 in)
SMR2002-050_15_06A.FM 15-06-1
ELECTRICAL GTX RX
Ignition system type Digital DC-CDI
Spark plug
Gap 0.4 - 0.5 mm (.016 - .020 in)
mm (in) 2.99 (.118)
Degrees 20° ± 1 @ 3500 RPM
Trigger coil 190 - 300 Ω
Primary 0.33 - 0.62 Ω
Ignition coil
Secondary 8.4 - 15.6 k Ω
MPEM 5A
Fuses
VTS system Not applicable 7.5 A
CARBURETION GTX RX
Type Mikuni BN-46i (diaphragm), fuel accelerator pump
Carburetor
Quantity 2
Main jet MAG and PTO: 162.5
Pilot jet 75
Spring 95 g
Low-speed screw 1-1/2 turn ± 1/4
High-speed screw 0
Adjustment
Fuel
Fuel return line orifice MAG and PTO: 0.8 mm (.031 in)
COOLING GTX RX
15-06-2 SMR2002-050_15_06A.FM
PROPULSION GTX RX
Oil type
DIMENSIONS GTX RX
Number of passenger (driver incl.) 3 2
Overall length 315 cm (124 in) 285 cm (112 in)
Overall width 122 cm (48 in) 120 cm (47 in)
Dry weight 301 kg (664 lb) 275 kg (606 lb)
Load limit (passenger and 10 kg (22 lb) luggage) 243 kg (536 lb) 181 kg (400 lb)
CAPACITIES GTX RX
Fuel tank reserve 11.4 L (3 U.S. gal)
SMR2002-050_15_06A.FM 15-06-3
MATERIALS GTX RX
Hull Composite
PERFORMANCE GTX RX
Estimated pump output 51 kW (68 HP)
Cruising time at full Fuel tank without reserve 49 minutes
15-06-4 SMR2002-050_15_06A.FM
Section 16 WIRING DIAGRAMS
Subsection 01 (WIRING DIAGRAMS)
WIRING DIAGRAMS 0
WIRE COLOR CODES CAUTION: Do not apply dielectric grease on con-
tacts inside plug connector.
First color of a wire is the main color. Second color
To remove wire contacts from housing, proceed
is the tracer.
as follows:
Example: YELLOW/BLACK (YL-BK) is a YELLOW
– Using a long nose pliers, pull out the lock.
wire with a BLACK tracer.
WIRE DIGIT CODES

First number indicates in which connector the
wire is plugged in.
Second number indicates the position of the wire
in the connector.
The letter at the end of the number (if applicable)
indicates a common circuit in the MPEM printed
circuit with another wire bearing the same letter.
Example: 2-18 (g)
The first number indicates that the wire is posi-
tioned in the connector no. 2 of the MPEM.
The second number indicates that the wire is po-
sitioned in the terminal no. 18.
The letter (g) indicates a common circuit with an-
other wire(s) bearing the same letter (g) in the cir- V01G0OA 1
cuit.
FEMALE HOUSING
1. Female lock
DEUTSCH CONNECTORS
Deutsch connectors are used to connect wiring
harness to magneto, and to electrical box (some
models) and to the VCK on DI Models.
3 1
3
2
4
F00H1CA
1. Male housing V01G0PA 1

2. Female housing
3. Secondary lock MALE HOUSING
4. Sealing cap 1. Male lock
SMR2002-051_16_01A.FM 16-01-1
NOTE: Before extraction, push wire forward to re- PACKARD CONNECTOR

lieve pressure on retaining tab.
Packard connectors are used to connect electrical
– Insert a 4.8 mm (.189 in) wide screwdriver
harnesses and gauges.
blade inside the front of the contact cavity.
– Pry back the retaining tab while gently pulling
wire back until contact is removed.
C B A
F04H45A
VIEW OF A 3-POSITION PACKARD CONNECTOR

1. Identification letters
To remove terminal from Packard connector hous-

V01G0QA 1 ing, use Snap-on TT600-4 tool.
FEMALE CONNECTOR HOUSING
1. Retaining tab
To install: F01B1JA
– For insertion of signal contact, make sure the

lock is removed.  WARNING
– Insert contact into appropriate circuit cavity and Ensure all terminals are properly crimped on
push as far as it will go. wires and connector housings are properly fas-
– Pull back on the contact wire to be sure the re- tened.
tention fingers are holding the contact.
– After all required contacts have been inserted, AMP PLUG CONNECTOR
the lock must be installed.
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.
1 1
F04H6LA
1. Wire identification numbers
16-01-2 SMR2002-051_16_01A.FM
Description
5
7 4
1
F00H11A
3
1. Apply a thin coat of DEOXIT contact lubricant
89 CAUTION: Do not apply lubricant excessively.

F00H0WB 6 Care must be taken so that the lubricant will not
AMP PLUG CONNECTOR come in contact with the mating seal; the seal
1. Plug assembly may loose its sealing capacities. Do not apply
2. Cover assembly
3. Mating seal lubricant on contacts inside plug connector.
4. Wedge lock
5. Header assembly Each plug assembly is mechanically keyed to mate
6. Seal plug only with identical mechanical keyed header on
7. Power wire
8. Signal wire the MPEM.
9. Locking tab
Removal
To remove the plug connector from the header as-
sembly, press both tabs and pull plug.
F00H0NA
Step 1 : Press tabs (both sides)

Step 2 : Pull plug
Installation F00H12A 1
Apply a thin coat of DEOXIT contact lubricant (P/N 1. Mechanically keyed
293 550 015) to the pins of the header on the
MPEM only.
SMR2002-051_16_01A.FM 16-01-3
Contact Removal While rotating the wire back and forth over a half
turn (1/4 turn in each direction), gently pull the wire
SIGNAL WIRE until the contact is removed.
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
CAUTION: The wedge lock should never be re-
moved from the connector for insertion or re- 2
moval of the signal wire contacts.
1 2
F00H0QA
1. Rotate wire back and forth

2. Pull wire
POWER WIRE CONTACT

NOTE: The wedge lock must be removed to ex-
tract power contact.
F00H0OA
Open the wedge lock.
1. Screwdriver between wedge lock and connector
Pull both locking tabs and remove wedge lock
2. Locking tab from plug assembly.
Repeat the same steps for the other locking tab 1
retaining the wedge lock.
The wedge lock is now in the open position.
F00H0RA
F00H0PA
1. Pull locking tab (both sides)
1. Wedge lock opened
16-01-4 SMR2002-051_16_01A.FM
Before extraction, push wire forward to relieve pres-

sure on retaining tab.
Insert a 4.8 mm (.189 in) wide screwdriver blade
inside the front of the contact cavity.
F00B0EA
CRIMPING TOOL (P/N 295 100 164)
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 cavi-
ties be sealed with a seal plug, even if they are not
pierced.
1
F00H0ZA
Pry back the retaining tab while gently pulling wire

back until contact is removed.
Contact Crimping
The size of the wires must be 20 to 16 AWG with
a wire insulation diameter having a minimum di-
mension of 1.7 mm (.067 in) and a maximum di-
mension of 2.78 mm (.106 in).
The wire strip length 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 F00H10A 2
insulation. If these marks occur at the location of
the wire seal, leakage may result. Insulation sur- 1. Seal plug
2. Wire seal
face within 25 mm (1 in) from the tip of the con-
tact must be smooth. CAUTION: Do not pierce the diaphragm with a
All contacts in AMP plug connectors must be sharp point for electrical troubleshooting. The
crimped using the crimping tool (P/N 295 100 164). resulting pinholes in the insulation will allow
moisture to penetrate the system and possibly
CAUTION: If contacts are not crimped using the result in system failure.
proper crimping tool, the wire seal may be dam-
aged.
SMR2002-051_16_01A.FM 16-01-5
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 reten-
tion fingers in the housing are holding the contact
F12H10A
properly.
DEUTSCH JOINT CONNECTOR TOOL (NO. 114010)
After all required contacts have been inserted, the
wedge lock must be closed to its locked position.
MAIN FUSE HOLDER JOINT

CONNECTOR
DI Models
The fuse holder is located in the rear electrical box. 2 1
F12H11A
1. Hold the insulator

2. Push the tool until it bottoms
F12H0ZA 1
1. Main fuse holder joint connector
NOTE: In the following illustrations, the joint insu- F12H12A 1 2

lator has been removed for clarity purpose only. It
1. While holding tool pressure, pull wire until terminal releases
is not necessary to remove it to separate the joint. 2. Joint connector
The same procedure is to be used each side of the
joint. For installation, simply push the wire in the con-
nector. You should hear a locking “click”. Try to
Insert the Deutsch joint connector tool (no. 114010) pull the wire out to ensure terminal is properly
on the wire and push tool toward the joint to re- locked. If not, remove the wire and bend the tabs
lease it. While holding the joint insulator, push the inside the joint connector to allow proper locking.
tool until it bottoms. It is now unlocked. Maintain- Recheck.
ing the pressure with the tool, pull the wire out.
16-01-6 SMR2002-051_16_01A.FM
2002 GTI MODEL
2002 GTI MODEL
F17Z01
SMR2002-051_16_00A.FM
2002 GTI LE MODEL
2002 GTI LE MODEL
F11Z02
SMR2002-051_16_00A.FM
2002 GTX MODEL
2002 GTX MODEL
F07Z01
SMR2002-051_16_00A.FM
2002 GTX RFI MODEL
2002 GTX RFI MODEL
F15Z04
SMR2002-051_16_00A.FM
2002 XP MODEL
2002 XP MODEL
F08Z02
SMR2002-051_16_00A.FM
2002 RX MODEL
2002 RX MODEL
F16Z03
SMR2002-051_16_00A.FM
2002 RX DI MODEL
2002 RX DI MODEL
F16Z04
SMR2002-051_16_00A.FM
2002 LRV DI MODEL
2002 LRV DI MODEL
A
B
BATT. 25A
REG. 25A
BILGE 3A
ACC. 2A
FP 15A
RE
INJ.
RE-PU
GY-RE
N
W E
S
GY-RE
F11Z02
SMR2002-051_16_00A.FM
2002
Shop Manual
Volume 2
GTX DI, GTX 4-TEC

TABLE OF CONTENTS
SECTION SUBSECTION PAGE
SAFETY NOTICE .................................................................................................................................. III
INTRODUCTION ................................................................................................................................... IV
01 SERVICE TOOLS 01 - Table of contents ...................................................................... 01-01-1

AND PRODUCTS 02 - Mandatory service tools............................................................ 01-02-1
03 - Optional service tools................................................................ 01-03-1
04 - Service products ....................................................................... 01-04-1
02 MAINTENANCE 01 - Table of contents ...................................................................... 02-01-1
02 - Periodic inspection chart ........................................................... 02-02-1
03 - Flushing and lubrication............................................................. 02-03-1
04 - Water-flooded engine................................................................ 02-04-1
05 - Storage...................................................................................... 02-05-1
03 TROUBLESHOOTING 01 - Troubleshooting chart ............................................................... 03-01-1
04 ENGINE (DI) 01 - Table of contents ...................................................................... 04-01-1

02 - Leak test ................................................................................... 04-02-1
04 - Magneto system ....................................................................... 04-04-1
05 - Top end ..................................................................................... 04-05-1
06 - Bottom end ............................................................................... 04-06-1
07 - Exhaust system......................................................................... 04-07-1
05 ENGINE (4-TEC) 01 - Table of contents ...................................................................... 05-01-1
02 - Leak test ................................................................................... 05-02-1
03 - Intake system............................................................................ 05-03-1
04 - Exhaust system......................................................................... 05-04-1
06 - PTO housing/Magneto .............................................................. 05-06-1
07 - Lubrication................................................................................. 05-07-1
08 - Cylinder head and valves........................................................... 05-08-1
09 - Engine block.............................................................................. 05-09-1
MANAGEMENT (DI) 02 - Overview................................................................................... 06-02-1
03 - Component inspection and adjustment .................................... 06-03-1

MANAGEMENT 02 - Overview................................................................................... 07-02-1
(4-TEC) 03 - Component inspection and adjustment .................................... 07-03-1
08 COOLING SYSTEM 01 - Table of contents ...................................................................... 08-01-1

02 - Circuit, components and care ................................................... 08-02-1
09 FUEL SYSTEM 01 - Table of contents ...................................................................... 09-01-1

02 - Fuel circuit................................................................................. 09-02-1
03 - Air intake (DI)............................................................................. 09-03-1
10 LUBRICATION 01 - Table of contents ...................................................................... 10-01-1

SYSTEM (DI) 02 - Oil injection system................................................................... 10-02-1
03 - Oil injection pump ..................................................................... 10-03-1
SMR2002-053_00A2.FM I
TABLE OF CONTENTS
11 ELECTRICAL 01 - Table of contents ...................................................................... 11-01-1

SYSTEM 02 - Charging system....................................................................... 11-02-1
03 - Starting system......................................................................... 11-03-1
04 - Instruments and accessories.................................................... 11-04-1
12 PROPULSION 01 - Table of contents ...................................................................... 12-01-1

SYSTEM 02 - Jet pump................................................................................... 12-02-1
03 - Drive system............................................................................. 12-03-1
04 - Reverse system........................................................................ 12-04-1
13 STEERING 01 - Table of contents ...................................................................... 13-01-1

SYSTEM 02 - Steering system........................................................................ 13-02-1
03 - Alignment ................................................................................. 13-03-1
14 HULL/BODY 01 - Table of contents ...................................................................... 14-01-1

02 - Adjustment and repair .............................................................. 14-02-1
15 TECHNICAL DATA 01 - GTX DI model ........................................................................... 15-01-1

02 - GTX 4-TEC model ..................................................................... 15-02-1
16 WIRING DIAGRAMS 01 - Wiring diagrams........................................................................ 16-01-1
II SMR2002-053_00A2.FM
SAFETY NOTICE
SAFETY NOTICE 0
This manual has been prepared as a guide to correctly service and repair 2002 SEA-DOO watercraft. See
model list below.
This edition was primarily published to be used by watercraft mechanical technicians who are already
familiar with all service procedures relating to Bombardier made watercraft. Mechanical technicians
should attend training courses given by Bombardier Training Dept.
Please note that the instructions will apply only if proper hand tools and special service tools are used.
This Shop Manual uses technical terms which may be slightly different from the ones used in the Parts
Catalog.
It is understood that this manual may be translated into another language. In the event of any discrepancy,
the English version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at time of writing. Service
and Warranty Bulletins may be published to update the content of this manual. Make sure to read and
understand these.
In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the
general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas
of the parts.
The use of Bombardier parts is most strongly recommended when considering replacement of any com-
ponent. Dealer and/or distributor assistance should be sought in case of doubt.
The engines and the corresponding components identified in this document should not be utilized on
product(s) other than those mentioned in this document.
Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking tab,
self-locking fasteners, etc.) must be installed or replaced with new ones. If the efficiency of a locking
device is impaired, it must be renewed.
This manual emphasizes particular information denoted by the wording and symbols:
 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 vehicle components.
NOTE: Indicates supplementary information needed to fully complete an instruction.
Although the mere reading of such information does not eliminate the hazard, your understanding of the
information will promote its correct use. Always use common shop safety practice.
Bombardier Inc. disclaims liability for all damages and/or injuries resulting from the improper use of the
contents. We strongly recommend that any services be carried out and/or verified by a highly skilled
professional mechanic. It is understood that certain modifications may render use of the vehicle illegal
under existing federal, provincial and state regulations.
SMR2002-053_00A2.FM III
INTRODUCTION
INTRODUCTION 0
This Shop Manual covers the following BOMBAR- HULL IDENTIFICATION NUMBER
DIER made SEA-DOO® 2002 watercraft models.
(H.I.N.)
ENGINE MODEL It is located on footboard at the rear of watercraft.
MODELS
TYPE NUMBER
GTX DI and GTX 4-TEC
GTX DI International
947 DI 5563
(green)
GTX DI (green) 947 DI 5564
GTX 4-TEC International
1503 5573
(red)
GTX 4-TEC (red) 1503 5574
GTX 4-TEC International
1503 5593
(blue)
GTX 4-TEC (blue) 1503 5594
GTX DI International
947 DI 5595
(blue)
GTX DI (blue) 947 DI 5596
1
F18L0ZA
The Hull Identification Number is composed of 12

digits:
ZZN12345L495
Model year
Serial
number* Year of production
Month of production
Manufacturer
F00A0CB
*A letter may also be used as a digit.
IV SMR2002-053_00A2.FM
INTRODUCTION
ENGINE IDENTIFICATION ARRANGEMENT OF THIS

NUMBER (E.I.N.) MANUAL
947 DI Engine The manual is divided into 16 major sections:
The Engine Identification Number is located on the 01 SERVICE TOOLS AND PRODUCTS
upper side of the magneto housing. 02 MAINTENANCE
03 TROUBLESHOOTING
04 ENGINE (DI)
1
05 ENGINE (4-TEC)
06 ENGINE MANAGEMENT (DI)
07 ENGINE MANAGEMENT (4-TEC)
08 COOLING SYSTEM
09 FUEL SYSTEM
10 LUBRICATION SYSTEM (DI)
11 ELECTRICAL SYSTEM
12 PROPULSION SYSTEM
F01D01A
13 STEERING SYSTEM
TYPICAL
14 HULL/BODY
1. Engine Identification Number (E.I.N.) 15 TECHNICAL DATA
1503 Engine 16 WIRING DIAGRAMS
The Engine Identification Number is located be- Several sections are divided in various subsections.
side the oil separator. There is a table of contents at the beginning of
many sections.
F18A04A 1
SMR2002-053_00A2.FM V
INTRODUCTION
TYPICAL PAGE
Page heading
indicates section
and subsection
detailed.
Subsection title
indicates
beginning of the
subsection. Subsection 04 (MAGNETO SYSTEM)
Italic sub-title
above exploded
view indicate
pertaining models.
Drop represents
a liquid product
to be applied to a
surface. In this case
Loctite 243 to
screw threads.
Loctite
243
Loctite
243
Dotted box
contains parts of
a particular
Exploded view assits Loctite model or an
243
you in identifying exploded view.
parts and related
positions. Loctite
243
Loctite
243
Bold face number

indicates special
procedure
concerning this part.
Loctite
648
145 Nm
(107 lbfft)
Anti-seize
lubricant
F01D4WS
Illustration number
for publishing
process.
03-04-1
Page numbering system:

03: ENGINE section
04: MAGNETO SYSTEM subsection
1: First page of this subsection
F01A0CS
VI SMR2002-053_00A2.FM
INTRODUCTION
TYPICAL PAGE
Sub-title with part

name(s) from
exploded view.

Subsection 03 (CARBURETORS)
Title indicates main

procedure to be CARBURETOR REMOVAL DISASSEMBLY AND INSPECTION
carried-out. To remove carburetors from engine, proceed as fol- Inspect parts for corrosion dammage (shaft, butterfly,
lows: spring screw, check valve housing, etc.).
Remove air vent tube support.
Sub-sub-title in
Unlock retaining slides holding air intake silencer base.
Diaphragm capital indicates a
Remove air intake silencer base from watercraft. PUMP DIAPHRAGM LEAK TEST particular testing,
Remove screws holding flame arrester base support Using a suitable pump gauge tester, perform the fol- adjustment or
lowing test proceeding as follows:
to cylinder head cover.
- Install pump gauge tester (P/N 295 000 083) on pulse
repair procedure.
Unscrew base retaining screws then remove base from
Service tool to be carburetors and move to front of watercraft. nipple.
used to perform a Turn the valve to OFF position. - Pump tester until it reaches 28 kPa (4 PSI).
certain procedure. NOTE: For fuel line removal, use pliers (P/N 295
000 054). 1 A
Disconnect pulse line from fuel pump.
Disconnect fuel fuel supply line from fuel pump. Illustration
Disconnect fuel return line. always follows
Title in italic indicates a Disconnect oil injection pump cable, throttle cable and text it is
particular procedure choke cable.
pertained to.
concerning a model. XP Model Only
Remove screws no. 6 and lock washers no. 7 retaining
carburetors.
Sub-sub-title in this All Others Models

case indicates that Remove 4 bolts no. 8 and lock washers no. 12 from
rotary valve cover then move carburetors and rotary 2 1 2 TYPICAL mention
particular procedure valve cover on top of engine.
F01F0XB
indicates a general
for XP is finished, so NOTE: When removing rotary valve cover , pay
TYPICAL
view which does not
from this point, all
1
attention that the rotary valve stay in place, other-wise
represent full detail.
2
it must be timed.
others models are
concerned. Remove carburetors from intake manifold.
Diaphragm must stand pressure for 10 seconds. If
Disconnect fuel bypass line between carburetors (twin
carburetors). pressure drops, replace diaphragm. Numbers in a frame
Remove carburetor(s) from rotary valve cover. are used to give a
sequence to be
perfomed.
Letters are used for

any measures.
06-03-4
Bold numbers in the

text refer to the parts Numbers are used
shown in the exploded for description of
view at the beginning components.
of the subsection.
F01A0BS
SMR2002-053_00A2.FM VII
INTRODUCTION
LIST OF ABBREVIATIONS USED OPS Oil Pressure Sensor

IN THIS MANUAL OPT Optional
DESCRIPTION OSPS Oil Separator Pressure Sensor
AC Alternate Current P/N Part Number
ADC Analog to Digital Conversion PFD Personal Flotation Device
APS Air Pressure Sensor PSI Pound Per Square Inch
ATS Air Temperature Sensor PTO Power Take Off
Bombardier Utility and Diagnostic RAVE Rotax Adjustable Variable Exhaust
B.U.D.S.
Software
RFI Rotax Fuel Injection
CAPS Camshaft Position Sensor
RPM Revolution Per Minute
CDI Capacitor Discharge Ignition
STD Standard
CPS Crankshaft Position Sensor
TBD To Be Determined
CSI Cooling System Indicator
TDC Top Dead Center
CTS Coolant Temperature Sensor
TOPS Tip-Over Protection System
DC Direct Current
TPS Throttle Position Sensor
DESS Digitally Encoded Security System
VCK Vehicle Communication Kit
DI Direct Injection
VDC Volt Direct Current
DLA Digital Linear Actuator
VTS Variable Trim System
E.I.N. Engine Identification Number
WTS Water Temperature Sensor
ECU Electronic Control Unit
EGT Exhaust Gas Temperature
EMS Engine Management System
EPA Environmental Protection Agency (USA)
HP Horse Power
KS Knock Sensor
LED Light Emitting Diode
MAG Magneto
MAPS Manifold Air Pressure Sensor
MATS Manifold Air Temperature Sensor
MPEM Multi-Purpose Electronic Module
MPH Mile Per Hour
MPI Multi Protocol Interface
N.A. Not Applicable
OPAS Off-Power Assisted Steering
VIII SMR2002-053_00A2.FM
INTRODUCTION
GENERAL INFORMATION As many of the procedures in this manual are in-

terrelated, we suggest, that before undertaking
The use of LEFT (port) and RIGHT (starboard) indi- any task, you read and thoroughly understand the
cations in the text, always refers to driving position entire section or subsection in which the proce-
(when sitting on watercraft). dure is contained.
Besides, in the marine industry, FRONT is called A number of procedures throughout the book re-
BOW and REAR is called STERN. quire the use of special tools. Before undertaking
any procedure, be sure that you have on hand all
the tools required, or approved equivalents.
1 2
ENGINE EMISSIONS
INFORMATION
Manufacturer’s Responsibility
Beginning with 1999 model year engines, PWC
manufacturers of marine engines must determine
the exhaust emission levels for each engine horse-
power family and certify these engines with the
F01L45B
United States of America Environmental Protec-
tion Agency (EPA). An emissions control informa-
1. Left (port)
2. Right (starboard) tion label, showing emission levels and engine
specifications, must be placed on each vehicle at
The information and component/system descrip- the time of manufacture.
tions contained in this manual are correct at time
of writing. Bombardier Inc. however, maintains a Dealer Responsibility
policy of continuous improvement of its products
without imposing upon itself any obligation to in- When performing service on all 1999 and more re-
stall them on products previously manufactured. cent Sea-Doo watercrafts that carry an emissions
control information label, adjustments must be
Bombardier Inc. reserves the right at any time to kept within published factory specifications.
discontinue or change specifications, designs,
features, models or equipment without incurring Replacement or repair of any emission related
obligation. component must be executed in a manner that
maintains emission levels within the prescribed
This Shop Manual uses technical terms which certification standards.
may be different from the ones of the Parts Cata-
logs. Dealers are not to modify the engine in any man-
ner that would alter the horsepower or allow emis-
When ordering parts always refer to the specific sion levels to exceed their predetermined factory
model Parts Catalogs. specifications.
Exceptions include manufacturer’s prescribed
ILLUSTRATIONS AND changes, such as altitude adjustments for exam-
PROCEDURES ple.
The illustrations show the typical construction of
the different assemblies and, in all cases, may not Owner Responsibility
reproduce the full detail or exact shape of the parts The owner/operator is required to have engine
shown, however, they represent parts which have maintenance performed to maintain emission lev-
the same or a similar function. els within prescribed certification standards.
CAUTION: These watercraft are designed with The owner/operator is not to, and should not allow
parts dimensioned mostly in the metric system. anyone to modify the engine in any manner that
However some components may be from the impe- would alter the horsepower or allow emissions
rial system. When replacing fasteners, make sure to levels to exceed their predetermined factory spec-
use only those recommended by Bombardier. ifications.
SMR2002-053_00A2.FM IX
INTRODUCTION
EPA Emission Regulations LOCTITE APPLICATION

All new 1999 and more recent Sea-Doo water- PROCEDURE
crafts manufactured by Bombardier are certified
to the EPA as conforming to the requirements of The following describes the most common appli-
the regulations for the control of air pollution from cation procedures when working with Loctite
new watercraft engines. This certification is con- products.
tingent on certain adjustments being set to factory NOTE: Always use proper strength Loctite prod-
standards. For this reason, the factory procedure uct as recommended in this Shop Manual.
for servicing the product must be strictly followed
and, whenever practicable, returned to the original THREADLOCKER
intent of the design.
The responsibilities listed above are general and in no Uncovered Holes (bolts and nuts)
way a complete listing of the rules and regulations
pertaining to the EPA requirements on exhaust emis-
sions for marine products. For more detailed informa-
tion on this subject, you may contact the following
locations:
1
VIA U.S. POSTAL SERVICE:

Office of Mobile Sources
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J)
401 M St. NW
Washington, DC 20460
2
A00A3LA
VIA EXPRESS or COURIER MAIL:
Office of Mobile Sources 1. Apply here
2. Do not apply
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J) 1. Clean threads (bolt and nut) with solvent.
501 3rd St. NW 2. Apply Loctite Primer N (P/N 293 800 041) on
Washington, DC 20001 threads and allow to dry.
EPA INTERNET WEB SITE: 4. Fit bolt in the hole.
http:/www.epa.gov/omswww
5. Apply a few drops of threadlocker at proposed
tightened nut engagement area.
SELF-LOCKING FASTENERS 6. Position nut and tighten as required.
PROCEDURE
cation procedures when working with self-locking
fasteners.
Use a metal brush or a screwtap to clean the hole
properly then use a solvent (Methyl-Chloride), let
act during 30 minutes and wipe off. The solvent
utilization is to ensure the adhesive works properly.
X SMR2002-053_00A2.FM
INTRODUCTION
Blind Holes 1. Clean threads (stud and hole) with solvent.

1 3. Put several drops of proper strength Loctite
threadlocker on female threads and in hole.
2 4. Apply several drops of proper strength Loctite
on stud threads.
5. Install stud.
6. Install cover, etc.
7. Apply drops of proper strength Loctite on un-
covered threads.
8. Tighten nuts as required.
A00A3MA
1. On threads
Preassembled Parts
2. On threads and at the bottom of hole
1. Clean threads (bolt and hole) with solvent.

threads (bolt and nut) and allow to dry for 30
1
seconds.
4. Apply several drops along the threaded hole and
at the bottom of the hole.
5. Apply several drops on bolt threads.
6. Tighten as required.
Stud in Blind Holes 2

A00A3OA
1. Apply here
2. Do not apply
1 3
1. Clean bolts and nuts with solvent.
2. Assemble components.
2
3. Tighten nuts.
4. Apply drops of proper strength Loctite on bolt/nut
contact surfaces.
A00A5RA NOTE: For preventive maintenance on existing
1. On threads
equipment, retighten nuts and apply proper strength
2. On threads and in the hole Loctite on bolt/nut contact surfaces.
3. Onto nut threads
SMR2002-053_00A2.FM XI
INTRODUCTION
Adjusting Screw Standard Thread Repair

1. Follow instructions on Loctite FORM-A-THREAD
81668 package.
2 2. If a plate is used to align bolt:
1
a. Apply release agent on mating surfaces.
b. Put waxed paper or similar film on the surfaces.
3. Twist bolt when inserting it to improve thread
conformation.
NOTE: NOT intended for engine stud repairs.
Repair of Small Holes/Fine Threads
Option 1: Enlarge damaged hole, then follow Stan-
dard Thread Repair procedure.
A00A3PA
Option 2: Apply FORM-A-THREAD on the screw
1. Apply here and insert in damaged hole.
2. Plunger
Permanent Stud Installation (light duty)
1. Adjust screw to proper setting.
1. Use a stud or thread on desired length.
2. Apply drops of proper strength Loctite thread-
locker on screw/body contact surfaces. 2. DO NOT apply release agent on stud.
3. Avoid touching metal with tip of flask. 3. Do a Standard Thread Repair.
NOTE: If it is difficult to readjust, heat screw with 4. Allow to cure for 30 minutes.
a soldering iron (232°C (450°F)). 5. Assemble.
STRIPPED THREAD REPAIR GASKET COMPOUND

Stripped Threads All Parts
5 1 2
1
6
8
2
3 1
A00A3QA 4 7
1. Release agent
2. Stripped threads
3. Form-A-Thread
4. Tape
5. Cleaned bolt
6. Plate A00A3SA 1 3
7. New threads
8. Threadlocker 1. Proper strength Loctite
2. Loctite Primer N (P/N 293 800 041) and Gasket Eliminator 518
(P/N 293 800 038) on both sides of gasket
3. Loctite Primer N only
1. Remove old gasket and other contaminants

with Loctite Chisel remover (P/N 413 708 500).
Use a mechanical mean if necessary.
XII SMR2002-053_00A2.FM
INTRODUCTION
NOTE: Avoid grinding. Mounting in Tandem

2. Clean both mating surfaces with solvent. 1. Apply retaining compound on internal element
3. Spray Loctite Primer N on both mating surfaces bore.
and on both sides of gasket. Allow to dry 1 or 2 2. Continue to assemble as shown above.
minutes.
4. Apply GASKET ELIMINATOR 518 (P/N 293 800 CASE-IN COMPONENTS
038) on both sides of gasket, using a clean ap-
plicator. Metallic Gaskets
5. Place gasket on mating surfaces and assemble
immediately.
NOTE: If the cover is bolted to blind holes (above),
apply proper strength Loctite in the hole and on
threads. Tighten.
If holes are sunken, apply proper strength Loctite
on bolt threads.
6. Tighten as usual.
MOUNTING ON SHAFT
Mounting with a Press
A00A3VA 1
1. Proper strength Loctite
1. Clean inner housing diameter and outer gasket

diameter.
2. Spray housing and gasket with Loctite Primer N
(P/N 293 800 041).
1
3. Apply a strip of proper strength Loctite on lead-
ing edge of outer metallic gasket diameter.
2
NOTE: Any Loctite product can be used here. A
3
low strength liquid is recommended as normal
strength and gap are required.
A00A3UA
4. Install according to standard procedure.
5. Wipe off surplus.
1. Bearing
2. Proper strength Loctite 6. Allow it to cure for 30 minutes.
3. Shaft
NOTE: Normally used on worn-out housings to
Standard prevent leaking or sliding.
1. Clean shaft external part and element internal It is generally not necessary to remove gasket
part. compound applied on outer gasket diameter.
2. Apply a strip of proper strength Loctite on shaft
circumference at insert or engagement point.
NOTE: Retaining compound is always forced out
when applied on shaft.
3. DO NOT use anti-seize Loctite or any similar
product.
4. No curing period is required.
SMR2002-053_00A2.FM XIII
INTRODUCTION
TIGHTENING TORQUES N•m

FASTENER SIZE
Lbf•ft
(8.8 grade)
Tighten fasteners to torque mentioned in explod-
37 27
ed views and text. When they are not specified
refer to following table.The table also gives the 38 28
metric conversion. 39 29
40 30
FASTENER SIZE
N•m Lbf•in 41 30
(8.8 grade)
42 31
1 9
43 32
2 M4 18
44 32
3 27
45 33
4 M5 35
46 34
5 44
47 35
6 53
48 M10 35
7 62
49 36
8 71 50 37
9 80 51 38
10 M6 89 52 38
11 97 53 39
12 106 54 40
13 115 55 41
14 124 56 41
15 133 57 42
16 142 58 43
17 150 59 44
18 159 60 44
19 168 61 45
62 46
FASTENER SIZE 63 46
N•m Lbf•ft
(8.8 grade)
64 47
20 15
65 48
21 15
66 49
22 16
67 49
23 M8 17
68 50
24 18
69 51
25 18
70 52
26 19
71 52
27 20
72 53
28 21
73 54
29 21
74 55
30 22
75 55
31 23
76 56
32 24
77 57
33 24
78 58
34 25
79 58
35 26
80 M12 59
36 27
XIV SMR2002-053_00A2.FM
INTRODUCTION
FASTENER SIZE FASTENER SIZE

N•m Lbf•ft N•m Lbf•ft
(8.8 grade) (8.8 grade)
81 60 116 86
82 60 117 86
83 61 118 87
84 62 119 88
85 63 120 89
86 63 121 89
87 64 122 90
88 65 123 91
89 66 124 91
90 66 125 92
91 67 126 93
92 68 127 94
93 69 128 94
94 69 129 95
95 70 130 96
96 71 131 97
97 72 132 97
98 72 133 98
99 73 134 99
100 74 135 M14 100
101 74 136 100
102 75 137 101
103 76 138 102
104 77 139 103
105 77 140 103
106 78 141 104
107 79 142 105
108 80 143 105
109 80 144 106
110 81 145 107
111 82 146 108
112 83 147 108
113 83 148 109
114 84 149 110
115 85 150 111
TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTS
Bombardier Inc.
Valcourt (Quebec), Canada
SMR2002-053_00A2.FM XV
TABLE OF CONTENTS 0
MANDATORY SERVICE TOOLS ........................................................................................... 01-02-1
ENGINE .............................................................................................................................. 01-02-1
STEERING SYSTEM .......................................................................................................... 01-02-7
OPTIONAL SERVICE TOOLS ................................................................................................ 01-03-1

ENGINE .............................................................................................................................. 01-03-1
WATERCRAFT HANDLING................................................................................................ 01-03-5
SERVICE PRODUCTS ............................................................................................................ 01-04-1
SMR2002-095_01-01ATOC.FM 01-01-1
MANDATORY SERVICE TOOLS 0

ENGINE
Piston circlip installer Air compressor ring compressor Starter drive bearing pusher
P/N 529 035 563 P/N 529 035 713 P/N 290 876 502
F06B054
APPLICATION
F06B014
F12B0L4
All engines.
APPLICATION
947 DI engine. APPLICATION
947 DI engine. Piston pin puller
P/N 529 035 503
NEW
Carbon dam guide
Piston circlip installer P/N 529 035 715
P/N 529 035 765
F12B0M4
F00B0T4
V04B0B4
APPLICATION
947 DI engine. 947 DI engine.
4 -TEC engine.
Carbon dam compressor
Sleeve set
P/N 529 035 716
P/N 529 035 543
(21 mm sleeve)
F00B0U4
F12B0N4
947 DI engine. 947 DI engine.
SMR2002-054_01_02A.FM 01-02-1
Puller Alignment support plate kit VCK (Vehicle Communication Kit)

P/N 529 035 547 P/N 529 035 506 P/N 529 035 844
1) Alignment plates Individual B.U.D.S. diskettes v1.1
P/N 529 035 507 P/N 529 035 845
2) Support Individual CD-Rom
P/N 529 035 511
P/N 529 035 886
A00C1A4 3) Screw (2)
P/N 207 182 544
Puller plate
P/N 420 876 080 4) Lock washer (2)
P/N 234 181 601
5) Flat washer (2)
P/N 234 081 410
A00C1R4
Extension handle
P/N 295 000 125
F01D164
F00B0F4
Screw M8 x 35 (3) APPLICATION

P/N 420 841 591 All models. F12H0A4
155.6 mm jet pump. APPLICATION

F00A094 All models.
Sleeve (3) Alignment shaft
P/N 295 000 141 Engine leak tester kit
P/N 290 847 220
P/N 295 500 352
Pump only
P/N 529 021 800
F00B0G4
F00A0A4
APPLICATION
APPLICATION
All models.
PTO flywheel on 947 DI engine.
NEW
Alignment adaptor
P/N 529 035 719
F01B2Q5
APPLICATION
947 DI engine.
F18B0C4
APPLICATION
GTX 4-TEC models.
01-02-2 SMR2002-054_01_02A.FM
Supplementary engine leak test kit Crankshaft protective cap Engine oil pressure adapter
P/N 295 500 780 P/N 290 877 414 P/N 529 035 652
1) 947 DI Intake plate
P/N 296 000 025
2) 947 DI Rave plate
P/N 296 000 026
3) 947 DI Exhaust plate
P/N 296 000 027
APPLICATION
F00B1R4
947 DI engine.
APPLICATION
NOTE: This kit is supplementary
to P/N 295 500 352. 947 DI engine.
V00B074
Handle Polygonal wrench APPLICATION

P/N 420 877 650 P/N 529 035 505 4-TEC engine.
NEW
Crankshaft looking tool

A00C3V4
F00B0Y4 P/N 529 035 821
APPLICATION
APPLICATION
Use with pushers
(P/N 290 876 609 and 290 877 740). Exhaust system of the 947 DI en-
gine. F18B064
APPLICATION
Ring gear puller tool
Intake plug 4-TEC engine.
P/N 420 976 235 (puller ass’y)
P/N 529 035 708
P/N 529 035 549 (puller bolt)
NEW
APPLICATION
Camshaft looking tool
947 DI engine.
P/N 529 035 839
Oil pressure gauge (1 to 8 bars)

F18B074
P/N 529 035 709
APPLICATION
F01B294 4-TEC engine.
APPLICATION
947 DI engine.
V00B064
APPLICATION
4-TEC engine.
SMR2002-054_01_02A.FM 01-02-3
Pliers Fuel line disconnect tool NEW
P/N 295 000 070 P/N 529 035 714

Oetiker 1099 Oil seal guide
P/N 529 035 822
F01D174
F12B0G4
APPLICATION
APPLICATION F18B094
All models. 947 DI engine. APPLICATION

4-TEC engine.
Pliers 1. Fuel pressure gauge
P/N 295 000 054
P/N 529 035 709 NEW
Caillau
2. Fuel pressure gauge T-fitting
P/N 529 035 710 Coolant pump seal pusher
P/N 529 035 823
3. Fuel pressure gauge pressure
relief valve
F01B1T4 P/N 529 035 711
APPLICATION 4. Fuel pressure gauge air com-
All models. pressor adapter
NOTE: This tool is also used for P/N 529 035 712
the propulsion system.
F18B084
Fuel pressure gauge 1 APPLICATION

P/N 529 035 591 4-TEC engine.
3 2 4
F12R014
APPLICATION
947 DI engine.
F02B0B4
APPLICATION
4-TEC engine.
01-02-4 SMR2002-054_01_02A.FM
PROPULSION SYSTEM
Impeller remover/installer Bearing/seal installer Pliers
A) P/N 295 000 001 P/N 295 000 107 P/N 295 000 054
B) P/N 529 035 820 Caillau
F01J0T4 F01B1T4
A) GTX DI models. F01J4K4
All models.
B) GTX 4-TEC models. APPLICATION NOTE: This tool is also used for
the fuel system.
NOTE: This tool is also used for GTX DI models.
the PTO flywheel.
NEW
Inner seal installer
Pliers
P/N 529 035 609 PTO seal support
P/N 295 000 069
Oetiker 1090 P/N 529 035 842
F01D184
APPLICATION
All models.
F18B0F4
Impeller shaft holder F08B014

APPLICATION
P/N 295 000 082 APPLICATION GTX 4-TEC models.
GTX DI models.
NEW
Impeller shaft guide

Drive shaft holder
P/N 295 000 002
P/N 529 035 871
F01B0W4
APPLICATION
GTX DI models.
F01J1O4
Jet pump bearing remover APPLICATION

P/N 295 000 144 GTX DI models.
F18B0G4
F01J114
APPLICATION
APPLICATION GTX 4-TEC models.
GTX DI models.
SMR2002-054_01_02A.FM 01-02-5
NEW NEW NEW
Drive shaft/floating ring Shaft pusher Pressure cap

P/N 529 035 841 P/N 529 035 818 P/N 529 035 843
F18B054
F18B044
APPLICATION
APPLICATION
GTX 4-TEC models.
GTX 4-TEC models.
NEW
F18B0E4
Seal/bearing pusher APPLICATION

P/N 529 035 819 GTX 4-TEC models.
F18B0D4
APPLICATION
GTX 4-TEC models.
01-02-6 SMR2002-054_01_02A.FM
STEERING SYSTEM
NEW
OPAS cylinder nut wrench

P/N 529 035 840
F18B0A4
APPLICATION
All models.
SMR2002-054_01_02A.FM 01-02-7
OPTIONAL SERVICE TOOLS 0

ENGINE
Distance gauge Dial indicator (TDC gauge) Crimping tool
A) P/N 529 035 100 P/N 295 000 143 P/N 295 100 164
11.5 mm (.453 in)
B) P/N 529 035 000
7.5 mm (.295 in)
A00B4E4
APPLICATION
947 DI engine. F00B0E4
APPLICATION
Digital/induction type
Contacts of AMP plug connectors.
F01B0H4
tachometer
A) 947 DI engine (MAG). Terminal (Packard) remover
B) 947 DI engine (PTO). Not sold by Bombardier
Snap-on
TT 600-4
Stroboscopic timing light
P/N 529 031 900
F01B1J4
APPLICATION
F01B1G4
All models.
APPLICATION
All models.
Joint connector tool
Timing mark pointer
A00B4F4 Deutsch
APPLICATION P/N 295 000 135 114010
947 DI engine.
Six-pin magneto harness

P/N 295 000 136
F01H544
F01B284 APPLICATION
APPLICATION 947 DI engine.
F12B0C4
947 DI engine.
APPLICATION
947 DI models.
SMR2002-054_01_03A.FM 01-03-1
Safety lanyard switch tool Exhaust outlet tool MPEM programmer

P/N 529 034 600 P/N 295 000 132 P/N 529 035 878
F01B2A4
F01B244
APPLICATION
APPLICATION A01B5B4
All models. APPLICATION

All models.
947 DI models.
Engine lifting device
Protective mat
Not sold by Bombardier Piston ring compressor (2)
P/N 295 000 128
Do it yourself P/N 290 876 965 (88 mm)
Refer to REMOVAL AND INSTAL-
LATION section of engine.
F01B1T4
APPLICATION
F02B0A4
947 DI engine.
APPLICATION
All models. NEW
F01D0A4
APPLICATION
NEW Digital multimeter
947 DI engine.
P/N 529 035 868
Spring installer/remover
Steering cable tool
P/N 529 035 559
P/N 295 000 145
F01B2P4
APPLICATION
A00C3S4 All models.
APPLICATION
GTX 4-TEC models. Rubber pad
P/N 290 877 032
V00B0H4
APPLICATION
F06B064
All models.
APPLICATION
947 DI engine.
01-03-2 SMR2002-054_01_03A.FM
NEW NEW
9 9
8 8 7 7
Valve spring compressor clamp Special pliers for valve stem seal
P/N 529 035 724 removal
1
5 Snap-on YA 8230
2
4
3
6 4
V02B064
V00B044 APPLICATION
APPLICATION 4-TEC Engine.
4-TEC Engine.
MAG side PTO side
NEW
F01D885
NEW
1) Puller ass’y Valve stem seal installer
P/N 420 877 635 Valve spring compressor cup P/N 529 035 687
2) Protective cap P/N 529 035 725
P/N 420 876 557
P/N 290 877 414
(947 DI engine)
3) Ring (both ends)

P/N 420 977 490 V04B094
P/N 420 977 480
(947 DI engine) APPLICATION
V04B0H4
4-TEC Engine.
4) Ring halves (PTO) APPLICATION
P/N 420 977 475 (2)
4-TEC Engine.
P/N 420 876 330 NEW
(947 DI engine)
Ring compressor NEW
5) Distance ring (MAG)

P/N 420 876 569 Torque angle gauge
Snap-on RC980
6) Ring halves (MAG) Not sold by Bombardier
P/N 420 276 025 (2) Snap-on TA362
7) Screw M8 x 40
P/N 420 840 681 (2)
V04B084
8) Screw M8 x 70
P/N 420 841 201 (2) APPLICATION
4-TEC Engine.
9) Puller bolt
P/N 420 940 755
APPLICATION V04B0I4
947 DI engine. APPLICATION

4-TEC Engine.
SMR2002-054_01_03A.FM 01-03-3
Leak test kit pump NEW
P/N 529 021 800

Oil VAC
P/N 529 035 880
F18B0B4
V00B084
APPLICATION
APPLICATION
4-TEC Engine.
4-TEC Engine.
Lighted adjustable mirror Hose pincher Flushing adapter
Not sold by Bombardier P/N 295 000 076 P/N 295 500 473
Snap-on
50101
F01B1I4
APPLICATION
All models. F00B104
A01B2I4
APPLICATION
APPLICATION
Hose pincher All models.
All models. Use with coupler hose (P/N 295
P/N 529 032 500
500 258).
Flexible spout (oil)
P/N 414 837 300 NEW
Test radiator cap

P/N 295 021 400
F04B044
F01B234 APPLICATION
PA
UD
All models.
S
OU A
V RIR A CH
F18E1P4
APPLICATION
4-TEC models.
01-03-4 SMR2002-054_01_03A.FM
PROPULSION SYSTEM
Fitting Slide hammer puller Hacksaw
P/N 295 000 086 Not sold by Bombardier Not sold by Bombardier
Snap-on: Snap-on
Handle: CJ93-1 HS3
Hammer: CJ125-6
Claws: CJ93-4
F01B1M4
APPLICATION
F01J0Z4 All models.
F01B0Z4
APPLICATION
APPLICATION
All 947 DI models.
GTX DI models.
NOTE: This tool is also used to re-
move rotary valve shaft bearing.
WATERCRAFT HANDLING
Dolly (with wheels) Tie-down Tie-down with ratchet
P/N 295 000 126 1.50 m (5 ft) long 3.60 m (12 ft) long
P/N 295 100 103 P/N 295 100 104
APPLICATION
All models.
F01B014
Beach wheels (set of 2 wheels)

F00B014
P/N 295 000 005
APPLICATION
All models.
F01B074
APPLICATION
Dolly.
SMR2002-054_01_03A.FM 01-03-5
SERVICE PRODUCTS 0
Loctite® is a trademark of Loctite™ Corporation.
Permatex® is a trademark of Loctite™ Corporation.
Dow Corning® is a trademark of Dow Corning Corporation.
Medium strength threadlocker High temperature threadlocker Retaining compound
P/N 293 800 060 P/N 420 899 788 P/N 413 703 100
Loctite 243 (blue) Loctite 648 (green) Loctite RC/609 (green)
(10 mL) (5 g) (10 mL)
A00B3D4 A00B2S4
High temperature retaining General purpose instant adhesive

compound P/N 293 800 021
F00A0O4
P/N 293 800 054 Loctite 495
Loctite 642
High strength threadlocker (50 mL)
P/N 293 800 005
Loctite 271 (red) A00B2V4
(10 mL)
Gasket eliminator
P/N 293 800 038
Loctite 518
(50 mL)
F00B024
F01B124
A00B2U4
SMR2002-054_01_04A.FM 01-04-1
Flange sealant Thread sealant Pipe sealant

P/N 293 800 081 P/N 293 800 050 A) P/N 293 800 013
Loctite 5910 Loctite 577 B) P/N 293 800 018
(300 mL) (250 mL)
A) Loctite 567 (250 mL)
B) Loctite 592 (50 mL)
F00B0W4
A00B2W4
Solvent
P/N 413 711 809 Hylomar sealant
Loctite Safety Solvent
320 g (11 oz)
P/N 293 800 001
PL-32
(100 g)
F00B1A4
A00B3F4
NEW
Sealant
RTV silicone sealant
P/N 293 530 011
P/N 293 800 066
Sikaflex 221 (black)
Loctite 5900 (350 mL)
(300 mL)
F01B1D4
A00B4X4
A02B0B4 NEW
Molykote 111
Chisel gasket remover P/N 413 707 000 High temperature RTV sealant
P/N 413 708 500 P/N 293 800 090
(510 mL)
111
Ultra Copper
(80 mL)
A00B3W4
Primer for gasket eliminator

P/N 293 800 041
Loctite 764
A00B574
A00B5A4
A00B3N4
01-04-2 SMR2002-054_01_04A.FM
Dielectric grease Super Lube grease NEW
P/N 293 550 004 P/N 293 550 030

Dow Corning Loctite 82328 Grease Isoflex
(150 g)
P/N 293 550 021
(50 g)
A00B1X4
Deoxit contact lubricant

P/N 293 550 015
(200 mL)
V00B0I4
Anti-seize lubricant A00B554
P/N 293 800 070

Loctite 76764 BOMBARDIER LUBE
454 g (16 oz)
P/N 293 600 016
(12 x 14 oz)
F00B0X4
Grease
P/N 293 550 005
(400 g)
A00B2L4
A00B624
A00B594
Synthetic grease
P/N 293 550 010
(400 g)
F01B154
SMR2002-054_01_04A.FM 01-04-3
BOMBARDIER storage oil NEW NEW
P/N 413 711 600

(12 x 350 g) Premixed coolant 50/50 BOMBARDIER Formula XP-S II
- 37°C (- 35°F) synthetic injection oil
P/N 293 600 038 P/N 293 600 245
(16 x 1 L) (12 x 1 L)
A00B634
A00B5T4
Sea-Doo fuel stabilizer
P/N 413 408 600 A00B5X4
P/N 293 600 246
236 mL (8 oz) (3 x 4 L)
Sealant adhesive
P/N 293 800 086
Loctite 5150
(29647)
A00B5S4 A00B5U4
P/N 293 600 247

(205 L)
A00B604
732 Multi-purpose sealant

P/N 293 800 086
Dow Corning (90 mL)
(clear)
F01B1C4
01-04-4 SMR2002-054_01_04A.FM
NEW Sea-Doo Cleaner

P/N 293 110 001 (400 g)
Instant gasket P/N 293 110 002 (4 L)
P/N 293 800 088
(7 oz)
F01B2J4
NEW
Pulley flange cleaner

A02B0C4 P/N 413 711 809
Jet pump synthetic oil

P/N 293 600 011
(12 x 6 oz)
A00B5V4
F01B0P4
NEW
Jet pump grease

P/N 293 550 032
(110 g)
SMR2002-054_01_04A.FM 01-04-5
TABLE OF CONTENTS 0
PERIODIC INSPECTION CHART ........................................................................................... 02-02-1
FLUSHING AND LUBRICATION ........................................................................................... 02-03-1

GENERAL ........................................................................................................................... 02-03-1
PROCEDURE ...................................................................................................................... 02-03-1
WATER-FLOODED ENGINE .................................................................................................. 02-04-1

GENERAL ........................................................................................................................... 02-04-1
PROCEDURE ...................................................................................................................... 02-04-1
STORAGE............................................................................................................................... 02-05-1
ENGINE DRAINING ........................................................................................................... 02-05-1
FUEL SYSTEM ................................................................................................................... 02-05-1
ENGINE OIL CHANGE AND FILTER ................................................................................. 02-05-2
COOLING SYSTEM FLUSHING AND ENGINE INTERNAL LUBRICATION .................... 02-05-2
ENGINE LUBRICATION ..................................................................................................... 02-05-2
BATTERY............................................................................................................................ 02-05-3
WATERCRAFT CLEANING ................................................................................................ 02-05-3
ADDITIONAL RECOMMENDED PROTECTION ................................................................ 02-05-3
ANTICORROSION TREATMENT....................................................................................... 02-05-5
CHECKLIST ........................................................................................................................ 02-05-6
SMR2002-095_02-01ATOC.FM 02-01-1
PERIODIC INSPECTION CHART 0

The schedule should be adjusted according to operating conditions and use.
NOTE: The chart gives an equivalence between number of hours and months/year. Perform the maintenance
operation to whatever time comes first.
IMPORTANT: Schedule for watercraft rental operations or higher number of hour use, will require greater
frequency of inspection and maintenance.
DI Models
FREQUENCY
100 HOURS OR
25 HOURS OR
50 HOURS OR
3 MONTHS
6 MONTHS
DESCRIPTION
10 HOURS
1 YEAR
EVERY
EVERY
EVERY
FIRST
GENERAL
Lubrication/corrosion protection ➀ ✔
ENGINE
Support and rubber mount condition/tightness ✔ ✔
Exhaust system fasteners ➄ ✔ ✔
RAVE valve cleaning ➄ ✔ ✔
Top end inspection (leak test, piston and ring clearance) ➄ ➈
Counterbalance shaft oil level ✔ ✔
Spark plug inspection, cleaning and gap adjustment ➄ ✔➃
Spark plug replacement ➄ ✔
TDC setting ➄ ➈
COOLING SYSTEM
Flushing ✔➂
Hose condition and fasteners ✔ ✔
Inspect/clean engine drain tubes ✔➀
Water flow regulator valve inspection ✔
FUEL SYSTEM
Throttle, inspection/lubrication ➀ ✔
Fuel filter and lines inspection ✔ ✔
Fuel filter replacement ➇
Visually check for oil leakage between cylinder head and injector ➄ ✔ ✔
Fuel injection system sensors (except throttle body), visual inspection ➄ ✔ ✔
Throttle body cleaning and their sensors ➄ ➅ ✔ ✔
Fuel vent line pressure relief valve inspection ✔
Fuel lines, connections, check-valve and fuel system leak test ➄ ✔ ✔
Visual inspection: throttle bodies, sensors, fuel lines, fuel rail and fittings ➄ ✔ ✔
Air intake silencer fit/tightness ✔ ✔
Fuel tank straps visual inspection ✔ ✔
SMR2002-055_02_02A.FM 02-02-1
FREQUENCY
100 HOURS OR
25 HOURS OR
50 HOURS OR
3 MONTHS
6 MONTHS
DESCRIPTION
10 HOURS
1 YEAR
EVERY
EVERY
EVERY
FIRST
LUBRICATION SYSTEM
Oil injection pump adjustment ➄ ✔ ✔
Oil filter and lines inspection ✔ ✔
Oil filter replacement ✔
Oil reservoir straps ✔
ELECTRICAL SYSTEM
Check fault codes ✔ ✔
Electrical connections condition and fastening (ignition system, electrical
✔ ✔
box(es), starting system, fuel injectors, etc.)
MPEM mounting brackets/fasteners ✔
Digitally Encoded Security System and safety lanyard/post condition ✔ ✔
Monitoring beeper ✔ ✔
Battery condition and strap(s) ✔ ✔
STEERING SYSTEM
Inspection and cable adjustment ✔ ✔
O.P.A.S. SYSTEM
Check O.P.A.S. system operation and condition including filter ✔ ✔
PROPULSION SYSTEM
Drive shaft boot and spline condition ✔➁
Drive shaft protection hose inspection ✔➁
Shifter system/cable adjustment ✔ ✔
Jet pump reservoir oil level/oil condition Replace ✔ Replace
Jet pump cover pusher inspection ✔
Impeller shaft seal replacement ➆
Impeller condition and impeller/wear ring clearance ✔➁
Water intake grate condition ✔➁
HULL AND BODY
Bailer pick-ups, check for obstructions ✔ ✔
Hull condition ✔ ✔
➀ Every 10 hours in salt water use. ➄ Emission-related component.
➁ These items have to be initially checked after 25 hours. ➅ In salt water use.
Thereafter, servicing to be made as specified in this ➆ Replace at 150 hours.
chart.
➇ Replace at 250 hours.
➈ Check at 350 hours or 5 years.
➃ Except DI models.
02-02-2 SMR2002-055_02_02A.FM
4-TEC Models
FREQUENCY
100 HOURS OR
25 HOURS OR
50 HOURS OR
3 MONTHS
6 MONTHS
DESCRIPTION
10 HOURS
1 YEAR
EVERY
EVERY
EVERY
FIRST
GENERAL
Lubrication/corrosion protection ✔
ENGINE
Engine oil and filter replacement ✔ ✔
Support and rubber mount condition/tightness ✔ ✔
Condition of seals and fasteners ✔ ✔
Exhaust system fasteners ➄ ✔ ✔
Spark plug replacement ➄ ✔
COOLING SYSTEM
Flushing (exhaust system) ✔ ➂
Hose condition and fasteners ✔ ✔
Coolant replacement ➆
Coolant expansion tank cap/cooling system pressure test ➃
FUEL SYSTEM
Throttle cable, inspection/lubrication ✔
Fuel injection system sensors, visual inspection ➄ ✔ ✔
Throttle body cleaning and inspection. Fault code reading ➄ ➀ ✔
Fuel vent line pressure relief valve inspection ✔
Fuel lines, connections and fuel system leak test ➄ ✔ ✔
Visual inspection: throttle body, sensors, fuel lines, fuel rail and fittings ➄ ✔ ✔
Air intake silencer fit/tightness ✔ ✔
Fuel tank straps visual inspection ✔ ✔
ELECTRICAL SYSTEM
Check fault codes ✔ ✔
Electrical connections condition and fastening (ignition system, starting system,
✔ ✔
fuel injectors etc.)
MPEM and EMS ECU connectors inspection and lubrication ✔➀
MPEM mounting brackets/fasteners ✔
Digitally Encoded Security System and safety lanyard/post condition ✔ ✔
Monitoring beeper ✔ ✔
Battery condition and fasteners ✔ ✔
SMR2002-055_02_02A.FM 02-02-3
FREQUENCY
100 HOURS OR
25 HOURS OR
50 HOURS OR
3 MONTHS
6 MONTHS
DESCRIPTION
10 HOURS
1 YEAR
EVERY
EVERY
EVERY
FIRST
STEERING SYSTEM
Inspection and cable adjustment ✔ ✔
O.P.A.S. FUEL SYSTEM
Check O.P.A.S. system operation and condition including filter ✔ ✔
PROPULSION SYSTEM
Drive shaft protection boot inspection ✔ ➁
Grease splines in jet pump ✔ ➁
Shifter system/cable adjustment ✔ ✔
Impeller shaft seal replacement ➅
Impeller condition and impeller/wear ring clearance ✔ ➁
Water intake grate condition ✔ ➁
Ride plate inspection including coolant leak ✔ ✔
HULL AND BODY
Bailer pick-ups, check for obstructions ✔ ✔
Hull condition ✔ ✔
➀ In salt water use. ➃ Every 200 hours or 2 years.
➁ These items have to be initially checked after 25 ➄ Emission-related component.
hours. Thereafter, servicing to be made as specified ➅ Replace after the vehicle completed 100 hours of
in this chart. use, not every year.
➂ Daily flushing in salt water or foul water use. ➆ Replace for storage periode.
02-02-4 SMR2002-055_02_02A.FM
FLUSHING AND LUBRICATION 0

GENERAL
DI Engines
Flushing the cooling system with fresh water is
essential to neutralize corroding effects of salt or
other chemical products present in water. It will
help to clean up sand, salt, shells or other particles
in water jackets (engine, exhaust manifold, tuned
pipe) and/or hoses.
Cooling system flushing and engine internal lubri-
cation should be performed when the watercraft
is not expected to be used further the same day
or when the watercraft is stored for any extended
time. 1
F06E01A
CAUTION: Failure to flush cooling system, when

1. Flushing adaptor
necessary, will severely damage engine and/or
exhaust system. Never flush a hot engine. Make NOTE: A quick connect adapter with a flushing
sure engine operates during entire procedure. adaptor (P/N 295 500 473) can be used to ease
garden hose installation.
PROCEDURE
 WARNING
Clean jet pump by spraying water in its inlet and F00E05A 1 2

outlet and then spray BOMBARDIER LUBE lubri- 1. Quick connect adapter
cant. 2. Flushing adaptor (P/N 295 500 473)
 WARNING
Always remove safety lanyard cap from switch
to prevent unexpected engine starting before
Connect a garden hose to the flushing adaptor.
F07E01B 1 2
1. Garden hose installed
2. Quick connector adaptor
SMR2002-055_02_03A.FM 02-03-1
Start the engine then immediately open the water

tap.  WARNING
Always use spark plug cable grounding de-
 WARNING vice when removing spark plugs.
CAUTION: Never flush a hot engine. Always start

the engine before opening the water tap. Open
water tap immediately after engine is started to
prevent overheating.
Run the engine about 3 minutes at a fast idle
around 3500 RPM.
Spray BOMBARDIER LUBE lubricant through air
intake silencer keeping engine at fast idle for ap- F01H7DA 1
proximately one minute. 1. Grounding device
Spray, through hole of air intake silencer.
Remove both spark plugs and spray BOMBARDIER
NOTE: An increase of engine RPM may be noticed LUBE lubricant into each cylinder.
while spraying the lubricant in the air intake silencer.
NOTE: Proceeding in this order, no fuel will be inject-
ed and no ignition will occur in the engine.
While engine is stopped, fully depress throttle lever
and HOLD for cranking.
Wait 2 seconds then press the start/stop button
to crank the engine a few turns and distribute the
lubricant onto cylinder walls.
NOTE: A 1 second beep every second indicates the
drowned mode is active.
Apply anti-seize lubricant on spark plug threads
then reinstall them.
Reinstall plug on air intake silencer cover.
NOTE: Engine fogging should be done with
F12F01A 1
BOMBARDIER LUBE lubricant whenever the wa-
1. Partially pull tube out of air box to inject BOMBARDIER LUBE tercraft is to be stored for a few days or a long period.
CAUTION: Never leave rags or tools in the engine
Close the water tap then stop the engine. compartment or in the bilge.
stopping the engine. 4-TEC Engines
Disconnect the garden hose. Closed Loop Cooling System
CAUTION: Remove quick connect adapter after 4-TEC engines are equipped with a closed loop
flushing operation (if used). cooling system which does not need to be flushed
Wipe up any residual water from the engine. even after salt water use.
Remove spark plug cables and connect them on Open Loop Cooling System
Flushing the exhaust cooling system with fresh wa-
ter is essential to neutralize corroding effects of salt
or other chemical products present in water. It will
help to remove sand, salt, shells or other particles in
water jackets and/or hoses.
02-03-2 SMR2002-055_02_03A.FM
Flushing should be performed when the watercraft is Flushing

not expected to be used further the same day or
To flush the exhaust cooling system, start the en-
when the watercraft is stored for any extended time.
gine then immediately open the water tap.
 WARNING  WARNING
burn. Do not touch any electrical part or jet pump
Proceed as follows: area when engine is running.
Clean jet pump by spraying water in its inlet and CAUTION: Never flush a hot engine. Always
outlet and then apply a coating of BOMBARDIER start the engine before opening the water tap.
LUBE lubricant or equivalent. Open water tap immediately after engine is
started to prevent overheating.
 WARNING Run the engine about 20 seconds at a fast idle
Always remove safety lanyard cap from switch between 4000 - 5000 RPM.
to prevent unexpected engine starting before
Connect a garden hose to connector located at the Ensure water flows out of exhaust outlet while
rear of watercraft on jet pump support. flushing. Otherwise, refer to an authorized Sea-Doo
dealer for servicing.
 WARNING CAUTION: Never run engine longer than 5 min-
When operating the engine while the water- utes. Drive line seal has no cooling when water-
craft is out of the water, the heat exchanger in craft is out of water.
the ride plate may become very hot. Avoid any Close the water tap, then stop the engine.
contact with ride plate as burns may occur.
NOTE: An optional quick connect adapter can be stopping the engine.
used (P/N 295 500 473). No hose pincher is required NOTE: Engine valves fogging should be done
to flush engine. whenever the watercraft is to be stored for a long
period. Refer to STORAGE section.
F07E01C 3 2 1
TYPICAL
1. Hose adapter
2. Quick connect adapter (optional, not mandatory)
3. Garden hose
SMR2002-055_02_03A.FM 02-03-3
WATER-FLOODED ENGINE 0
GENERAL NOTE: Proceeding in this order, no fuel will be in-
jected into the engine and ignition will be cut.
If engine is water-flooded, it must be serviced
Remove the air pressure hose from the compres-
within a few hours after the event. Otherwise en-
sor.
gine will have to be overhauled.
CAUTION: Failure to remove the air pressure
CAUTION: A water-flooded engine must be prop-
hose from the compressor will result in the bend-
erly lubricated, operated then lubricated again,
ing of the compressor connecting rod, when
otherwise parts will be seriously damaged.
cranking the engine.
PROCEDURE 1
DI Models
Check fuel and oil reservoirs for water contamina-
tion. If necessary, siphon and refill with fresh fluids.
 WARNING
Never crank engine with spark plugs removed
unless spark plug cables are connected to the
grounding device.
F18D1AA
1. Disconnect this hose
Remove the flywheel guard and turn the PTO fly-

wheel several times, by hand.
While engine is stopped, fully depress throttle le-
ver and HOLD for cranking.
Crank engine several times to drain crankcase.
F01H7DA 1 If water does not completely go out, it may be nec-
GTX DI MODELS essary to remove the air intake silencer then to
1. Grounding device lean the vehicle so that water can flow out from
throttle bodies.
Remove spark plugs and dry them with a clean
cloth. A contact cleaner spray can be used. It may Spray BOMBARDIER LUBE lubricant (P/N 293 600
be preferable to replace spark plugs. Do NOT in- 016) into spark plug holes and into the air compressor.
stall spark plugs on engine yet. Crank engine again.
Reinstall spark plugs and spark plug cables.
 WARNING Reinstall the air pressure hose to the compressor.
Be careful when cranking engine in the fol-
lowing procedure, water will spray out from Reinstall the flywheel guard.
spark plug holes. Start engine according to normal starting proce-
dure.
SMR2002-056_02_04A.FM 02-04-1
CAUTION: To avoid starting motor overheat- Whenever the engine is stopped, all the valves
ing, the cranking period should not exceed 5- close to prevent water from being ingested in the
10 seconds and a rest period of 30 seconds engine.
should be observed between cranking cycles. If water is suspected to be in the intake manifold
NOTE: If engine does not start after several at- and the exhaust system, it must be drained as fol-
tempts, check ignition system for spark occur- lows:
rence. Refer to IGNITION SYSTEM. Remove the intake manifold and suck out the wa-
Check crankshaft if needed, it may be misaligned ter from the intake valve ports. Refer to subsec-
or deflected. Refer to BOTTOM END. tion INTAKE SYSTEM.
After engine has started, spray BOMBARDIER Remove the water from oil/air separator breather
LUBE lubricant through air intake silencer while hose.
engine is running. Remove the exhaust pipe, the muffler and the res-
onator and drain them. Refer to subsection EX-
HAUST SYSTEM.
If water gets in the oil (oil will be milky), change
the engine oil and filter as follows:
Oil Change Procedure

ENGINE WITHOUT THE SCAVENGE OIL PUMP
COVER DRAIN PLUG
CAUTION: Never crank or start engine when si-
phon tube is in dipstick hole. Never start engine
1. Using the oil VAC (P/N529 035 880), siphon oil
F12F01A 1 through dipstick hole.
1. Spray BOMBARDIER LUBE here 2. Remove the oil vac tool from the dip stick hole.
3. While in drowned engine mode, crank the en-
Run the engine for at least 30 minutes to ensure
gine for 5 seconds.
that the engine is dried out.
CAUTION: Engine must be cooled using the flush
kit. 5. Again, siphon oil from the reservoir.
4-TEC Models cap.
Check fuel reservoir for water contamination. If
necessary, siphon and refill with fresh fuel.
8. Run the engine for 3 minutes in a test tank or
To limit damages to the engine, perform the fol-
connected to a flush kit
lowing procedure as soon as possible.
9. Repeat the above steps 1 to 7.
If it was submerged in salt water, spray bilge and
all components with fresh water using a garden a. Recommended procedure BOIL OUT PRO-
hose to stop the salt corroding effect. CEDURE IN A TEST TANK OR TIED TO A
CAUTION: Never try to crank or start the
engine. Water trapped in the intake manifold b. Optional procedure: BOIL OUT PROCEDURE
would enter the combustion chamber through CONNECTED TO A FLUSH KIT.
the intake valves and may cause damage to the
engine.
02-04-2 SMR2002-056_02_04A.FM
cap.
a. Recommended procedure BOIL OUT PRO-
CEDURE IN A TEST TANK OR TIED TO A
b. Optional procedure: BOIL OUT PROCEDURE
CONNECTED TO A FLUSH KIT.
 WARNING
Make sure to safely secure the watercraft.
F18D19A 1
Boil Out Procedure in a Test Tank or Tied to a
1. Scavenge oil pump cover drain plug
Trailer with Watercraft in Water
ENGINE WITH THE SCAVENGE OIL PUMP 1. Run the engine for 5 minutes at 3500 RPM.
COVER DRAIN PLUG
2. With the engine still running at 3500 RPM, in-
CAUTION: Never crank or start engine when si- stall a hose pincher to the coolant line going to
phon tube is in dipstick hole. Never start engine the oil cooler.
1. Using the oil VAC (P/N529 035 880), siphon oil  WARNING
through dipstick hole. Certain components in the engine compart-
2. Remove the oil vac tool from the dip stick hole. ment may be very hot. Direct contact may re-
3. While in drowned engine mode, crank the en- sult in skin burn. Do not touch any electrical
gine for 5 seconds. parts or jet pump area when engine is running.
1
5. Again, siphon oil from the reservoir.
6. Put a rag under the scavenge oil pump cover.
7. Remove the scavenge oil pump cover drain
plug and install fitting (P/N 293 710 037).
8. Connect the oil vac tool Bombardier (P/N 529
035 880) to the fitting.
9. The front of the engine must be tilt down ap-
proximately 15 degrees to facilitate the remov-
al of the oil. Raise the rear of the boat accord-
ingly. Siphon the oil from the fitting.
10. Level the engine.
F18E1QA
11. Remove the oil vac tool and the fitting. Rein-
stall the drain plug. 1. Oil cooler coolant inlet hose
NOTE: Do not forget to install the sealing washer 3. Continue to run the engine at 3500 RPM for 15
on the drain plug. more minutes (20 minutes total run time).
NOTE: If spillage occurs, clean immediately with 4. Shut the engine off.
the Pulley flange cleaner (P/N 413 711 809) to pre-
vent oil stains.
SMR2002-056_02_04A.FM 02-04-3
3. Run the engine for 5 minutes at 3000 RPM.

 WARNING 4. With the engine still running at 3000 RPM, in-
Certain components in the engine compart- stall a hose pincher to the coolant line going to
ment may be very hot. Direct contact may re- the oil cooler.
sult in skin burn. Do not touch any electrical
parts or jet pump area when engine is run-
ning.
 WARNING
Certain components in the engine compart-
CAUTION: Hose pincher should be remove be- ment may be very hot. Direct contact may re-
fore operating the watercraft engine. Failure to sult in skin burn. Do not touch any electrical
do this will result in damage to the engine. parts or jet pump area when engine is run-
ning.
going to the oil cooler. 5. Continue to run the engine at 3000 RPM for 15
6. Change the oil and filter again. more minutes (20 minutes total run time).
7. Procedure is now completed. 6. Shut off the engine
Boil Out Procedure Connected to a Flush Kit CAUTION: Hose pincher should be remove be-
fore operating the watercraft engine. Failure to
1. On drive shaft, remove the C-Clip then move
do this will result in damage to the engine.
forward the ring seal carrier. Refer to DRIVE
SYSTEM section. 7. Remove the hose pincher on the coolant line
going to the oil cooler
CAUTION: Make sure that the ring seal carrier
is not in contact with the PTO seal assembly, 8. Change the oil and filter again.
neither with the carbon ring. 9. Move rearward the Ring Seal Carrier and rein-
2. Connect a flush kit to the coolant line. stall the C-Clip. Refer to DRIVE SYSTEM sec-
tion.
water to the exhaust cooling system when wa- 10. Procedure is now completed.
02-04-4 SMR2002-056_02_04A.FM
STORAGE 0
DI Models PTO Flywheel
ENGINE DRAINING Lubricate PTO flywheel at grease fitting with syn-
Disconnect the quick connect fitting. Press both thetic grease (P/N 293 550 010).
tabs and pull fitting. CAUTION: Do not lubricate excessively. Imme-
diately stop when a slight movement is noticed
on rubber boot.
F01I0BA 1
1. Grease PTO flywheel
CAUTION: Never leave any clothing, tool or oth-

er objects near PTO flywheel and drive shaft.
F18E02A
DISCONNECT THIS HOSE

FUEL SYSTEM
Lower hose as necessary so that draining can take All Engines
place. Verify fuel system. Check fuel lines and injectors
Reconnect fitting when done. for leaks. Replace damaged hoses or clamps if
necessary.
Also ensure air compressor drain line is not ob-
structed. Clean as necessary. Sea-Doo Fuel Stabilizer (P/N 413 408 600) or equiv-
alent should be added in fuel tank to prevent fuel
deterioration. Follow manufacturer’s instructions
PROPULSION SYSTEM for proper use.
Jet Pump Fill up fuel tank completely. Ensure there is no wa-
ter inside fuel tank.
Lubricant in impeller shaft reservoir should be
drained. Reservoir should be cleaned and refilled CAUTION: Should any water be trapped inside
with SEA-DOO synthetic 75W90 GL5 polyolester fuel tank, severe internal damage may occur to
oil. Refer to JET PUMP for proper procedure. the fuel injection system.
CAUTION: Use only SEA-DOO jet pump oil or CAUTION: Fuel stabilizer should be added prior
equivalent synthetic gear oil, otherwise com- to engine lubrication to ensure fuel system com-
ponent service life could be reduced. Do not ponents protection against varnish deposits.
mix oil brands or types.
SMR2002-057_02_05A.FM 02-05-1
CAUTION: Install new O-rings.

 WARNING – Torque the two bolts that hold the fuel rail on.
Fuel is inflammable and explosive under cer-
tain conditions. Always work in a well venti-
lated area. Do not smoke or allow open flames  WARNING
or sparks in the vicinity. Fuel tank may be pres- At preseason preparation, ensure to perform a
surized, slowly turn cap when opening. Never fuel pressure test and ensure there is no leak.
use an open flame to check fuel level. When Also run engine and check for leaks. Refer to
fueling, keep watercraft level. Do not overfill ENGINE MANAGEMENT section.
or top off the fuel tank and leave watercraft in
the sun. As temperature increases, fuel ex- – Pull engine cover upward to remove it.
pands and might overflow. Always wipe off – Disconnect ignition coil connectors.
any fuel spillage from the watercraft. Always
wipe off any fuel spillage from the watercraft.  WARNING
ENGINE OIL CHANGE AND FILTER ways disconnect coil from main harness first.
4-TEC Engines open coil and/or spark plug in the engine
Change engine oil and filter. Refer to LUBRICA- compartment as spark may cause fuel vapor
TION in ENGINE section. to ignite.
IMPORTANT: Never cut the locking ties of coil

COOLING SYSTEM FLUSHING connectors. This would allow mixing the wires be-
AND ENGINE INTERNAL tween cylinders.
LUBRICATION – Remove ignition coils.
DI Engines CAUTION: Ensure there is no dirt in coil holes
prior to removing the spark plugs. Otherwise,
Cooling system has to be flushed with fresh wa-
dirt would fall into cylinder and will damage the
ter to prevent salt, sand or dirt accumulation which
internal components.
will clog water passages.
– Remove the spark plugs.
Engine must be lubricated to prevent corrosion on
internal parts. – Apply BOMBARDIER LUBE lubricant into the
cylinders
For proper procedure, refer to FLUSHING AND
LUBRICATION. – Reinstall spark plugs and ignition coils.
– Reconnect ignition coil connector.
ENGINE LUBRICATION NOTE: Prior to inserting the ignition coil to its lo-
4-TEC Engines cation, apply some BOMBARDIER LUBE lubricant
around the seal area that touches the spark plug
Fogging of the engine is recommended at the end hole. After installation, ensure the seal seats prop-
of the season and before any extended storage erly with the engine top surface.
period. This will lubricate the intake engine valves,
the cylinders and the exhaust valves. – To reinstall engine cover, push it downward until
it snaps.
To fog the intake engine valves proceed as follows:
– Crank engine several times while keeping throt-
– Remove the two bolts that hold the fuel rail on. tle fully depressed.
– Remove the rail along with the three fuel injec-
tors.
– Apply BOMBARDIER LUBE lubricant into the
intake ports.
– Crank engine at wide open throttle to prevent
fuel injection and ignition.
– Reinstall the injectors.
02-05-2 SMR2002-057_02_05A.FM
In cool regions (where freezing point may be encoun-

1
tered), cooling system should be filled with water and
antifreeze solution (40% water, 60% antifreeze).
CAUTION: Remaining water in cooling system
will freeze. If antifreezing is not performed ade-
quately engine/exhaust system may freeze and
cause severe engine damage. Always use ethyl-
ene glycol antifreeze containing corrosion inhib-
itors specifically recommended for aluminum
engines.
NOTE: When available, it is recommended to use
biodegradable antifreeze compatible with internal
combustion aluminum engines. This will contrib-
ute to protect the environment.
F18M01A
NOTE: The engine will not have to run during this
1. Engine intake ports operation.
BATTERY Hose Pinchers Installation

For battery removal, cleaning and storage, refer to Some hoses have to be plugged to prevent drain-
CHARGING SYSTEM. ing, before filling cooling system jackets with the
antifreeze.
WATERCRAFT CLEANING Install hose pinchers at the following location:
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. 1
CAUTION: The watercraft must never be Ieft in

water for storage. Never leave the watercraft
stored in direct sunlight.
ADDITIONAL RECOMMENDED
PROTECTION
DI Engines
NOTE: This procedure requires approximately 2.5 L
(2.6 U.S. qt.) of antifreeze. F18E05A

SMR2002-057_02_05A.FM 02-05-3
Hose Disconnection
Disconnect water INLET hose at engine between
T-fitting and cylinder head fitting.
F18E0FA
1. Crankcase cooling cover outlet hose
F18E0BA
Temporarily install a short piece of hose to replace

the one removed.
Antifreeze
Insert a funnel into the temporary hose and pour
antifreeze mix in engine until the colored solution
appears at cooling system bleed outlet.
F18E08A
1. Engine cylinder drain hose
F07E0LA
02-05-4 SMR2002-057_02_05A.FM
At this point, install a hose pincher on bleed outlet Pour approximately 200 mL (7 oz) of antifreeze in
hose. the water regulator valve supply hose to allow an-
tifreeze flowing through the valve and into muffler
to protect it.
Remove temporary hose and reconnect engine
water outlet hose.
Most of the antifreeze will drain out when removing
the hose pinchers. Use a container to recover it. DIS-
POSE ANTIFREEZE AS PER YOUR LOCAL LAWS
AND REGULATIONS.
NOTE: Although antifreeze will mainly drain out,
possibly trapped in the cylinder water jackets and
thus preventing freezing problems.
At preseason preparation, drain the remaining an-
F18E0EA 1 tifreeze from cooling system prior to using the wa-
1. Bleed outlet hose tercraft.
Continue to pour until antifreeze flows in air com- 4-TEC Engines
pressor water outlet hose. Refer to the COOLING SYSTEM section.
ANTICORROSION TREATMENT
All Engines
Wipe off any residual water in the engine compart-
ment.
Spray BOMBARDIER LUBE lubricant over all me-
tallic components in engine compartment.
Lubricate the throttle cable with BOMBARDIER
LUBE lubricant.
The seat should be partially left opened during
storage. This will avoid engine compartment con-
F18E01A 1 densation and possible corrosion.
Remove pinchers in this order to allow proper flow

of antifreeze.
1. Bleed outlet hose.
2. Crankcase cooling cover outlet hose.
3. Engine cylinder drain hose.
4. Water outlet hose.
SMR2002-057_02_05A.FM 02-05-5
CHECKLIST
OPERATION ✔
Check engine drain hose (DI engines)
Drain and clean impeller shaft reservoir
(DI engines)
Lubricate PTO flywheel (DI engines)
Verify fuel system
Add Sea-Doo fuel stabilizer
Flush the cooling system (DI engines)
Change engine oil and filter (4-TEC engines)
Flush the exhaust cooling system by
running the engine (4-TEC engines)
Lubricate the engine
Remove, clean and store the battery
Clean the bilge
Wash the body
Add antifreeze solution to the cooling
system (in cool regions) (DI engines)
Replace antifreeze. Check solution
concentration in the cooling system
(in cool regions) (4-TEC engines)
Spray BOMBARDIER LUBE over all metallic
components in engine compartment and on
throttle cable. For DI engine, spray on
injection pump cables
02-05-6 SMR2002-057_02_05A.FM
TROUBLESHOOTING CHART 0
The following is provided to help in diagnosing the probable source of troubles. It is a guideline and should
not be assumed to show all causes for all problems.
NOTE: On DI and 4-TEC models, always check for fault codes recorded in the MPEM (DI models) or
EMS ECU (4-TEC models) first using the VCK (vehicle communication kit (P/N 529 035 844). If a fault
code is detected, service the fault code and recheck operating conditions. Refer to DIAGNOSTIC PRO-
CEDURES in ENGINE MANAGEMENT section.
ENGINE WILL NOT START
• Wrong safety lanyard • Use one that has been programmed
for that watercraft
• DESS operation non functional • If 2 short beeps are not heard when
installing safety lanyard, refer to
ELECTRICAL SYSTEM and ENGINE
MANAGEMENT
• Safety lanyard switch faulty or discon- • Replace
nected or harness damaged
• Disconnected or faulty DESS auxil- • Refer to ENGINE MANAGEMENT
liary module (4-TEC models)
• Burnt fuse on MPEM or in rear elec- • Check wiring then replace fuse
trical box: battery, starting system,
fuel pump
• Starting system fuse keeps on burning • Check wiring, starting system solenoid
and MPEM
• Discharged or disconnected battery • Check/recharge
Engine does not turn over • Defective or disconnected start/stop • Check, refer to STARTING SYSTEM or
switch ENGINE MANAGEMENT
• Battery connections • Check/clean/tighten
• Water/fuel hydrolock • Check, refer to section MAINTENANCE
• Starter malfunction • Check, refer to section ELECTRICAL
SYSTEM
• Starter solenoid • Check, refer to section ELECTRICAL
SYSTEM
• Seized or obstructed engine • Check/repair, refer to section ENGINE
• Hydraulically locked air compressor • Check/repair as needed
(DI models)
• Seized jet pump • Check, refer to section PROPULSION
SYSTEM
• Faulty EMS ECU (4-TEC models) or • Check faulty codes in MPEM or EMS
MPEM ECU memory, refer to section ENGINE
MANAGEMENT
SMR2002-058_03-01A.FM 03-01-1

• Loose battery cable connections • Check/clean/tighten
• Discharged/weak battery • Check/charge/replace
• Restriction in jet pump • Check/clean pump
• Partial seizure in jet pump • Inspect, refer to section PROPULSION
SYSTEM
• Partial engine hydrolock • Check, refer to section MAINTENANCE
Engine turns slowly
• Partial engine seizure • Check compression, refer to section
ENGINE
• Worn starter • Check, refer to section ELECTRICAL
SYSTEM
• Outside temperature too low • Oil is too “thick”. Change oil viscosity
• Battery capacity is not sufficient for
cold temperature
03-01-2 SMR2002-058_03-01A.FM

• Faulty component in the fuel injection • Check for fault codes with the VCK
system (DI models) (vehicle communication kit). Refer to
DIAGNOSTIC PROCEDURES in
ENGINE MANAGEMENT
• Engine drowned mode is active • Release throttle lever
• Low battery voltage • Recharge or replace battery
• Low or no fuel pressure • Check fuel pump operation
(DI models) • Check fuel pump pressure output
• Check air/fuel rail
• Check fuel pump fuse
• Check wiring harness
• Fuel injectors not working • Check fuel injector operation. Replace
(DI models) as necessary
• Check output signal from MPEM
• Low or no air pressure (DI models) • Check air/fuel rail
• Check air compressor system
• Check RAVE valve system for leaks
• Direct injector not working • Check direct injector operation
(DI models) • Check output signal from MPEM
Engine turns over • No spark at the spark plug • Check spark plugs condition and
replace as necessary
• Check ignition system and repair
• Defective MPEM or EMS ECU • Replace MPEM or EMS ECU
(as applicable)
• Defective crankshaft position sensor • Check operation of CPS and replace if
necessary
• Water-contaminated fuel • Check/siphon and refill
• Dirty fuel filter • Clean/replace
• Fouled or defective spark plug • Replace
• Water in engine • Check, refer to section MAINTENANCE
• Defective ignition circuit • Check, refer to section ELECTRICAL
SYSTEM
• Internal engine damage • Check, refer to section ENGINE
• Defective encoder wheel • Check, refer to section ENGINE MAN-
AGEMENT
• Insufficient engine compression • Replace defective part(s)
• Incorrectly aligned flywheel and en- • Properly position flywheel and encoder
coder wheel (4-TEC models) wheel, refer to section PTO HOUSING/
MAGNETO
• Ignition • Check, refer to section ELECTRICAL
No spark at spark plugs SYSTEM
• Faulty EMS ECU (4-TEC models) or • Replace EMS ECU or MPEM
MPEM (as applicable)
SMR2002-058_03-01A.FM 03-01-3
ENGINE HARD TO START

• Defective idle bypass valve • Refer to ENGINE MANAGEMENT
(4-TEC models)
• Wrong TPS zero setting • Refer to ENGINE MANAGEMENT
(4-TEC models)
• Wrong throttle body mechanical ad- • Refer to ENGINE MANAGEMENT
justment of cable
• Temperature too low for available • Battery capacity is not sufficient for cold
battery capacity temperature
• Air lock in fuel rail (4-TEC models) • Refer to ENGINE MANAGEMENT
• Water in intake system (defective • Check and remove water
sensor) (4-TEC models) • Refer to intake system in ENGINE
MANAGEMENT
• Water in fuel reservoir or • Flush reservoir and refill with fresh gas
contaminated fuel
• Mechanical engine failure • Check cylinder compression
• Check for cylinder head leaks
• Check starting system
• Low fuel pressure • Check fuel pump operation. Refer to
ENGINE MANAGEMENT
• Check fuel pressure regulator. Refer to
ENGINE MANAGEMENT
• Low air pressure (DI models) • Check air/fuel rail. Refer to ENGINE
MANAGEMENT
• Check air compressor system. Refer to
ENGINE MANAGEMENT
• Check RAVE valve for leaks
ENGINE STARTS BUT RUNS ONLY AT IDLE SPEED

• The system is in limp home mode • Refer to section ENGINE and check the
fault codes in the EMS ECU
(4 TEC models) or MPEM or
(DI models)
• Broken or loose throttle cable • Change/readjust
03-01-4 SMR2002-058_03-01A.FM
ENGINE MISFIRES, RUNS IRREGULARLY

• Fouled, defective, worn spark plugs • Check/verify heat range/gap/replace
• Faulty EMS ECU (4-TEC models) • Check, refer to section ENGINE
MPEM (DI models) MANAGEMENT
MANAGEMENT
Weak spark • Too much oil supplied to engine • Adjust oil injection pump
(DI models)
• Bad ignition coil wiring • Check wiring condition and proper
grounding of ignition coil
• Faulty ignition coil, or bad connector • Check coil. Refer to ENGINE
MANAGEMENT
• Low fuel level • Check/refill
• Low fuel pressure • Check pump, regulator, injectors and
hose pinchers or if filter is plugged.
Replace if necessary
• Stale or water fouled fuel • Check/siphon and refill
• Fuel filter dirty or restricted • Check/clean/replace
Lean fuel mixture
Dry spark plug (except • Clogged fuel injectors • Remove and clean fuel injectors
when water fouled) • Clogged direct injectors • Remove and clean direct injectors
(DI models)
• Clogged fuel injectors
(4-TEC models)
• Defective sensor or EMS ECU • Check faulty codes in EMS ECU or
(4-TEC models)/MPEM (DI models) MPEM (as applicable) memory, refer to
section ENGINE MANAGEMENT
• Flame arrester dirty or restricted • Check/replace
• Improper air/fuel rail pressure • Check pressures, refer to ENGINE
(DI models) MANAGEMENT
• Faulty fuel injector(s) • Remove and replace fuel
injector(s), refer to section ENGINE
MANAGEMENT
• Faulty direct injector(s) (DI models) • Remove and replace direct
injector(s), refer to section
ENGINE MANAGEMENT
• Defective sensor or EMS ECU • Check faulty codes in EMS ECU or
(4-TEC models)/MPEM (DI models) MPEM (as applicable) memory, refer to
Rich fuel mixture section ENGINE MANAGEMENT
Fouled spark plug
(DI models) ENGINE
• Leak in RAVE valve system • Check, refer to ENGINE MANAGEMENT
(DI models)
• Oil injection pump adjustment • Check/adjust, refer to section
(DI models) LUBRICATION SYSTEM
• Fuel pressure fluctuating • Inspect fuel pressure regulators. Refer
to ENGINE MANAGEMENT
• High fuel pressure • Check pump, regulator, injectors, hose
pinchers or if filter is plugged. Replace
if necessary
SMR2002-058_03-01A.FM 03-01-5

• Check spark plug condition, check • Check, refer to section ENGINE
fault codes in the EMS ECU or MPEM MANAGEMENT. If some work has
Start but run poorlys memory, check fuel pressure, check been performed on the unit, make sure
RAVE valves operation injector wire connectors were not
mixed. Refer to the wiring diagram for
wire colors and positions
• Bent or missing tooth on encoder • Check, refer to ENGINE
wheel MANAGEMENT under component
Also fuel injection inspection and adjustment
misinjecting • Injector wiring reversed • Check with wiring diagram
• Damaged fuel injector • Check, refer to ENGINE MANAGEMENT
ENGINE CONTINUALLY BACKFIRES

Weak spark • Fouled, defective spark plugs • Clean/replace
Spark plugs • Ignition coil leads or wiring reversed • Check with wiring diagram
• Incorrect setting (DI models) • Check/reset, refer to section
ELECTRICAL SYSTEM
Ignition timing/TDC setting
MANAGEMENT
• Intake or exhaust valve(s) leak • Pressure check engine, refer to section
Engine
(4-TEC models) ENGINE
ENGINE DETONATION OR PINGING

• Timing too far advanced • Check/reset
Ignition
• Engine overheats and exhaust over- • Check, see engine overheats
heats
Engine/exhaust high • Fuel octane too low of poor quality • Use good quality fuel
temperature • KS disconnected or faulty • Check, refer to ENGINE MANAGEMENT
• Bad KS connection • Check, refer to ENGINE MANAGEMENT
• Bad Kostal connection (on engine) • Check, refer to ENGINE MANAGEMENT
03-01-6 SMR2002-058_03-01A.FM
ENGINE LACKS ACCELERATION OR POWER

• Weak spark • Check/replace, refer to section
ELECTRICAL SYSTEM
• Throttle does not open fully • Check/readjust, refer to section
ENGINE MANAGEMENT
• Low compression • Check/repair, refer to section ENGINE
• Water in fuel • Check/siphon/replace
• Impeller leading edge damaged • Check/replace, refer to section
PROPULSION SYSTEM
• Too much engine oil (4-TEC models) • Siphon or adjust level. Refer to LUBRI-
CATION
• Twisted crankshaft (DI models) • Check, refer to section ENGINE
• Poor quality • Siphon then refill with fresh fuel
• Clogged direct injectors • Remove and clean direct injectors
(DI models)
• Low fuel pressure • Check fuel line and fuel pump pressure
• Incorrect throttle position sensor • Check and adjust TPS, refer to section
(TPS) adjustment ENGINE MANAGEMENT
• Improper timing chain alignment • Refer to section CYLINDER HEAD
(4-TEC models)
• Overheated engine • See ENGINE OVERHEATS in this chart
Engine revs lower than • RAVE valve does not open • Check, refer to section ENGINE
its maximum operational (DI models)
RPM • Limp home mode activated • Refer to ENGINE MANAGEMENT
Peak performance is • RAVE valve is stuck opened • Check, refer to section ENGINE
delayed until higher (DI models)
RPM range is reached
ENGINE STOPS RUNNING

Engine dies during regular • Improper ignition timing (DI only) • Check/reset
operation (piston seizure) • Compression ratio is too high • Install genuine parts
• Poor oil quality • Use proper BOMBARDIER oil
Engine was running below • Electrical noise (DI models) • Refer to section ENGINE
2000 RPM. MANAGEMENT
No maintenance light
• Low air pressure (DI models) • Check air delivery circuit for leaks
Engine stalls at idle • Air in fuel rail (4-TEC models) • Check air compressor
• Refill fuel tank
• Engine running out of fuel • Check fuel delivery system for proper
fuel pressure and delivery
Engine start but stops after • Air in fuel rail • Refill fuel tank
approximately 2 seconds
• Low air pressure (DI models) • Check air system
(compressor, air/fuel rail etc.)
SMR2002-058_03-01A.FM 03-01-7
ENGINE CANNOT REACH MAXIMUM RPM

• RAVE valve does not open • Check, refer to section ENGINE and
(DI models) COOLING SYSTEM
• Faulty water regulator valve • Check, refer to COOLING SYSTEM
(DI models)
• The system is in limp home mode. • Refer to section ENGINE and check the
“MAINT” is displayed on Information fault codes in the EMS ECU
Center
• Low fuel pressure • Check fuel pump pressure output
• Jet pump related problem • Check propulsion components.
Refer to JET PUMP
• Limp home mode activated • Refer to ENGINE MANAGEMENT
• Exhaust system blockage/muffler • Check and repair
damage (DI models)
• Exhaust gases in bilge (leak) • Check exhaust system for leaks
ENGINE RUNS TOO FAST (vehicle cannot reach its top speed)
• Faulty rev limiter in EMS ECU • Check, refer to section ENGINE
(4-TEC models)/MPEM (DI models) MANAGEMENT
• Improper impeller pitch (too low) • Check/replace, refer to section
Engine RPM too high • Incorrect throttle position sensor PROPULSION SYSTEM
(TPS) adjustment • Check and adjust TPS, refer to ENGINE
MANAGEMENT
• Damaged impeller • Replace impeller. Refer to PROPULSION
• Damaged leading or trailing edge of • Check/replace
impeller NOTE: Leading edge damage contributes
to poor performance from start. Trailing
Jet pump cavitation edge damage contributes to poor top per-
formance and stator vanes erosion.
• Sealing of ride plate, jet pump support • Check/reseal, refer to section
or jet pump PROPULSION SYSTEM or HULL/BODY
ENGINE OVERHEATS
• Coolant level low • Refill/check for leaks
• Water leaking out of weep hole
• Replace rotary seal
Coolant level too low (PTO housing)
(4-TEC models) • Hoses or clamps missing/defect • Repair/replace
• Cylinder head gasket leaks • Replace cylinder head gasket
(white exhaust gas)
• Check/replace. Refer to ENGINE
• Temperature sensor defect MANAGEMENT
• Worn water pump impeller • Check/replace
Monitoring beeper sounds • Cooling system restriction • Check/flush, refer to section
continuously MAINTENANCE
• Damaged ride plate or hoses • Check, refer to COOLING SYSTEM
and HULL/BODY
• Thermostat defective
• Check/replace
(4-TEC models)
03-01-8 SMR2002-058_03-01A.FM
ENGINE SMOKE IN THE EXHAUST

• Coolant leak • Check/repair. Refer to LEAK TEST
White smoke • Damaged head gasket • Check/replace the head gasket
(4-TEC models) • Water ingestion • Inspect the intake manifold for the
presence of water
• Valve guide seals • Check/replace valve guide seals, refer
to cylinder head and valves
Blue smoke
(4-TEC models)
• Oil rings worn out • Replace rings
• at engine starting
• Oil rings • Inspect/repair oil rings, refer to engine
• with engine under load block
• Oil level too high • Siphon some oil from the oil tank
LOW OR NO ENGINE OIL PRESSURE (GTX 4-TEC)

• Oil level too low • Refill. See TECHNICAL DATA for
specifications
• Leaking gasket • Replace
• Oil leaking out of weep hole • Replace oil seal on pump shaft
(PTO housing)
• Oil pressure sensor defective • Check/replace
• Oil pump malfunctioning • Clean rotor and check wear limits
• Oil regulator valve sticks open, or • Clean/replace
spring load to small
• Heavy wear on plain bearings • Replace
ENGINE OIL CONTAMINATION (WHITE APPEARANCE) (GTX 4-TEC)

• Oil seal and rotary seal on water pump • Replace both seals. Refer to section
shaft leaking PTO HOUSING. Change oil
• Cylinder head gasket leaking • Replace gasket. Refer to section CYLIN-
Water and oil mixture DER HEAD. Change oil
leaking out of weep hole • Loose screws on cylinder head, PTO • Retorque. Change oil
(PTO housing) housing or oil seperator
(4-TEC models) • Oil contamination due to metal or • Replace possibly damaged parts.
plastic particles Change oil
• Water ingestion (intake manifold, • Refer to MAINTENANCE
TOPS valve, dipstick)
SMR2002-058_03-01A.FM 03-01-9
UNUSUAL ENGINE NOISE AND/OR VIBRATION (GTX 4-TEC)

• Worn chain tensioner • Replace
• Worn chain guide • Replace
• Stretched chain and/or worn out • Replace chain and sprockets
sprockets
• Sprocket screws got loose • Retorque
• Hydraulic element inside rocker • Replace faulty rocker arm(s)
arm(s) is(are) worn out (valve adjust-
ment)
• Rocker arm screws not tightened • Retorque
• Heavy wear on crankshaft and/or bal- • Replace
ancer shaft bearings
• Crankshaft and balancer shaft not • Check marks and readjust shafts
aligned
• Heavy wear on thrust washers, or • Check/replace
thrust washers missing
ABNORMAL NOISE FROM PROPULSION SYSTEM

• Weeds/debris caught in intake grate • Check/clean
or impeller
• Low oil level in jet pump (DI models) • Check/troubleshoot source of leak/
refill supply, refer to section
PROPULSION SYSTEM
• Worn anti-rattle system (DI models) • Check/replace pusher in cover, refer to
section PROPULSION SYSTEM
• Damaged or bent drive shaft • Check/replace, refer to section
PROPULSION SYSTEM
• Idle speed too low • Check fault codes
• Broken engine mounts • Check/replace, refer to section ENGINE
NOTE: Prior to replacing a EMS ECU or MPEM, refer to the appropriate EMS ECU/MPEM section or EMS
ECU/MPEM REPLACEMENT in the ENGINE MANAGEMENT section and read carefully the tests to do
before replacing a EMS ECU/MPEM that could otherwise be good.
03-01-10 SMR2002-058_03-01A.FM
Section 04 ENGINE (DI)
TABLE OF CONTENTS 0
LEAK TEST............................................................................................................................. 04-02-1
GENERAL ........................................................................................................................... 04-02-1
PREPARATION ................................................................................................................... 04-02-1
ENGINE LEAKAGE DIAGNOSTIC FLOW CHART ............................................................ 04-02-4

GENERAL ........................................................................................................................... 04-03-1
ENGINE REMOVAL............................................................................................................ 04-03-1
CLEANING ......................................................................................................................... 04-03-3
INSTALLATION .................................................................................................................. 04-03-4
MAGNETO SYSTEM ............................................................................................................. 04-04-1

DISASSEMBLY .................................................................................................................. 04-04-2
CLEANING ......................................................................................................................... 04-04-3
ASSEMBLY......................................................................................................................... 04-04-3
TOP END ................................................................................................................................ 04-05-1

GENERAL ........................................................................................................................... 04-05-2
DISASSEMBLY................................................................................................................... 04-05-3
CLEANING ......................................................................................................................... 04-05-6
INSPECTION ...................................................................................................................... 04-05-7
USED PISTON MEASUREMENT ...................................................................................... 04-05-8
ASSEMBLY......................................................................................................................... 04-05-10
BOTTOM END........................................................................................................................ 04-06-1

DISASSEMBLY................................................................................................................... 04-06-2
CLEANING ......................................................................................................................... 04-06-5
INSPECTION ...................................................................................................................... 04-06-6
ASSEMBLY......................................................................................................................... 04-06-10
EXHAUST SYSTEM............................................................................................................... 04-07-1

REMOVAL........................................................................................................................... 04-07-2
TUNED PIPE REPAIR ......................................................................................................... 04-07-6
INSTALLATION .................................................................................................................. 04-07-6
SMR2002-095_04-01ATOC.FM 04-01-1
LEAK TEST 0
GENERAL PREPARATION
A Sea-Doo Engine Leak Test Kit (P/N 295 500 352) Verify fuel system for leaks.
and Supplementary Engine Leak Test Kit (P/N 295
500 780) are available to help diagnose engine  WARNING
problems such as engine seizure, poor perfor- If any fuel leak is found, do not start the en-
mance, oil leakage, etc. gine. Correct the leak and wipe off any fuel
Before disassembling any components of the en- spillage. Do not use electric powered tools
gine, it is important to perform a leakage test to unless fuel system has passed pressure test.
determine which part is defective.
It is also very important after servicing the engine, Disconnect battery BLACK negative cable.
even for a complete engine rebuilt, to perform an-
other leakage test; at this stage, it may avoid fur-  WARNING
ther engine problems and minimizing the risk of Always disconnect battery cables in the speci-
having to remove and reinstall the engine again. fied order, BLACK negative cable first.
Static bench testing is the most effective way to
Disconnect battery RED positive cable.
conduct a leakage test. Inboard testing does not
allow complete access to, and observation of all
engine surfaces and should be avoided whenever TESTING PROCEDURE
possible.
Engine Cooling System
When installing hoses of the Engine Leak Test Kit
or Supplementary Engine Leak Test Kit, use the Remove the tuned pipe. Refer to EXHAUST SYS-
collars provided in the kit to ensure a proper seal- TEM.
ing. Remove the exhaust manifold gasket and ensure
When pressurizing the engine, first confirm that the surface is clean.
the components of the Engine Leak Test Kit or Disconnect engine cooling hoses.
Supplementary Engine Leak Test Kit are not leak-
Install the appropriate exhaust manifold plate from
ing by spraying a solution of soapy water on all
the Engine Leak Test Kit (P/N 295 500 352) or Sup-
hoses, connections, fittings, plates, etc. If there is
plementary Engine Leak Test Kit (P/N 295 500 780).
a leak, bubbles will indicate leak location.
Tighten plate using fasteners provided in the kit.
Three areas of the engine will be tested in se-
NOTE: Do not torque plate excessively.
quence as per the diagnostic flow chart (see the
end of this subsection). Install a hose pincher on engine drain hose.
1. Engine Cooling System. Use hoses provided in the kit and install them on
the engine.
2. Bottom End and Top End.
Install pump using reducer and appropriate tube(s)
NOTE: If a leak is found, it is important to continue
as necessary.
testing as there is the possibility of having more
than one leak. Continue pumping to compensate
for the air lost to find another leak.
SMR2002-059_04_02A.FM 04-02-1
2 Activate pump and pressurize engine cooling sys-

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

Remove throttle bodies.
F12E08A 1 Install intake manifold plugs (P/N 529 035 708).
947 DI ENGINE — SIDE VIEW
1. Block engine drain hose with a hose pincher
2. Install pump to water inlet hose
F12D14A 1
1. Intake manifold plugs
Remove the RAVE valves and gaskets.

F12E07A
Install the RAVE valve plates with fasteners from
947 DI ENGINE — FRONT VIEW the kit and tighten adequately.
1. Exhaust manifold plate
The O-ring can be checked for leakage with the
NOTE: Water is not required for testing. valve in place. Simply remove the cover to expose
It is not necessary to pressurize the bottom crank- the parts.
case cover nor the magneto cover. There is no pos- Make sure the spark plugs and the air/fuel rail are
sible water leak path toward the internal compo- installed and tightened.
nents of the engine.
04-02-2 SMR2002-059_04_02A.FM
Install pump to the exhaust plate fitting. Wait 3 minutes and check if pressure drops; if so,
1 2
If kit components are not leaking, verify engine
jointed surfaces as per following areas:
– spark plugs
– direct injector sealing
– cylinder head gasket
– cylinder base gasket
– crankcase halves
– engine plugs
– exhaust manifold
– intake flanges.
Check also small oil injection pump lines and fit-
tings; check for air bubbles or oil column going to-
ward pump, which indicate a defective check valve.
Check for leak through cournterbalancing shaft
seal toward air compressor. Air bubbles in lowest
fitting (oil return line) underneath compressor indi-
cates a seal leakage.
At this point, proceed with testing (if so equipped).
F08D05A 3
If there is still some leakage, remove the PTO fly-
947 DI ENGINE
1. Exhaust plate
wheel to verify outer seal.
2. Rave valve plates If no leak is found on the PTO side outer seal, re-
3. Intake plates
move magneto flywheel and verify crankshaft out-
Activate pump and pressurize engine to 34 kPa (5 PSI). er seals.
CAUTION: Do not exceed this pressure.
SMR2002-059_04_02A.FM 04-02-3
ENGINE LEAKAGE DIAGNOSTIC FLOW CHART

947 DI Engine
F00D28T
04-02-4 SMR2002-059_04_02A.FM

GENERAL Disconnect connectors from fuel injectors and di-
rect injectors.
On some models, it is not necessary to remove
Disconnect connector from knock sensor.
engine from watercraft to service TOP END, PTO
FLYWHEEL or MAGNETO. However, engine remov- Disconnect RAVE valve hose where shown. Inspect
al is necessary to repair BOTTOM END. hose. If it has hardened or is slit, replace hose.
ENGINE REMOVAL
Use the VCK (Vehicle Communication Kit) (P/N 529
035 676) and release the fuel pressure in the fuel
system. Refer to ENGINE MANAGEMENT section.
In order to remove engine from watercraft proceed
as follows.
First, disconnect battery cables from battery.
 WARNING 1
first then the RED positive battery cable last. F16D03A
1. Disconnect hose here
Electrical Connections Refer to ENGINE MANAGEMENT for location of sen-

It is recommended to disconnect electrical con- sors and connectors.
nections prior to disconnecting fuel lines. Unplug air compressor lines (inlets and outlets):
Disconnect temperature sensor wire and spark plug cooling, oil (outlet only) and air (inlet only on throt-
cables. tle body side).
Disconnect magneto wiring harness. Disconnect vent hose from balancing shaft gear
housing.
Jet Pump Removal

To withdraw jet pump, refer to JET PUMP.
CAUTION: Whenever removing engine from
watercraft, engine/jet pump alignment must be
performed at reinstallation.
Drive System
To withdraw drive shaft(s), refer to DRIVE SYSTEM.
Cooling System
Disconnect the engine water supply hose.
F07D08A 1 Disconnect the engine water return hose.
1. Unplug connector NOTE: Engine will have to be raised inside bilge
Disconnect both throttle position sensors (TPS), to disconnect drain hose before removing from
manifold air pressure sensor (MAPS) and manifold bilge.
air temperature sensor (MATS). Refer to COOLING SYSTEM for proper water hose
location.
SMR2002-060_04_03A.FM 04-03-1
Tuned Pipe Lifting Engine

To remove tuned pipe, refer to EXHAUST SYSTEM. 947 DI Engine
Air Intake Silencer Engine can be easily lifted using the following sug-
gested tools:
To remove air intake silencer, refer to AIR INTAKE.
– Cut porcelain from two old spark plugs.
Throttle Body – Weld a lock washer approximately 20 mm (3/4 in)
diameter on each spark plug as shown.
Remove air/fuel rail. Refer to ENGINE MANAGE-
MENT.
Engine Support 1
NOTE: Be careful when removing engine sup-
port(s) or rubber mount adapters, shims could
have been installed underneath. Shims control
of shims for reinstallation, to avoid altering engine
alignment.
Remove engine support mount screws.
F01D0AA 2
1. Weld a lock washer
2. Old spark plug
Remove spark plugs and replace by special tools.

Hook a sling into holes of special tools.
ment, slightly lift engine to ease the remaining
component removal.
CAUTION: Take care not to damage cable or oil
injection hoses.
Remove rear engine support.
F06D35A 1
FRONT SUPPORT 1
1. Remove screw
F07F12A
TYPICAL
1. Rear support
F07F12C 1
REAR SUPPORT
1. Remove screws
04-03-2 SMR2002-060_04_03A.FM
Removal of Remaining Components 2

Lift up engine slowly until oil injection hoses can be
reached.
Install a hose pincher to oil supply hoses of oil in-
jection pump then, disconnect hoses.
F06H35A 1
2. Ground cable
A01B2JB
Carry on engine lifting then tilt engine so that it can
TYPICAL be removed from the body opening.
1. Hose pincher (P/N 295 000 076)
CAUTION: Be careful not to scratch body or to
Disconnect RED positive cable from starter post. hit any component.
F01H1JB 1
TYPICAL F01D7RA
TYPICAL
Disconnect BLACK negative cable from engine
crankcase. CLEANING
cleaner.
SMR2002-060_04_03A.FM 04-03-3
INSTALLATION Positive Starter Cable

Installation of engine in watercraft is essentially Torque nut of positive starter cable to 6 N•m
the reverse of removal procedures. However pay (53 lbf•in). Apply dielectric grease on nut.
Engine/Jet Pump Alignment
Rubber Mount, Shim and Screw Alignment is necessary to eliminate possible vi-
Check tightness and condition of rubber mounts. bration and/or damage to components. Check
If they have been removed, apply Loctite 243 alignment of engine using the following alignment
(blue) on screw threads. Torque screws to 25 N•m tools.
(18 lbf•ft). Support plate kit (P/N 529 035 506).
CAUTION: Strict adherence to this torque is im- NOTE: Use plate (P/N 529 035 508) for the 139.5 mm
portant to avoid damaging threads of alumi- (5-1/2 in) jet pump and plate (P/N 529 035 507) for
num insert in bilge. the 155.6 mm (6-1/8 in) jet pump.
Engine Support
Install and torque the engine support screws to
24 N•m (17 lbf•ft) in the indicated order. Refer to
the following illustration.
4
1 2
3 5
F00B0FA 1 2
1. Plate
F12D13A
2. Support
TORQUE TO 24 N•m (17 lbf•ft) AS PER SEQUENCE
Alignment shaft (P/N 295 000 141).
NOTE: Remember to install sleeves and flat washers.
2 1 2 1 2
F00B0GA 1
1. Alignment shaft
To verify alignment proceed as follows:

– Install the appropriate plate with the support to
hull with four nuts.
F12D13B
1. Sleeves
2. Flat washers
04-03-4 SMR2002-060_04_03A.FM
F00B0HA
– Carefully slide shaft through support.

– Insert shaft end into PTO flywheel. F00D0CA 1
NOTE: Ensure the protective hose and carbon
TYPICAL
ring (or seal carrier) is removed to check engine
1. Shim
alignment. If the alignment is correct, the shaft will
slide easily without any deflection in PTO flywheel. CAUTION: Whenever shims are used to correct
alignment, never install more than 1.3 mm
(0.051 in) shim thickness
Engine Support Screws

Apply Loctite 243 (blue) (P/N 293 800 060) on
screw threads.
F07D05A 2 1
TYPICAL
1. Alignment shaft
2. PTO flywheel

end.
NOTE: Use shim(s) (P/N 270 000 024 or P/N 270
000 025) as necessary between engine supports F06D35A 1
and rubber mounts to correct alignment. FRONT ENGINE SUPPORT
SMR2002-060_04_03A.FM 04-03-5
F07F12C 1
REAR ENGINE SUPPORT
Final Inspection
After its installation, properly adjust and bleed oil in-
jection pump as specified in OIL INJECTION PUMP
and adjust throttle cable as specified in ENGINE
MANAGEMENT.
tem, refer to FUEL CIRCUIT.
 WARNING
craft or if any components of the fuel system
are disconnected, a pressure test must be done

04-03-6 SMR2002-060_04_03A.FM
MAGNETO SYSTEM 0
Molykote
111
11
9 Nm 9
(80 lbfin) Molykote
111 Loctite
Loctite 243
243
20
13 Nm
1 (115 lbfin)
29
25 5 Nm 16 Loctite
(44 lbfin) 243
21
9 Nm
(80 lbfin)
Loctite
243
8
14
13
115 Nm
(85 lbfft) Loctite
243
F12D0SS
SMR2002-061_04_04A.FM 04-04-1
DISASSEMBLY
Cover
cover no. 1.
F06D0LA 1
1. Screw
To remove the ring gear/rotor assembly, unscrew

nut no. 13 counterclockwise when facing it.
F06D1RA 1 2
TYPICAL
1. Cover
2. Screw
Remove oil pump shaft from magneto rotor nut.
F06D0MA 1
1. Nut
The magneto rotor is easily freed from crankshaft

Install protective cap (P/N 290 877 414) to crank-
shaft.
F06D23A 1
Fully thread puller in magneto rotor.
1. Remove oil pump shaft
Rotor and Ring Gear

To remove the rotor no. 8 or the ring gear no. 3,
the crankshaft must be locked. For procedure, re-
fer to BOTTOM END.
If necessary, the magneto rotor can be removed
without removing the ring gear. Remove the six
screws no. 17.
04-04-2 SMR2002-061_04_04A.FM
CAUTION: Ensure to completely screw the puller CLEANING

until it bottoms. Otherwise, not enough threads
would be engaged and damage may occur. Clean all metal components in a solvent.
CAUTION: Clean coils and magnets using only
a clean cloth.
Clean crankshaft taper and threads using acetone.
Apply the acetone on a rag first then clean the
crankshaft.
ASSEMBLY
Battery Charging Coil
Position new coil, crimp and solder all wires.
Prior to assembly, apply Loctite 243 (blue).
and install it so that it fits around armature plate
before tightening screws no. 23.
F06D0PA 1
1
1. Puller

CAUTION: Be careful after ring gear removal
not to bend the encoder wheel teeth. Also pay
attention when putting away. If you suspect a
bent tooth, refer to ENGINE MANAGEMENT for
inspection procedure.
F00D0AA
(Crankshaft Position Sensor) 1. Magneto coil centering tool (P/N 420 876 922)
Loosen screws no. 20 and no. 21 to remove the

stator no. 9 and trigger coil no. 10 from the engine Magneto Flywheel and Ring Gear
magneto cover. 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.
F06D0NA 1
1. Remove screws
SMR2002-061_04_04A.FM 04-04-3
Pay particular attention to position ring gear teeth When reinstalling armature plate on a new crank-
chamfer side as per following illustration. case housing, proceed as follows.
Find manufacturer’s mark on armature plate. In
line with this mark, punch another mark on adja-
cent crankcase lug.
2 1
F01D3BA 1
F01D4FA
1. Teeth chamfer
TYPICAL
NOTE: Ensure that ring gear contacts magneto 1. Manufacturer’s mark on armature plate
flywheel flange. 2. Punch a mark on crankcase lug aligned with plate mark
Whenever replacing either ring gear or magneto The new mark on crankcase will be used for fur-
flywheel, Gun Kote must be applied to prevent ther assembly positioning as a pre-timing position.
possible corrosion.
CAUTION: Always assemble magneto flywheel
and ring gear prior to apply Gun Kote. If not done
correctly, ring gear won’t contact magneto fly-
wheel flange.
To apply Gun Kote proceed as follows:
1. Clean thoroughly and degrease replacement
part using a non oil base solvent.
2. Apply coating in light thin coats using a spray
gun.
NOTE: Do not spray Gun Kote into magneto fly- 1
wheel threaded holes.
3. Bake parts in oven at 175°C (350°F) for 1 hour
to cure Gun Kote.
CAUTION: Do not eliminate Gun Kote heat cur- F01D4GA
ing time because it will lose all its resistance

TYPICAL
and it will not give any protection. 1. For further assembly, use these marks
Magneto Housing Apply a drop of Loctite 243 (blue) on threads of

screws no. 15 and torque to 6 N•m (53 lbf•in).
no. 5 and engine crankcase.
Magneto Flywheel
Install magneto housing and torque screws no. 16
to 9 N•m (80 lbf•in). Apply Loctite 243 (blue) on crankshaft taper.
Position Woodruff key and magneto flywheel. Ap-
Armature Plate ply Loctite 243 (blue) on nut no. 13. Install nut with
lock washer and torque to 145 N•m (107 lbf•ft).
Position the armature plate on the crankcase,
aligning the marks on both parts. CAUTION: Never use any type of impact wrench
at magneto installation.
04-04-4 SMR2002-061_04_04A.FM
Ignition Timing Rotor and Ring Gear

For ignition timing procedures, refer to ENGINE Apply Loctite 648 (green) on mating surface of the
MANAGEMENT. rotor no. 8.
When reinstalling rotor to ring gear no. 3, one of
Magneto Housing Cover the protrusion end of rotor must be aligned with
Properly install O-ring no. 25 in magneto housing. Ap- hole in ring gear.
ply Loctite 767 anti-seize on screws no. 11, install
cover and wire support no. 12. Torque screws no. 11 1 2
in a criss-cross sequence to 9 N•m (80 lbf•in).
Install the stator no. 9 and trigger no. 10 coil in engine
magneto cover. Torque screws to 9 N•m (80 lbf•in).
Reinstall wiring harness bracket no. 29 using tap-
tite screws no. 16.
Torque trigger coil screws no. 21 to 9 N•m (80 lbf•in).
Torque stator screws no. 20 to 13 N•m (115 lbf•in).
NOTE: The trigger coil is not adjustable.
F15D01A
1. Protrusion
2. Hole
Apply Loctite 648 (green) on screws no. 17 retain-

ing rotor to ring gear and torque screws in a criss-
cross sequence to 13 N•m (115 lbf•in).
F06D0NB 1 2 3
2. Taptite screws
Cover
Before installation, properly install O-ring no. 25 in F06D24A 1
engine magneto cover no. 1. 1. Loctite 243 (blue) on crankshaft taper
Install flywheel and make sure to align keyway
with the crankshaft Woodruff key.
with lock washer and torque to 115 N•m (85 lbf•ft).
CAUTION: Never use any type of impact wrench.
Unlock crankshaft. Reinstall pulse fitting with wash-
er and torque to 19 N•m (14 lbf•ft).
SMR2002-061_04_04A.FM 04-04-5
Cover
If heat exchanger cover has been removed, en-
sure to align its notch with the emboss in casing.
1
F12R0EA
1. Align notch with the emboss
04-04-6 SMR2002-061_04_04A.FM
TOP END 0
7
8 14 40 Nm
Loctite (30 lbfft)
243
Molykote 111
3
Engine oil
4
5
6
Engine oil
2
34
13
40 Nm
15 (30 lbfft) Molykote
111
3 Nm
18 (27 lbfin)
16 17 19 20 Loctite
243
9
Molykote 111 25
24 23 22
26 Loctite 243 10
10 Nm
(89 lbfin)
F12D0TS
SMR2002-062_04_05A.FM 04-05-1
GENERAL 4 5 3 1
The 2-stroke ROTAX engine rotates counterclock-
wise seen from the rear (PTO flywheel).
The 947 engine uses reed valves in the crankcase.
The engine is also equipped with the RAVE system
(Rotax Adjustable Variable Exhaust).
CAUTION: No engine components can be inter-
changed between engines.
RAVE System
(Rotax Adjustable Variable Exhaust)
BASIC OPERATION
The RAVE valves change the height of the exhaust
port. The RAVE valve solenoid, which is controlled by
the MPEM, allows a pressure from the air compres- 6
F12D06A 2
sor to inflate the bellows and open the RAVE valves.
1. Solenoid
To open the RAVE valves, the MPEM activates a so- 2. Pressure from air compressor
lenoid which directs the pressure from air compres- 3. Pressure to RAVE valves
sor to the valves. 5. Check valve
6. Vent from counterbalancing shaft oil cavity
1
To close the RAVE valves, the MPEM deactivates the
solenoid which blocks the air compressor pressure.
The RAVE valves are opened to the atmosphere.
The vent on couterbalancing shaft oil cavity is neces-
sary to prevent pressure buildup in the cavity by the
air compressor piston movement. The check valve al-
lows pressure to escape from the cavity but does not
allow liquid to enter into the cavity.
F12D02A
1. Pressure from solenoid
04-05-2 SMR2002-062_04_05A.FM
MAINTENANCE
3 There are no wear parts anywhere in the system
2
and there are no adjustments to be periodically
checked. The only possible maintenance required
4 would be cleaning of carbon deposits from the
guillotine slide. Cleaning intervals would depend
upon the user’s riding style and the quality of the
oil used. We suggest annual cleaning of the valve.
If a customer uses a lower quality oil, than recom-
mended, 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 cyl-
1 inder. This is the minimum production clearance.
F12D04A
There is only a first oversize piston available. That pis-
RAVE VALVE OPENED
ton is 0.25 mm (.010 in) larger in diameter than the
2. Solenoid activated stock piston. When the oversize is installed, the guil-
3. Pressure to solenoid lotine will have a minimum clearance of 0.375 mm
4. Pressure to RAVE valves
(.015 in) with the cylinder bore. This is the minimum
operating clearance the guillotine should be used
3 with. Clearance less than 0.375 mm (.015 in) will re-
2 quire reworking of the guillotine to achieve the proper
clearance and radius.
4
DISASSEMBLY
6
RAVE Valve
7
1
F12D05A
RAVE VALVE CLOSED

2. Solenoid deactivated
3. Pressure to solenoid
4. Pressure to RAVE valves blocked by the solenoid
6. Check valve
7. Counterbalancing shaft oil cavity vent
F12D0UA 1 1
1. Remove screws
SMR2002-062_04_05A.FM 04-05-3
Remove RAVE valve no. 15. Unscrew valve piston no. 20 from sliding valve
Remove the cover no. 18 of the valve by releasing no. 22.
the spring no. 16. NOTE: Hold the sliding valve to prevent it from
turning.
 WARNING 2
F12D0XA 1
1. Unscrew piston
F12D0VA 1 2. Hold sliding valve
1. Spring Remove sliding valve from valve housing.

Remove the compression spring no. 19.
F12D0YA 1 2 3
1. Valve piston
2. Valve housing
3. Sliding valve
Cylinder Head Cover and Cylinder Head

Disconnect temperature sensor wire and spark
plug cables.
F12D0WA 1
Connect spark plug cables on grounding device.
1. Remove spring
Disconnect hose of RAVE valves.
Remove air/fuel rail. Refer to ENGINE MANAGE-
MENT.
Use Snap-On Torx socket E12 and unscrew cylin-
der head screws no. 14 following the sequence
shown in the next illustration.
04-05-4 SMR2002-062_04_05A.FM
To extract piston pin no. 4, use piston pin puller

1 (P/N 529 035 503) with the appropriate set of
5
2 11 sleeves.
10 8 ENGINE SLEEVE SET

6 9
12 947 DI P/N 529 035 543
4
7 1 2 3
3
F12D08B
Remove cylinder head no. 2 and gasket no. 34.
Cylinder
NOTE: When removing cylinder, be careful that
connecting rods do not hit crankcase edge.
Remove cylinders screws then cylinders no. 9.
F00B0IA
Piston
1. Puller
NOTE: All engines feature cageless piston pin 2. Shoulder sleeve
3. Sleeve
bearings.
To remove circlip no. 5, insert a pointed tool in pis- – Fully thread on puller handle.
ton notch then pry it out and discard. – Insert extractor spindle into the piston pin.
– Slide the sleeve and shoulder sleeve onto the
 WARNING spindle.
Always wear safety glasses when removing – Screw in extracting nut with the movable ex-
piston circlips. tracting ring towards spindle.
1 2 3 4
F00B0JA
1. Puller
2. Sleeve
F01D0PA 3. Shoulder sleeve
4. Extracting nut
TYPICAL
1. Piston notch
SMR2002-062_04_05A.FM 04-05-5
NOTE: The tool cutout must be positioned toward

1
the bottom of the piston.
F00B0MA
1. Remove shoulder sleeve

F00B0KA 1
1. Tool cutout toward bottom of piston
– Carefully remove the piston no. 3.
– The needles, thrust washers and the sleeve re-
– Firmly hold puller and rotate handle to pull pis- main in the connecting rod bore and may be
ton pin no. 4. used again.
– Rotate spindle until the shoulder sleeve is
flushed with the piston recess. 1 2
F00B0NA
1. Needles and thrust washer

2. Sleeve
F00B0LA
CLEANING
1. Shoulder sleeve flush with piston recess
Discard all gaskets and O-rings.
– Loosen the extracting nut and remove puller. Clean all metal components in a solvent.
– Remove the shoulder sleeve from piston. Clean water passages and make sure they are not
clogged.
Remove carbon deposits from cylinder exhaust
port, RAVE valve, cylinder head and piston dome.
Clean piston ring grooves with a groove cleaner
04-05-6 SMR2002-062_04_05A.FM
INSPECTION
Visually inspect all parts for corrosion damage.
sanded with a fine sand paper.
NOTE: When repairing a seized engine, connecting
rods should be checked for straightness and crank-
shaft for deflection/misalignment. Refer to BOTTOM
END for procedures.
Inspect plane surfaces for warpage. Small deforma- 1
tion can be corrected by grinding surface with a fine
sand paper. Install sand paper on a surface plate and A
rub part against oiled sand paper.
The inspection of engine top end should include
the following measurements.
TOLERANCES
ENGINE 2
NEW PARTS WEAR F01D8AA
MEASUREMENT
(min.) (max.) LIMIT 1. Measuring perpendicularly (90°) to piston pin axis
2. Auxiliary transfer port
0.05 mm 0.1 mm A. 16 mm (5/8 in)
Cylinder taper N.A.
(.002 in) (.004 in)
0.08 mm 0.08 mm Cylinder Out of Round
Cylinder out of round N.A.
(.003 in) (.003 in) Using a cylinder bore gauge, measure cylinder di-
Piston/cylinder wall 0.12 mm 0.20 mm ameter at 16 mm (5/8 in) from top of cylinder. Mea-
N.A.
clearance for the (.0047 in) (.008 in) sure diameter in piston pin axis direction then per-
Ring/piston groove 0.044 mm 0.089 mm 0.20 mm pendicularly (90°) to it. If the difference between
clearance for the (.002 in) (.003 in) (.008 in) readings exceed specification, cylinder should be
rebored and honed or replaced.
0.55 mm 0.70 mm 1.1 mm
Ring end gap for the
(.022 in) (.028 in) (.043 in)
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 diam-
eter at 16 mm (5/8 in) from top of cylinder just below A A
auxiliary transfer port, facing exhaust port and just be- 2
low the auxiliary transfer port facing the exhaust port.
Compare readings. If the difference between read-
ings exceed specification, cylinder should be rebored
and honed or replaced.
F01D8BA
1. Measuring in piston pin axis

A. 16 mm (5/8 in)
SMR2002-062_04_05A.FM 04-05-7
USED PISTON MEASUREMENT The measured dimension must not be less than
0.12 mm (.005 in) of the one scribed on piston
Note the measurement on the piston dome. dome. Otherwise, install a new piston.

Used and New Pistons
IMPORTANT: Make sure used piston is not worn
more than specified. See USED PISTON MEA-
SUREMENT above.
To determine the piston dimension, take the mea-
surement on the piston dome.
F00D0EA 2 1
1. Piston dome
Using a micrometer, measure piston skirt perpen-

dicularly (90°) to piston pin according to the follow-
ing table.
MAXIMUM A
ENGINE TYPE
mm (in)
F00D0EA 2 1
947 DI 24 (.945)
1. Piston dome
Adjust and lock a micrometer to the specified val-

ue on the piston dome.
A 1
1
F01D0NA
F00B08A

A. See previous table 1. Micrometer set to the piston dimension
With the micrometer set to the piston dimension,

MAXIMUM PISTON adjust a cylinder bore gauge to the micrometer di-
ENGINE TYPE SKIRT WEAR
mm (in)
mension and set the indicator to zero.
All 0.12 (.005)
04-05-8 SMR2002-062_04_05A.FM

The result is the exact piston/cylinder wall clearance.
NOTE: Make sure the cylinder bore gauge indica-
tor is set exactly at the same position as with the
micrometer, otherwise the reading will be false.
2 1
Ring/Piston Groove Clearance
F00B09A

2. Dial bore gauge
1 2
F01D0XA
1. Feeler gauge
2. Rectangular ring (bottom)
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.
1
F00B0AA

1. Indicator set to zero
Position the dial bore gauge at 16 mm (5/8 in) be- placed.
low cylinder top edge.
2
A
F01D0OA 1
F01D0KA
1. Top of cylinder
2. Ring end gap
A. 16 mm (5/8 in)
SMR2002-062_04_05A.FM 04-05-9
Cylinder Base Gasket

or if a crank repair has involved replacement of
connecting rods, refer to the COMBUSTION CHAM-
BER VOLUME MEASUREMENT to properly deter-
mine the required gasket thickness.
Different thicknesses of cylinder base gaskets are
used for a precise adjustment of the combustion
chamber volume. F12D0ZA 1
To identify gasket thickness, refer to the identifi- 1. Piston valve O-ring
cation holes on the gasket. Check the sliding valve O-ring. Replace if neces-
sary.
1
F01D67A
TYPICAL
1. Identification holes
F12D10A 1
GASKET IDENTIFICATION
1. Sliding valve O-ring
THICKNESS HOLES
Check the O-ring under valve housing. Replace if
0.3 MM (.012 IN) 3 necessary.
0.4 MM (.016 IN) 4
0.5 MM (.020 IN) 5
0.6 MM (.024 IN) 6

0.8 MM (.031 IN) 8
ASSEMBLY
to the following.
Check the piston valve O-ring. Replace if neces-
sary.
F12D11A 1
1. Valve housing O-ring
04-05-10 SMR2002-062_04_05A.FM
There is only one way to insert the sliding valve – Replace the inner halves by the appropriate
no. 22 in valve housing no. 25. sleeve tool in the connecting rod bore.
– Insert piston pin into piston until it comes flush
with inward edge of piston hub.
– Warm piston to approximately 50 - 60°C (122 -
140°F) and install it over connecting rod.
NOTE: Make sure thrust washers are present each
side of needles.
– Install the shoulder sleeve tool on the opposite
1 side of the piston pin.
1 2
F06D12A
1. Sliding valve ridge toward housing groove
Piston
At assembly, place the pistons no. 3 with the let-
ters “AUS” (over an arrow on the piston dome)
facing in direction of the exhaust port.
F00B0OA
1. Piston pin
2. Shoulder sleeve
1
AUS – Insert extractor spindle into the piston pin,
screw on extracting nut.
2 1
A01C01A
1. Exhaust side
NOTE: The exhaust ports are located on the same

side as the intake.
Carefully cover crankcase opening as for disas-
sembly.
Piston Pin and Roller Bearing F00B0PA
To install roller bearing no. 6 and piston pin no. 4

1. Puller installed on the opposite side of the piston pin
use, piston pin puller (P/N 529 035 503) with the 2. Tighten extracting nut
appropriate set of sleeves as for disassembly.
– Rotate handle to pull piston pin carefully into the
– Replacement bearings are held in place by a lo- piston.
cating sleeve outside and 2 plastic cage halves
inside.
– Push needle bearing together with inner halves
out of the locating sleeve into the connecting
rod bore.
SMR2002-062_04_05A.FM 04-05-11
Plastic Mounting Device Method – Insert piston pin into piston until it comes flush
This is an alternate method when no service tool with inward edge of piston hub.
is available.
Replacement roller bearings are delivered in a con-
venient plastic mounting device. For installation,
proceed as follows: 1
– Align replacement roller bearing with connect-
ing rod bore.
– Carefully push inner plastic sleeve into connect-
ing rod bore; outer plastic ring will release rollers.
2
1
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 oppo-
site side. Support piston from opposite side.
F01D0QA
1. Outer ring removal after inner sleeve insertion into bore
– Make sure thrust washers are present each

side of rollers.
F01D0SA
1
– As necessary, pull halves of inner sleeve with
long nose pliers.
F01D0VA
1. Thrust washer each side
04-05-12 SMR2002-062_04_05A.FM
F06B01A 1
1 1. Circlip installer
– Remove sleeve from pusher then insert circlip

into its bore.
– Reinstall sleeve onto pusher and push until cir-
clip comes in end of tool.
F01D0TA 1
1. Pulling inner sleeve half
Circlip
Always use new circlips.
 WARNING
Always wear safety glasses when installing
F00B0QA
piston circlips.
TYPICAL
CAUTION: Always use new circlips. At installa- 1. Circlip near end of tool
tion, take care not to deform them. Circlips – Position end of tool against piston pin opening.
must not move freely after installation.
– Firmly hold piston against tool and tap tool with
Secure circlip in piston groove with its bent end in a hammer to insert circlip into its groove.
piston notch as shown.
1
F00B0RA
F07D0AB
1. Circlip end in piston notch CAUTION: The hand retaining the piston should
To easily insert circlip into piston, use circlip installer. absorb the energy to protect the connecting rod.
ENGINE TOOL P/N

947 DI 529 035 563
SMR2002-062_04_05A.FM 04-05-13
Cylinder Base Gasket NOTE: For each ring, make sure to align ring end
gap with piston locating pin.
Install new base gasket.
Install cylinder block.
Cylinder Screw
or if a crankshaft and/or crankcase repair or re- Apply Molykote 111 below the screw head.
placement was involved, refer to the COMBUS- The blue coating underneath the cylinder screw
TION CHAMBER VOLUME MEASUREMENT to head can be only used once. Either replace with
properly determine the required gasket thickness. new bolts or remove blue coating and apply Loc-
Five thicknesses of cylinder base gaskets are tite 243 (blue) below the screw heads.
available for a precise adjustment of the squish Install and torque screws to 40 N•m (30 lbf•ft) in the
gap. indicated order. Refer to the following illustration.
To identify gasket thickness, refer to the identifi-
Cylinder Block 7 3
2 5
Install cylinder base gasket no. 10. There is only
one way to install gasket.
The cylinder block is positioned with locating dowels.
Line up dowels with corresponding holes in cylin-
der block.
6 4 1 8
1
F12D07A
Cylinder Head
Install cylinder head gasket.
Apply Loctite 243 (blue) (P/N 293 800 060) below
head of cylinder head bolts no. 14.
Apply Molykote 111 on threads of cylinder head
bolts no. 14.
Torque bolts to 20 N•m (15 lbf•ft) as per following
sequence in the next picture. Repeat the torquing
sequence by retightening to 40 N•m (30 lbf•ft).
F02D0UA 1
1. Dowels 12
2 8
To easily slide cylinder block over pistons, use ring 11 3
compressor (P/N 290 876 965).
7 4
1 5
6 9
10
A01B1TA 1 F12D08A
1. Slide this edge
04-05-14 SMR2002-062_04_05A.FM
Combustion Chamber Volume 3. Open burette valve to fill its tip. Add liquid in
Measurement burette until level reaches 0 cc.
NOTE: This procedure is required to determine 4. Inject the burette content through direct injec-
the thickness of the cylinder base gasket to be in- tor hole until liquid touches the top hole.
stalled if a crank repair has involved replacement
of connecting rods or if you are experiencing re-
petitive engine seizure.
The combustion chamber volume is the region in
the cylinder head above the piston at Top Dead
Center. It is measured with the cylinder head in-
stalled on the engine.
F00D0HA 1
1. Top of spark plug hole
F01D5VA
NOTE: The liquid level in cylinder must not drop
1. Combustion chamber
for a few seconds after filling. If so, there is a leak
NOTE: When checking the combustion chamber between piston and cylinder. The recorded vol-
volume, engine must be cold, piston must be free ume would be false.
of carbon deposit and cylinder head must be lev- 5. Let burette stand upward for about 10 minutes,
eled. until liquid level is stabilized.
1. Remove both direct injectors and bring one pis- 6. Read the burette scale to obtain the quantity of
ton to Top Dead Center using a TDC gauge. liquid injected in the combustion chamber.
Keep spark plugs in their holes.
Compare the obtained value with the table below.
2. Obtain a graduated burette (capacity 0 - 50 cc) The volume should be within the allowable range.
and fill with an equal part (50/50) of gasoline and
If the volume of the combustion chamber is not
injection oil.
within specifications, change cylinder base gasket
thickness as follow.
A higher volume dictates a thinner gasket.
A lower volume dictates a thicker gasket.
COMBUSTION CHAMBER
ENGINE
VOLUME
1
947 DI 45.7 - 48.4 cc
7. Repeat the procedure for the other cylinder(s).
F00B0BA
1. Graduated burette (0 - 50 cc)
SMR2002-062_04_05A.FM 04-05-15
BOTTOM END 0
1.5 Nm
(13 lbfin)
28 Loctite
243
29
Loctite 243
30 9 Nm
(80 lbfin) 2
Molykote
111
6 Molykote
Loctite 111
243 14
6
5 16
4 15 17 13
Anti-seize Molykote
4 lubricant 31 111
32
7 Nm Loctite 243 15 Engine
(62 lbfin) Anti-seize oil
6
lubricant Molykote
Loctite
243 3 111
6 13
9 2 1 Loctite
Molykote 648
24 111 4
Loctite Synthetic 6.5 Nm
5910 grease (58 lbfin)
25 4 22 20 Loctite
27 648
5
23
Loctite 21
Loctite 243
518 115 Nm 23 Nm
7 (17 lbfft)
7 (85 lbfft)
Molykote 7
111 27 Nm 27 Nm
8 (20 lbfft)
(20 lbfft) 20 Nm
(15 lbfft)
8 40 Nm
Anti-seize (30 lbfft)
lubricant
6.5 Nm
F12D12S
(58 lbfin)
SMR2002-063_04_06A.FM 04-06-1
DISASSEMBLY Loosen bolt no. 22 retaining the PTO flywheel to the

crankshaft using a suitable socket and breaker bar.
Engine has to be removed from watercraft and top
end has to be disassembled to open bottom end. 3
Refer to REMOVAL AND INSTALLATION and TOP
END.
PTO Flywheel
Use PTO flywheel remover (P/N 295 000 001) to
hold flywheel and remove Allen screws no. 21 re-
taining coupler no. 20 to PTO flywheel.
F06D38A 2 1
F01J0TA 1. Puller plate
2. Extension handle
PTO FLYWHEEL REMOVER TOOL 3. Loosen bolt with socket and breaker bar
Remove the PTO flywheel using puller plate (P/N

529 035 533) and puller (P/N 529 035 547) and bolt
(P/N 529 035 549).
F06D37A 2 1
1. Loosen Allen screws
2. Breaker bar locking crankshaft F06D39A 4 3 1 2
Remove the coupler no. 20. 1. Puller plate
2. Puller
Install puller plate (P/N 529 035 533) and extension 3. Bolt
4. Extension handle
handle (P/N 295 000 125) to PTO flywheel.
NOTE: Puller plate can be used without the exten-
sion handle.
04-06-2 SMR2002-063_04_06A.FM
Starter Drive Assembly

Loosen 2 Allen screws no. 24 retaining starter
drive cover no. 25.
F06D0JA 1
1. Carburetor flange
Remove reed valves no. 28 from crankcase.
F06D1CA 2 1 Crankcase
1. Cover Before opening the bottom end, remove the fol-
2. Allen screw lowing parts:
Remove starter drive cover no. 25 and spring no. 9. – magneto flywheel
Remove starter drive assembly no. 27. (refer to MAGNETO SYSTEM subsection)
– starter
– starter drive assembly
– reed valves
– air compressor cover
Place engine upright on crankcase magneto side.
Loosen crankcase screws.
F06D1DA 1
1
1. Starter drive assembly
Reed Valve 1
Remove both carburetor flanges.
2
F07D09D
1. M8 x 45 flanged screws
SMR2002-063_04_06A.FM 04-06-3
Put engine back on a support. Insert a pry bar be-

tween crankcase lugs to separate halves.
CAUTION: Be careful to precision machined sur-
faces.
1
F01D1KA
F06D1GA 1
TYPICAL
TYPICAL
1. End seal
To remove end bearings from crankshaft, use the

following tools.
6 1 3 4 5
2
F06B03A 6
1 1. Puller (P/N 420 877 635)
3. Distance ring (P/N 420 876 569)
F01D1LA 4. Ring (P/N 420 977 480)
5. Ring halves (P/N 420 876 330)
TYPICAL 6. Screw (P/N 420 940 755)
Remove crankshaft and counterbalance shaft.

Open air compressor and disconnect the piston as
described in ENGINE MANAGEMENT. 1
Crankshaft Bearing and Seal

If a crankshaft end seal no. 5 has to be replaced,
bottom end must be opened.
NOTE: Do not needlessly remove crankshaft bear-
ings.
Remove end seal(s).
F01D1OA
TYPICAL
1. Removing crankshaft bearing
04-06-4 SMR2002-063_04_06A.FM
Or, use a bearing extractor such as Proto no. 4332 CLEANING

and a press to remove two bearings at a time.
Discard all oil seals, gaskets, O-rings and sealing
rings.
1 clogged.
Crankcase mating surfaces are best cleaned using
a combination of the chisel gasket remover (P/N
413 708 500) and a brass brush. Brush a first pass
in one direction then make the final brushing per-
pendicularly (90°) to the first pass cross (hatch).
CAUTION: Do not wipe with rags. Use a new clean
hand towel only.
F01D1PA
2
1. Press bearings out

2. Bearing extractor
Use a press to remove counterweights no. 16 and
bearings no. 15.
CAUTION: There is no woodruff key to position
the counterweights. An index mark must be traced
to retain the proper position of the counterweight.
F00D2BA
F06D1HA 1
1. Trace an index mark
Remove seals no. 17.

Remove bearing no. 31 and washer no. 32.
F00D2CA
Use a press to remove gear no. 14.
FIRST PASS
SMR2002-063_04_06A.FM 04-06-5
F01D1NA 1
1. Main journal alignment here
To accurately check if crankshaft is twisted on cen-

ter main journal, proceed as follows:
F00D2DA
– Remove magneto housing cover.
SECOND PASS
– Remove flywheel nut and magneto rotor. Refer
Finish the cleaning with acetone. to MAGNETO SYSTEM for procedures.
CAUTION: Ensure to clean compressor lubrica- – Install Bombardier degree wheel (P/N 529 035
tion nipple. 607) on crankshaft end. Hand-tighten nut only.
CAUTION: Be careful not to spray cleaner on – Remove both spark plugs.
the painted surface of the engine.
– Install a TDC gauge in spark plug hole on MAG
CAUTION: Never use a sharp object to scrape side.
away old sealant as score marks incurred are
– Bring MAG piston at Top Dead Center.
detrimental to crankcase sealing.
– As a needle pointer, secure a wire with a cover
INSPECTION screw and a washer.
– Rotate degree wheel (NOT crankshaft) so that
Assembled Engine needle pointer reads 360°.
The following checks can be performed with en-
gine in watercraft without overhauling engine.
Crankshaft Alignment at Center Main

Journal
Since it is an assembled crankshaft it can become
misaligned or deflected. Crankshaft can be twist-
ed on center main journal, changing timing of one
cylinder in relation with the other.
04-06-6 SMR2002-063_04_06A.FM
Such misalignment may cause a crankshaft hard

to be manually turned. Verification can be done by
1 measuring deflection each end of crankshaft.
If deflection is found greater than specified toler-
ance, this indicates worn bearing(s), bent and/or
2 disaligned crankshaft. Proceed with the disassem-
bly of the engine.
Disassembled Engine
The following verifications can be performed with
3 the engine disassembled.
4 Crankcase
Inspect plane surfaces for warpage. Small defor-
mation can be corrected by grinding surface with
a fine sandpaper. Install sandpaper on a surface
Bearing
F01D4IA
Inspect crankshaft bearings no. 4. Check for cor-
TYPICAL rosion, scoring, pitting, chipping or other evidence
1. TDC gauge of wear. Make sure plastic cage is not melted. Ro-
2. Degree wheel
3. Hand tighten nut tate and make sure they turn smoothly.
4. Needle pointer
– Remove TDC gauge and install on PTO side. Crankshaft

– Bring PTO piston at Top Dead Center. NOTE: If crankshaft and/or components are found
defective, it must be repaired by a specialized
Interval between cylinders must be exactly 180°
shop or replaced.
therefore, needle pointer must indicate 180° on
degree wheel (360° - 180° = 180°). Connecting Rod Straightness
Any other reading indicates a misaligned crank- Align a steel ruler on edge of small end connecting
shaft. rod bore. Check if ruler is perfectly aligned with
edge of big end.
Crankshaft Alignment at Connecting
Rod Journal 1
Counterweights can also be twisted on connect-
ing rod journal on any or both cylinder(s).
F01D1Q A 2
1. Ruler must be aligned with edge of connecting rod here
2. Align ruler here
F01D1NB 1
1. Connecting rod journal alignment here
SMR2002-063_04_06A.FM 04-06-7
Crankshaft Deflection
MEASUREMENT MAG SIDE PTO SIDE

Crankshaft 0.050 mm 0.030 mm 1
deflection (max.) (.002 in) (.001 in)
Crankshaft deflection is measured each end with

a dial indicator.
First, check deflection with crankshaft in crank-
case. If deflection exceeds the specified toler-
ance, it can be either ball bearings wear, bent or
twisted crankshaft at connecting rod journal.
F01D97A
1. Measuring MAG side deflection on V-shaped blocks
F01D1SA
1. Measuring PTO side deflection in crankcase
F01D98A
1. Measuring PTO side deflection on V-shaped blocks
NOTE: Crankshaft deflection cannot be correctly

measured between centers of a lathe.
CONNECTING ROD BIG END AXIAL PLAY

F01D1TA
NEW PARTS WEAR
1. Measuring MAG side deflection in crankcase MODEL
(min.) (max.) LIMIT
Remove crankshaft bearings and check deflection
0.390 mm 0.737 mm 1.2 mm
again on V-shaped blocks as illustrated. 947 DI engine
(.015 in) (.029 in) (.047 in)
04-06-8 SMR2002-063_04_06A.FM
Using a feeler gauge, measure distance between

thrust washer and crankshaft counterweight.
F01J0ZA
1
Close puller claws so that they can be inserted in
against bearing.
For installation, see below in this section.
2
F01D1WA Reed Valve
1. Measuring big end axial play Check reed valve petals no. 29 for cracks or other
2. Feeler gauge
defects. The reed petals must lie completely flat
Starter Drive Bearing against the reed valve body no. 30. To check, hold
against light.
Check bearing no. 23 of starter drive assembly
no. 27 in crankcase.
F06D1IA 1 F06D1JA 1
1. Bearing of starter drive assembly 1. No play
Removal In case of a play, turn reed petals upside down and
Starter drive bearing can be easily removed from recheck. If there is still a play, replace petals.
lower crankcase half using the following suggest- Check perfect condition of rubber coating on reed
ed tool or equivalent: valve body.
– Snap-on hammer puller including:
– handle CJ93-1
– hammer CJ125-6
– claws CJ93-4.
SMR2002-063_04_06A.FM 04-06-9
Check stopper distance from center of reed valve To properly position the outer bearing(s), a dis-
block. tance gauge must be temporarily installed against
the inner bearing. Slide the outer bearing until
stopped by the distance gauge, then remove it.
ENGINE DISTANCE GAUGE

P/N 529 035 100 (MAG)
947 DI
P/N 529 035 000 (PTO)
F01B0HA
F06D1EA
1. Distance gauge
A. 13 ± 0.25 mm (.512 ± .010 in)
NOTE: Distance should be the same on both sides. 1

Bent stopper as required to obtain the proper dis-
tance.
Air Compressor
Refer to ENGINE MANAGEMENT for compo-
nents inspection. However, if you find aluminum
dust or debris in this area, they may have flowed
toward the injection oil reservoir. In this case, the
oil reservoir and lines must be flushed and the fil- 2
ter replaced.
CAUTION: Failure to properly clean the oil sys-
tem will result in serious engine damage. F01D1YA
TYPICAL
ASSEMBLY 1. Distance gauge
2. Outer bearing
bly procedures. However pay particular attention Distance Ring
to the following.
When installing the distance ring no. 12, make
NOTE: It is recommended to spray BOMBARDIER- sure to position it with its chamfer toward the
ROTAX injection oil on all moving parts when re- counterweight of the crankshaft.
assembling the engine.
Crankshaft Seal
Crankshaft and Bearing
When installing seal assembly no. 5, apply a light
Apply Loctite 767 anti-seize on part of crankshaft coat of lithium grease on seal lips.
where bearing fits.
Seals are positioned with the outer lip in the crank-
Prior to installation, place bearings no. 4 into a case recess.
(167°F). This will expand bearing and ease instal-
lation.
04-06-10 SMR2002-063_04_06A.FM
1
Crankshaft and Counterbalance Shaft
Install crankshaft no. 3 first in crankcase.
After crankshaft installation, install counterbal-
ance shaft no. 13. Make sure to properly index
crankshaft and counterbalance shaft by aligning
marks of gears.
CAUTION: Marks on the crankshaft and coun-
terbalance shaft must be aligned, otherwise en-
gine will vibrate and premature wear will occur.
F06D1LA
1. Seal lip in crankcase recess
Drive Pin
Make sure drive pins no. 6 of bearings are proper-
ly installed in crankcase recesses at assembly.
1
F06D1MA 1
Turn by hand the crankshaft and counterbalance

shaft. Make sure they do not interfere with the
crankcase.
Properly position bearing no. 31 and washer
no. 32. Ensure to position lubrication hole on top
(if so equipped).
F00D0OA
1. Drive pins
Install bearing no. 31 and washer no. 32.
When installing seals no. 17, apply a light coat of
Molykote 111 on seal lips.
Prior to installation, place bearings no. 15 into a
(167°F). This will expand bearings and ease their F12R16A 3 2 1
installation.
1. Bearing
Reinstall counterweights no. 16 using a press and 2. Washer in crankcase groove
3. Lubrication hole on top (if so equipped)
take care to align index marks previously traced.
SMR2002-063_04_06A.FM 04-06-11
Place seals no. 17 in their respective positions. CAUTION: Do not use Loctite 515 or 518 to seal
crankcase. Do not use Loctite Primer N with the
Loctite 5910. Using these products or non silicone-
based sealant over a previously sealed crankcase
with Loctite 5910 will lead to poor adhesion and
possibly a leaking crankcase. These products are
chemically incompatibles. Even after cleaning, the
Loctite 5910 would leave incompatible microscos-
pic particules.
Use a plexyglass plate and apply some sealant on
it. Use a soft rubber roller (50 - 75 mm (2 - 3 in))
(available in arts products suppliers for printmak-
ing) and roll the sealant to get a thin uniform coat
on the plate (spread as necessary). When ready,
apply the sealant on crankcase mating surfaces.
F06D1OA 1
1. Seal in place
Air Compressor
Refer to ENGINE MANAGEMENT for procedures.
Crankcase
Crankcase halves are factory matched and there-
fore, are not interchangeable or available as single
halves.
Add 40 mL (1.35 oz) of Sea-Doo synthetic jet
pump oil (P/N 293 600 011) or standard gear oil in
the counterbalance shaft gear cavity.
CAUTION: Using different type of oil may re- F12R17A
duce engine component life.
torquing should be done within 10 minutes. It is
suggested to have all you need on hand to save
time.
sealant as described here to get an uniform appli-
cation without lumps. If you do not use the roller
tribute the sealant (unlike the Drei Bond sealing
compound, using a finger will not affect the adhe-
sion).
Use the silicone-based Loctite 5910 (P/N 293 800 F12R18A
081) on mating surfaces.
NOTE: The sealant curing time is similar to the Do not apply in excess as it will spread out inside
Loctite 518 without using the Primer N. crankcase.
CAUTION: If sealant spread out inside air com-
pressor area, it could plug the compressor lu-
brication nipple and serious compressor dam-
age may occur.
04-06-12 SMR2002-063_04_06A.FM
NOTE: Do not use Loctite Primer N with this seal-

ant. The sealant curing time is similar to the Loc- 10
9
tite 518 without using the Primer N, which is 4 to
24 hours. 8
7
Make sure all locating dowels are in place.
3 4
1 2
5 6
11
12
F07D09C
F06D1PA 1
1. Dowel
Starter Drive Bearing
To install bearing no. 23 of starter drive assembly,
Crankcase Screws use pusher (P/N 290 876 502) and handle (P/N 420
Apply Molykote 111 below head of screws and 877 650).
Loctite 518 on threads.
Torque crankcase screws to 12 N•m (106 lbf•in)
as per following sequence. Repeat procedure, re-
1
10
9 24
8
7
21 2
20 F06D32A
14
4 1. Handle
3 15 2. Pusher
1 13 PTO Flywheel
2
Apply Loctite 243 (blue) on bolt no. 22.
16 17
18 Using the same tools as for disassembly proce-
5 6 dure, torque bolt no. 22 to 115 N•m (85 lbf•ft).
19 Apply Loctite 648 on mating surface of PTO fly-
11 23 wheel and coupler.
22 12 Apply Loctite 243 (blue) to Allen screws no. 21 of
F07D09E coupler and torque to 23 N•m (17 lbf•ft).
As a final step, torque only the M10 x 73.5 bolts Final Assembly
to 40 N•m (30 lbf•ft) as per following sequence.
Add approximately 10 mL (.3 oz) of injection oil in
bottom of crankcase for each cylinder. This will give
an additional lubrication for the first engine startup.
SMR2002-063_04_06A.FM 04-06-13
EXHAUST SYSTEM 0
48 Nm 9 15 5 25 Nm
(35 lbfft) 14 Nm (18 lbfft)
(124 lbfin)
19
7 4
10 RTV sealant
16 22 12-13 18
14
6
40 Nm
(30 lbfft)
48 Nm 25 Nm
(35 lbfft) (18 lbfft) 21
19
8 9
18
Loctite 243
1 4 Nm 20
(35 lbfin)
40 Nm
(30 lbfft)
3
2 1 1
Ultra Cooper
sealant
11
Silicone
sealant
Body
RTV
RTV sealant
F18D2JS
sealant
SMR2002-065_04_07A.FM 04-07-1
REMOVAL Tuned Pipe Removal with Separation from

Remove seat(s).
1. Disconnect water return hose at tuned pipe
Remove rear vent hose support from body opening. head no. 10.
F06L0WA 1
F06E08A 1
TYPICAL
1. Rear vent hose support 1. Water return hose
Remove seat support. 2. Disconnect small hose from water outlet fitting
at the tuned pipe head no. 10.
2
F06E09A 1
F07L1KA 2 1
1. Disconnect hose from outlet fitting
TYPICAL
1. Seat support
2. Remove screws
To remove this tuned pipe, there are 2 possible

ways to proceed.
The first procedure separates the tuned pipe head
from the tuned pipe cone, using the following pro-
cedure. The second procedure removes the tuned
pipe without tuned pipe head and tuned pipe cone
separation. This procedure is explained further.
04-07-2 SMR2002-065_04_07A.FM
3. Disconnect the water injection hose at tuned 5. Loosen clamp no. 1 retaining exhaust hose no. 3
pipe head no. 10. to tuned pipe cone no. 5.
1
F06E0AA 1 F06D14A
1. Water injection hose TYPICAL

1. Loosen clamp
4. Disconnect the water bleed hose.
6. Loosen and remove clamp no. 4 retaining tuned
pipe head no. 10 to tuned pipe cone no. 5.
F06E0BA 1
1. Water bleed hose 1
F06D1SA
1. Loosen and remove clamp
SMR2002-065_04_07A.FM 04-07-3
7. Loosen Allen screw retaining carburetor brack-

et to tuned pipe head.
F06D1UA 1
1. Remove bolt
F06D3JA 1
11. Remove tuned pipe head no. 10.
12. Loosen bolt no. 6 of tuned pipe cone beside
8. Remove external seal. the engine water return hose.
9. Loosen Allen screws no. 7 and nut no. 8 at tuned
pipe flange.
NOTE: To loosen nut, use polygonal wrench (P/N
529 035 505).
F06D1VA 1
1. Loosen bolt
13. Remove tuned pipe cone no. 5.

F06D1TA 1 14. Block exhaust opening in the manifold to keep
debris from entering cylinder during threads
cleaning procedure.
10. Loosen bolt no. 20 of tuned pipe head above 15. Remove the stud no. 21 from “Y” manifold.
the engine magneto then remove bolts retain-
ing bracket to engine. 16. Use a M10 x 1.5 screw/tap to clean the 4
threaded holes on the “Y” manifold and the 2
threaded holes on tuned pipe. Clean out the
debris with a spray cleaner and air pressure.
locking fasteners.
04-07-4 SMR2002-065_04_07A.FM
Tuned Pipe Removal without Separation from Loosen bolt no. 20 of tuned pipe head above the
Tuned Pipe Head and Tuned Pipe Cone engine magneto then remove bolts retaining
Execute the above procedures 1 through 5. bracket to engine.
Later, use the following procedure:
Remove the strap no. 2 retaining the muffler then
remove the exhaust hose no. 3 from tuned pipe
cone no. 5.
Loosen Allen screw retaining carburetor bracket
to tuned pipe head.
F06D1UA 1
1. Remove bolt
Remove tuned pipe assembly.

Block exhaust opening in the manifold to keep de-
bris from entering cylinder during threads cleaning
procedure.
F06D2DA 1 Remove the stud no. 21 from “Y” manifold.
1. Loosen Allen screw Use a M10 x 1.5 screw/tap to clean the 4 threaded
Loosen Allen screws no. 7 and nut no. 8 at tuned holes on the “Y” manifold and the 2 threaded
pipe flange. holes on tuned pipe. Clean out the debris with a
spray cleaner and air pressure.
NOTE: To loosen nut, use polygonal wrench (P/N
529 035 505). CAUTION: It is very important that the threads
locking fasteners.
Exhaust Manifold
Remove 8 Allen screws no. 12 and lock washers
no. 13 then withdraw exhaust manifold.
Muffler
Disconnect the EGT (exhaust gas temperature)
sensor.
Disconnect hoses from muffler no. 11.
F06D1TA 1
SMR2002-065_04_07A.FM 04-07-5
Disconnect hoses of the water flow regulator INSTALLATION

valve.
the following.
Exhaust Manifold
Make sure gasket(s) no. 17 are properly posi-
tioned prior to finalizing manifold installation.
Apply Molykote 111 on threads of Allen screws
no. 12.
Install and hand tighten Allen screws no. 12 as per
following picture.
F01E1FD 1 2
TYPICAL
2. To injection fitting on tuned pipe
Disconnect retaining strap no. 2 of muffler.

Pull muffler no. 11 out of bilge.
TUNED PIPE REPAIR

This procedure is given to repair tuned pipe cracks
using T.I.G. welding process.
F06D1YA 1 2 1
Procedure
1. M10 x 60 Allen screws
– Sand the cracked area to obtain bare metal. 2. M10 x 110 Allen screws
– Perform a 1.50 mm (1/16 in) depth chamfer over Torque Allen screws to 24 N•m (17 lbf•ft) as per fol-
crack. lowing illustrated sequence. Repeat the procedure,
– Use pure argon gas with 5.55 mm (3/32 in) tung- retightening Allen screws to 40 N•m (30 lbf•ft).
sten electrode (puretung “green”, zirtung
“brown”) and AC current. 8 2 3 6
– Use a 5.55 mm (3/32 in) aluminum welding rod
(no. 4043), to fill crack.
– Sand welding slightly to remove material sur-
plus.
Test
– Use compressed air at 124 kPa (18 PSI) to pres-
surize tuned pipe.
CAUTION: Always ensure water passages are not
blocked partially or completely while welding
tuned pipe.
NOTE: Prior to verify leaks, plug all holes and pres- 7 4 1 5
F06D1YB
surize tuned pipe while immerging it in water.
04-07-6 SMR2002-065_04_07A.FM
Tuned Pipe Apply a thin layer of Ultra Copper heat resistant

sealant (P/N 413 710 300) all around sealing ring
CAUTION: Torque wrench tightening specifica-
no. 15.
tions must be strictly adhered to. Locking de-
vices (ex.: locking tabs, elastic stop nuts, self- CAUTION: Damage to bushings and/or sleeve
locking fasteners, etc.) must be installed or re- will eventually cause stress to tuned pipe and
placed with new ones where specified. If the may cause cracking.
effiency of a locking device is impaired, it must CAUTION: It is very important that the threads
be renewed. are free of debris before installing new self-
NOTE: Loosen all pipe supports from engine be- locking fasteners. Refer to removal procedure
fore install tuned pipe. for the proper thread cleaning procedure.
Make sure to install the sealing ring no. 15 on Clean the “Y” manifold and tuned pipe surfaces.
tuned pipe cone if it was removed. Screw stud no. 21 into the “Y” manifold. Torque
Install the new bushing no. 18.
Torquing Sequence:
CAUTION: Torque the tuned pipe in accor-
dance with the following sequence, otherwise
serious engine damage may occur.
NOTE: Apply Loctite 243 (P/N 293 800 060) on
stud nut before tightening to 2.5 N•m (22 lbf•in).
Use special tool (P/N 529 035 505).
Install external seal no. 22 and secure with a lock-
ing tie.
F07D0RA
1
TYPICAL
1. Sealing ring
SMR2002-065_04_07A.FM 04-07-7
40 Nm 40 Nm
6 (30 lbfft) 7 (30 lbfft)
6 Nm
(53 lbfin) 5
14 Nm 6 Nm
(124 lbfin) 16 9 (53 lbfin)
25 Nm
15 (18 lbfft)
6 Nm
(53 lbfin) 8
25 Nm
(18 lbfft) 14
6 Nm
6 Nm 3 (53 lbfin)
(53 lbfin) 2
48 Nm
48 Nm 12 (35 lbfft)
(35 lbfft) 11
2.5 Nm
(22 lbfin) 4 6 Nm
1 (53 lbfin)
48 Nm
(35 lbfft) 13 48 Nm
10 (35 lbfft)
F07D0SS
04-07-8 SMR2002-065_04_07A.FM
Install exhaust hose.

1
F06D14A
1. Torque clamp to 4 N•m (35 lbf•in)
SMR2002-065_04_07A.FM 04-07-9
Section 05 ENGINE (4-TEC)
TABLE OF CONTENTS 0
LEAK TEST............................................................................................................................. 05-02-1
LEAK TEST PROCEDURE .................................................................................................. 05-02-1
PREPARATION................................................................................................................... 05-02-1
PROCEDURE ...................................................................................................................... 05-02-2
INSTALLATION.................................................................................................................. 05-02-3
INTAKE SYSTEM ................................................................................................................... 05-03-1

REMOVAL........................................................................................................................... 05-03-2
ASSEMBLY......................................................................................................................... 05-03-6
EXHAUST SYSTEM............................................................................................................... 05-04-1

EXHAUST PIPE .................................................................................................................. 05-04-2
EXHAUST MANIFOLD ...................................................................................................... 05-04-5
MUFFLER (LH) ................................................................................................................... 05-04-6
MUFFLER (RH) ................................................................................................................... 05-04-7
EXHAUST OUTLET ........................................................................................................... 05-04-7

GENERAL ........................................................................................................................... 05-05-1
ENGINE REMOVAL............................................................................................................ 05-05-1
CLEANING ......................................................................................................................... 05-05-2
INSTALLATION .................................................................................................................. 05-05-2
PTO HOUSING/MAGNETO .................................................................................................. 05-06-1

GENERAL ........................................................................................................................... 05-06-2
PTO HOUSING................................................................................................................... 05-06-2
PTO SEAL........................................................................................................................... 05-06-5
COUPLING ......................................................................................................................... 05-06-5
STATOR ............................................................................................................................. 05-06-6
ROTOR AND ENCODER WHEEL....................................................................................... 05-06-7
RING GEAR ........................................................................................................................ 05-06-7
STARTER DRIVE ASS’Y .................................................................................................... 05-06-8
LUBRICATION SYSTEM ........................................................................................................ 05-07-1

GENERAL ........................................................................................................................... 05-07-3
OIL LEVEL VERIFICATION................................................................................................. 05-07-3
ENGINE PRESSURE TEST ................................................................................................ 05-07-4
OIL STRAINERS ................................................................................................................. 05-07-7
ENGINE OIL PRESSURE REGULATOR ............................................................................ 05-07-9
OIL PRESSURE PUMP....................................................................................................... 05-07-10
OIL SUCTION PUMP ......................................................................................................... 05-07-13
OIL FILTER BYPASS .......................................................................................................... 05-07-16
OIL COOLER....................................................................................................................... 05-07-16
OIL SEPARATOR ............................................................................................................... 05-07-17
SMR2002-095_05-01ATOC.FM 05-01-1
CYLINDER HEAD AND VALVES ........................................................................................... 05-08-1

GENERAL............................................................................................................................ 05-08-2
SPARK PLUG ...................................................................................................................... 05-08-2
VALVE COVER .................................................................................................................... 05-08-2
ROCKER ARM..................................................................................................................... 05-08-3
CAMSHAFT TIMING GEAR................................................................................................ 05-08-6
TIMING CHAIN ................................................................................................................... 05-08-8
CYLINDER HEAD ................................................................................................................ 05-08-8
CAMSHAFT......................................................................................................................... 05-08-10
VALVE SPRING................................................................................................................... 05-08-11
VALVE ................................................................................................................................. 05-08-12
ENGINE BLOCK ...................................................................................................................... 05-09-1

GENERAL............................................................................................................................ 05-09-3
CRANKSHAFT LOCKING ................................................................................................... 05-09-3
CRANKSHAFT .................................................................................................................... 05-09-3
TIMING CHAIN ................................................................................................................... 05-09-8
CHAIN TENSIONER............................................................................................................ 05-09-8
BALANCER SHAFT............................................................................................................. 05-09-9
ENGINE BLOCK .................................................................................................................. 05-09-11
PISTON/CONNECTING ROD ............................................................................................. 05-09-17
PISTON RINGS ................................................................................................................... 05-09-22
05-01-2 SMR2002-095_05-01ATOC.FM
LEAK TEST 0
LEAK TEST PROCEDURE – oil dipstick
The procedure has to be done when engine operat- 1

ing temperature of approx. 70°C (158°F) is reached.
 WARNING
Prevent burning yourself due to handling on
the hot engine.
PREPARATION
Remove:
– seat and vent tube support
– safety lanyard.
 WARNING
R1503motr153A
Safety lanyard must be removed to prevent
engine to be cranked while fuel rail is re- 1. Oil dipstick
moved to prevent fuel to be sprayed out.
– unplug ignition coil and pull it out
Fuel is flammable.
– spark plug from cylinder head.
– fuel rail cover then remove fuel rail retaining NOTE: Ignition coil may be used as an extractor.
screws and move away just enough to see the
injection holes 2 1
– exhaust pipe (refer to EXHAUST SYSTEM)
– drive shaft
(refer to JET PUMP in PROPULSION SYSTEM)
– coolant tank cap
 WARNING
To prevent burning yourself only remove the
coolant tank cap by wearing the appropriate
safety equipment.
R1503motr154A
1. Ignition coil
2. Spark plug
SMR2002_066_05_02A.FM 05-02-1
– Remove valve cover cowl. Hold the crankshaft in this position by using the im-
– Unscrew and remove valve cover. peller remover/installer tool (P/N 529 035 820) and
a wrench.
2 1 Install gauge adapter into previously cleaned spark
plug hole.
Connect to adequate air supply.
NOTE: Each tester will have specific instruction
on the gauge operation and required pressure.
Set needle of measuring gauge to zero.
Supply combustion chamber with air.
R1503motr155A
1. Valve cover 3
2. Valve cover screw
2
PROCEDURE
The following procedure has to be performed for
each cylinder separately, because of the 120° off-
set between the TDCs.
Rotate crankshaft until all valves are closed by using
PTO flywheel remover/installer (P/N 529 035 820). R1503motr157A
Therefore you have to monitor the rocker arms. 1. Measuring gauge

2. Adequate adapter for spark plug hole
1 3. Air supply
Note the amount of leaking or percentage (de-

pending on tester).
LEAKAGE ENGINE
PERCENTAGE CONDITION
0% to 7% Excellent condition
Fair condition; proceed
8% to 15% with tuned up or adjust-
ment
Poor condition; engine will
run a nd p erforma nc e
16% to 30%
might be down in some
cases.
R1503motr156A Very poor condition, diag-
30% and higher
nose and repair engine.
1. Intake rocker arms
Rotate the crankshaft counterclockwise until the

intake rocker arm has performed a full stroke.
Then rotate crankshaft for another half turn to be
sure that the valves are closed.
05-02-2 SMR2002_066_05_02A.FM
Diagnose General Engine Leakage

Pressurize area to be tested, spray soap/water so- Spray soap/water solution at the indicated location
lution at the indicated location and look and/or lis- and look and/or listen for air bubbles.
ten for air bubbles. Paying attention to the following checkpoints:
– air escaping on intake port means leaking intake – clamp(s) tightened
valve(s)
– coolant hoses
– air escaping on exhaust port means leaking ex-
haust valve(s) – air/oil escaping from crankcase means damaged
gasket(s) and/or loosened screws
– air bubbles out of coolant tank means leaking (refer to ENGINE BLOCK)
cylinder head gasket
– air/water escaping from cylinder/head means
– air escaping into crankcase area means exces- damaged gasket(s) and/or loosened screws
sively worn and/or broken piston rings. (refer to CYLINDER HEAD AND VALVES)
– oily contamination on weep hole (speed sensor
INSTALLATION area) means a damaged oil seal on coolant
NOTE: For installation use the torque values and pump shaft
Loctite products from the exploded views (refer to – coolant out of weep hole means a damaged ro-
proper engine subsection). tary seal on coolant pump shaft
For installation, reverse the preparation proce- (refer to COOLING SYSTEM)
dure.
NOTE: Prior to inserting the ignition coil to its lo-
cation, apply some BOMBARDIER LUBE lubricant
hole. After installation, ensure the seal seats prop-
erly with the engine top surface.
R1503motr158A 1
1. Weep hole
– coolant escaping from coolant pump housing

means damaged gasket(s) and/or loosened
screws (refer to COOLING SYSTEM).
NOTE: For all the checkpoints mentioned above
see the appropriate engine section to diagnose
and repair the engine.
SMR2002_066_05_02A.FM 05-02-3
Subsection 03 (INTAKE SYSTEM)
INTAKE SYSTEM 0
4-TEC Engines
Loctite 243
10 Nm
(88 lbfin)
Oil
Loctite 243
6 Nm 10 Nm
Loctite 243
Loctite 243
10 Nm
(88 lbfin)
Loctite 243
6 Nm 18 Nm 10 Nm
(53 lbfin) (159 lbfin) (88 lbfin)
R1503motr63S
SMR2002-067_05_03A.FM 05-03-1
REMOVAL 2
Air Intake Manifold
Remove seat and storage basket. 1
Disconnect vent tube as follows.
Lift lock tab and holding the tab, pull the tube to
release it.
1
F18E1MA
Step 1 : Push tab (each side) to release

Step 2 : Pull tank out

NOTE: Pay attention not to drop the nuts under
support when removing screws.
F18E0PA
1 2
1. Lift lock tab
Then proceed with the tab under the tube. Refer

to the following illustration to see it.
F18L1GA 2 3
1. Vent tube support
2. Remove retaining screws
3. Pay attention to nuts underneath
F18E0QA 1 Remove oil dipstick.

1. Other lock tab under tube Pull fuel rail cover out.
Unlock coolant expansion tank, pull out then move Disconnect battery cables from battery.
away.
05-03-2 SMR2002-067_05_03A.FM
 WARNING 1 2 3 10
first then the RED positive battery cable last.
Release the fuel pressure in the system, refer to 9

ENGINE MANAGEMENT section. 8
Disconnect fuel hose connector at fuel rail. 7
6
1
2
1
2 R1503motr60A 5 4
1. Ignition coils
2. TOPS
3. TPS (hidden behind throttle body)
4. Idle bypass valve
5. Engine connector
6. KS
7. CPS
8. Magneto
9. “B” Kostal connector
10. OSPS
1 1 For the TOPS valve connector, refer to the follow-
ing illustration.
1
R1503motr78A
Step 1 : Squeese
Step 2 : Pull out
1. Supporting tabs
2. Squeeze in middle of supporting tabs, hold and pull out
Cut locking ties where shown.
1
R1503motr69A
1. Push here and hold while pulling connector out
F18D0CA
1. Cut locking ties
Unplug connectors from ignition coils, TOPS valve,

OSPS, TPS, idle bypass valve, engine connector,
CTS, CAPS, KS, CPS, magneto, OPS and EGT.
SMR2002-067_05_03A.FM 05-03-3
NOTE: The TPS connector is hidden behind the

TOPS hose. Disconnect hose from TOPS valve
then move away to access the TPS connector.
Slightly pry locking tab of connector to unlock.
R1503motr65A 1
1. CAPS connector
R1503motr75A
1. TOPS hose disconnected and moved away

2. TPS connector
3. Slightly pry tab to unlock
R1503motr66A 1
1. EGT connector
R1503motr64A 1
1. CTS connector
F18D0BA 1 2
1. Oil filter housing
2. OPS
05-03-4 SMR2002-067_05_03A.FM
Unplug the “B” Kostal connector from the Engine

ECU.
2
R1503motr72A
1. Air intake silencer collar

2. Unlock throttle cable housing
R1503motr70A 1
Remove 7 retaining screws and push the oil dip-
1. Push this end to unlock stick tube out of the manifold slot.
R1503motr71A
1. Pull here to release R1503motr59A
Pull the connectors for KS, CPS and magneto out

of the ECU support. Lift intake manifold up to pull it out of the mount-
ing brackets just enough to reach throttle cable
Pull wiring harness away from intake manifold. end.
Slacken air intake silencer collar.
Unlock throttle cable housing from throttle body.
Cable is to be detached further.
SMR2002-067_05_03A.FM 05-03-5
NOTE: The flame arrester in intake manifold is

maintenance free.
ASSEMBLY
the following.
Air Intake manifold

Ensure that all gaskets are properly installed and
in a good condition.
R1503motr61A 1
1. Mounting brackets
Detach throttle cable end from throttle body.
R1503motr62A 1
INTAKE MANIFOLD
1. Gaskets
First, position intake manifold on front mounting

bracket then push manifold toward engine to thus
R1503motr76A 1 allow proceeding with rear mounting bracket.
1. Detach cable end from throttle body When installing the intake manifold, lift up the oil
dipstick tube a little bit to fit in the slot of the man-
Pull intake manifold out.
ifold.
R1503motr77A
05-03-6 SMR2002-067_05_03A.FM
R1503motr59B
1. Oil dipstick tube
Apply Loctite 243 (blue) on the intake manifold

screws. Torque them to 10 N•m (88 lbf•in) follow-
ing the tightening sequence shown.
5 3 1
6
2 7
4
R1503motr210A
Ensure to properly route and resecure wiring har-

ness with locking ties.
 WARNING
Always check O-ring for damage such as defor-
mation at reinstallation. Replace the O-ring if it is
damaged.
SMR2002-067_05_03A.FM 05-03-7
EXHAUST SYSTEM 0
9
11 Nm
(97 lbfin)
3 4
2
8 12
5
11 8 Nm
(71 lbfin) 15
4 Nm
16 (35 lbfin)
15
7 15
16 Nm
(142 lbfin) 17
4 Nm 10
(35 lbfin) 13
Silicone
sealant
6
14
Loctite 296
F18D0HS
SMR2002-068_05_04A.FM 05-04-1
EXHAUST PIPE Loosen the exhaust hose clamp no. 5 to the top
portion of the hose between muffler (LH) no. 6
Removal and the exhaust pipe no. 1.
1 2
 WARNING
burn. Let exhaust system cool down prior to re-
moving parts.
Remove seat and seat extension.

Remove seat support.
2
F18D0RA
1. Exhaust hose clamp

2. Exhaust pipe
Loosen both exhaust hose clamps no. 15 and re-

move the exhaust hose no. 16 between the muf-
F18L2GA 2 1
fler (LH) and the muffler (RH).
1. Seat support
2. Remove screws
Disconnect the 3 cooling hoses from exhaust pipe

no. 1.
1 3
F18D0QA 2 1
1. Hose clamp
2. Exhaust hose
Detach the strap no. 11 from the muffler (LH) using

the spring installer/remover (P/N 529 035 559).
F18D0IA 2
1. Exhaust pipe
2. Gear clamp
3. Exhaust clamp
05-04-2 SMR2002-068_05_04A.FM
Move muffler (LH) no. 6 backward enough to allow

the exhaust pipe to be pulled out.
Squeeze the exhaust hose no. 7 going to the exhaust
outlet with one hand, and withdraw the exhaust pipe
no. 1 from the exhaust manifold.
A00C3SA
2 1
F18D0KA
F18D0JA 3 1 2
1. Exhaust pipe
1. Muffler (LH) 2. Squeeze this hose to ease removal of pipe
2. Strap
3. Spring installer/remover
Apply sealant (P/N 413 710 200) on the welds of the
Slowly unscrew exhaust clamp nut no. 4 and re- exhaust tube, while the exhaust pipe is removed from
move it. the muffler (LH).
NOTE: Unscrewing the nut too fast generates heat
that will make it harder to unscrew.
2 1
F18D0TA 2 1
1. Sealant (P/N 413 710 200)
2. Exhaust pipe
F18D0SA
1. Exhaust clamp
2. Exhaust pipe
SMR2002-068_05_04A.FM 05-04-3
Inspection 2 1
Inspect exhaust pipe condition paying attention for
cracks or other damage. Check joints, coupling areas,
heat shield and hoses. Replace any defective part.
Installation
Installation is essentially the reverse of the remov-
al procedures. However, pay particular attention to
the following:
Insert the exhaust pipe end in the exhaust hose.
Align the exhaust pipe flange to the engine manifold.
To achieve a good fit, it could be necessary to push
the exhaust pipe further down into the hose over the
step of the exhaust pipe. Take note of the dimension
it is over the step, then cut the hose by this dimension.
Add a second clamp no. 5 to the top portion of the
hose. The two clamps must be separated by 3 - 5 mm F18D0UA
(1/8 - 3/16 in) and the screws must be at least 25 mm 1. Engine manifold
(1 in) apart. 2. Exhaust pipe flange
CAUTION: Exhaust pipe alignment with the man-

ifold is critical to the bellows life. Any constraint
on the flexible joint will result in the bellows fail-
ure. Gap between the exhaust pipe flange and
the engine manifold should not exceed 1 mm
(3/64 in).
Reinstall the exhaust clamp no. 4 to the exhaust
pipe flange and tighten enough to maintain the ex-
haust pipe in the proper position.
F18D0VA 3 2 1
1. Exhaust pipe step
2. Exhaust hose
3. Exhaust hose clamp
Pre-align the exhaust pipe no. 1 by rotating (axially)

and moving (longitudinally) the muffler (LH) so that
the exhaust pipe flange makes perfect contact with
the engine manifold.
F18D0XA 3 2 1
1. Exhaust pipe flange
2. Exhaust clamp
3. Engine manifold
05-04-4 SMR2002-068_05_04A.FM
Rotate (axially) and move (longitudinally) the muf-

fler (LH) so that the exhaust pipe flange makes
perfect contact with the engine manifold. A maxi-
mum gap of 1 mm (3/64 in) is allowed.
Torque the exhaust clamp no. 4 to 11 N•m (97
lbf•in) while maintaining the exhaust pipe in the
proper position.
Reinstall the muffler (LH) strap no. 11 using the
spring installer/remover (P/N 529 035 559). Care
must be taken not to induce strain in the flexible
joint of the exhaust tube.
Torque the two clamps located in the upper part
of the muffler (LH) hose to 8 N•m (71 lbf•in). Care
must be taken not to induce strain in the flexible
joint of the exhaust tube. R1503motr151A 2 1
1. Exhaust manifold
Reconnect the water lines to the exhaust pipe and 2. Cooling system supply hose location
Unscrew the exhaust manifold no. 9 beginning
with the bottom screws. This will help holding the
water to the exhaust cooling system when water-
manifold while you remove the screws.
Remove the manifold and move it out toward the
After installation, ensure there is no water or exhaust
front of the watercraft to withdraw.
gas leak when engine is running. Test run the engine
while supplying water to the flushing connector.
EXHAUST MANIFOLD
Removal
Disconnect the cooling hoses no. 2 and no. 3
from the exhaust pipe no. 1.
Remove the exhaust clamp no. 4 and detach the
muffler (LH) from its support. Move the muffler
(LH) no. 6 rearwards to separate the exhaust pipe
from the manifold. See above in EXHAUST PIPE.
Disconnect the cooling system supply hose no. 8
F18D0LA
underneath the front part of the exhaust manifold.
Inspection
Inspect exhaust manifold condition paying attention
for cracks or other damage. Check contact surfaces
and hose. Replace any defective part.
Inspect plane surfaces for warpage. Small deforma-
tion can be corrected by grinding surface with a fine
sand paper. Install sand paper on a surface plate and
rub part against oiled sand paper.
SMR2002-068_05_04A.FM 05-04-5
Installation
the following:
NOTE: There is no gasket between engine block
and exhaust manifold.
Apply Loctite 518 on threads of screws.
To help holding the manifold while installing
screws, first insert the exhaust manifold into the
exhaust pipe no. 1 then, install the upper front
screw. Continue with the remaining screws.
Torque screws to 10 N•m (88 lbf•in) as per follow-
ing illustrated sequence. Repeat the procedure, F18D0MA 1 2
torquing screws again to 10 N•m (88 lbf•in). 1. Temperature sensor connector
2. Outlet hose
7 5 1 3 9 11
Detach the strap no. 11 from the muffler (LH) using
the spring installer/remover (P/N 529 035 559).
A00C3SA
R1503motr152A 8 6 4 2 10 12

water to the exhaust cooling system when water-
After installation, ensure there is no coolant or ex-
haust gas leak when the engine is running. Test run
the engine while supplying water to the flushing con-
nector.
F18D0JA 3 1 2
MUFFLER (LH) 1. Muffler (LH)
2. Strap
Removal
Remove the exhaust pipe no. 1. See above. Carefully pull out the muffler (LH) no. 6.
Disconnect the temperature sensor connector.
Inspection
Disconnect the outlet hose.
Inspect parts condition paying attention for cracks or
other damage. Check hoses. Replace any defective
part.
05-04-6 SMR2002-068_05_04A.FM
Installation 1 2
Installation is the reverse of the removal procedures.
the engine while supplying water to the flushing con-
nector.
MUFFLER (RH)
Removal
Loosen both exhaust hose clamps no. 15 and discon-
nect the exhaust hoses no. 7 and no. 16 from the
muffler (RH) no. 10.
F18D0OA 3
1. Muffler (RH)
2. Strap
Carefully pull out the muffler (RH) no. 10.
Inspection
other damage. Check hoses. Replace any defective
part.
Installation
Installation is the reverse of the removal procedures.
F18D0NA 1
1. Disconnect inlet and outlet hoses from muffler (RH)
Detach the strap no. 12 from the muffler (RH) using the engine while supplying water to the flushing con-
the spring installer/remover (P/N 529 035 559). nector.
EXHAUST OUTLET
Removal
Remove the muffler (LH) no. 6. See above.
A00C3SA Remove the jet pump as an assembly. Refer to
PROPULSION SYSTEM.
SMR2002-068_05_04A.FM 05-04-7
From outside of hull, unscrew nut no. 13 with the

exhaust outlet tool (P/N 295 000 132).
F01B2AA
TYPICAL
F18D0PA 2
1. Exhaust outlet nut
2. Tool
From inside the bilge, pull out the exhaust hose

no. 7 and the adapter no. 14 together.
Detach the adapter no. 14 from the exhaust hose
no. 7.
Inspection
other damage. Check hose. Replace any defective
part.
Installation
Installation is essentially the reverse of the removal
procedures. However, pay particular attention to the
following:
Apply Loctite silicone sealant (P/N 293 800 086)
on the adapter flange to seal the bilge.
Test the bilge for water leaks.
05-04-8 SMR2002-068_05_04A.FM

GENERAL Drive System
Engine removal is necessary to repair BOTTOM To withdraw drive shaft, refer to PROPULSION
END. section.
ENGINE REMOVAL Cooling System

To remove cooling system hoses, refer to COOL-
Use the VCK (Vehicle Communication Kit) (P/N 529 ING SYSTEM section
035 844) and release the fuel pressure in the fuel sys-
tem. Refer to ENGINE MANAGEMENT section. Exhaust Pipe
In order to remove engine from watercraft proceed To remove exhaust pipe, refer to EXHAUST SYS-
as follows. TEM in ENGINE section.
First, disconnect battery cables from battery. Air Intake Silencer
 WARNING To remove air intake silencer, refer to INTAKE.
the specified order, BLACK negative cable Air Intake Module
first then the RED positive battery cable last. To remove air intake manifold, refer to INTAKE
section.
Electrical Connections Engine Support
It is recommended to disconnect electrical con- NOTE: Be careful when removing engine sup-
nections prior to disconnecting fuel lines. port(s) or rubber mount adapters, shims could
Disconnect magneto wiring harness. have been installed underneath. Shims control
Disconnect the throttle position sensor (TPS), of shims for reinstallation, to avoid altering engine
manifold air pressure sensor (MAPS) and manifold alignment.
air temperature sensor (MATS) (refer to INTAKE
section). Remove engine support mount screws.
Refer to ENGINE MANAGEMENT for location of sen-
sors and connectors.
OPAS
To disconnect OPAS, refer to STEERING section.
Jet Pump Removal

To withdraw jet pump, refer to PROPULSION
section.
CAUTION: Whenever removing engine from
watercraft, engine/jet pump alignment must be
performed at reinstallation.
F18D13A 1
FRONT SUPPORT
1. Remove screw
SMR2002-069_05_05A.FM 05-05-1
Removal of Remaining Components

Disconnect RED positive cable from starter post.
F18D14A 1
REAR SUPPORT
1. Remove screws
F18D12A 1
Lifting Engine TYPICAL
ment, slightly lift engine to ease the remaining com- Carry on engine lifting to remove from the body
ponent removal. opening.
CAUTION: Take care not to damage cables. CAUTION: Be careful not to scratch body or to
hit any component.
1 1
CLEANING
cleaner.
INSTALLATION
Installation of engine in watercraft is essentially
the reverse of removal procedures. However pay
F18D11A
TYPICAL
1. Transport brackets
05-05-2 SMR2002-069_05_05A.FM
Rubber Mount, Shim and Screw

Check tightness and condition of rubber mounts.
If they have been removed, apply Loctite 243
(blue) on screw threads. Torque screws to
25 N•m (18 lbf•ft).
CAUTION: Strict adherence to this torque is im-
portant to avoid damaging threads of alumi-
num insert in bilge.
Engine Support
Loctite 243 Loctite

243 1
1
F00B0FA 1 2
1. Plate
2. Support
Alignment shaft (P/N 295 000 141).
1 F00B0GA 1
1. Alignment shaft
Loctite 243
Engine alignment adapter (P/N 529 035 719).
F18D10A
Positive Starter Cable F18D16A 1

Torque nut of positive starter cable to 7 N•m 1. Engine alignment adapter
(62 lbf•in). Apply dielectric grease on nut.
To verify alignment proceed as follows:
Engine/Jet Pump Alignment – Install the appropriate plate with the support to
Alignment is necessary to eliminate possible vi- hull with four nuts.
bration and/or damage to components. Check
alignment of engine using the following alignment
tools.
Support plate kit (P/N 529 035 506).
NOTE: Use plate (P/N 529 035 508) for the 139.5 mm
(5-1/2 in) jet pump and plate (P/N 529 035 507) for
the 155.6 mm (6-1/8 in) jet pump.
F00B0HA
TYPICAL
SMR2002-069_05_05A.FM 05-05-3
– Install adaptor (P/N 529 035 719) on drive shaft.
F18D15A 1
F18D18A 1 TYPICAL
1. Shim
1. Engine alignment adaptor
– Carefully slide shaft through support. CAUTION: Whenever shims are used to correct
alignment, never install more than 5 mm
– Insert shaft end into engine alignment adaptor. (0.196 in) shim thickness.
NOTE: Ensure the protective hose and carbon
ring (or seal carrier) is removed to check engine Engine Support Screws
alignment. If the alignment is correct, the shaft will Apply Loctite 243 (blue) (P/N 293 800 060) on
slide easily without any deflection in engine align- screw threads.
ment adaptor.
Loctite 243 Loctite

243 1
1
F18D17A 1 2
TYPICAL
1. Engine alignment adapter 1
2. Alignment shaft
If the alignment is incorrect loosen engine support Loctite 243

screws to enable to align engine alignment adap-
tor with shaft end.
NOTE: Use shim(s) (P/N 270 000 024 or P/N 270
000 025) as necessary between engine supports F18D10A
and rubber mounts to correct alignment. 1. Torque to 25 N•m (18 lbf•ft)
05-05-4 SMR2002-069_05_05A.FM
Properly align exhaust pipe. Refer to EXHAUST

SYSTEM in ENGINE section.
Final Inspection
After its installation, properly adjust throttle cable as
specified in ENGINE MANAGEMENT.
tem, refer to FUEL SYSTEM section.
 WARNING
F18D13A 1 Whenever doing any type of repair on water-
craft or if any components of the fuel system
1. Torque to 25 N•m (18 lbf•ft) are disconnected, a pressure test must be done

F18D14A 1
SMR2002-069_05_05A.FM 05-05-5
Subsection 06 (PTO HOUSING/MAGNETO)
PTO HOUSING/MAGNETO 0
10 Nm
10 Nm (88 lbfin)
(88 lbfin)
1 Engine oil
24 Nm(17 lbfft)
Loctite 10 Nm Multi-purpose grease

243 (88 lbfin)
3 30 Nm Loctite
10 (22 lbfft) 243
11
Engine oil
9 24 Nm
(17 lbfft) 76
8
15
14
3 Nm (26 lbfin) 22
Left handed threads 10 Nm
4 (88 lbfin)
Engine oil
18 250 Nm
10 Nm (88 lbfin) (184 lbfft)
Loctite 243 5 17 16 13
Loctite
243 12
Loctite 5910
Engine oil 19
18 Nm 20
(159 lbfin) Engine
Loctite 243 Engine 21 oil
oil 10 Nm
(88 lbfin) Loctite anti-seize
12 Nm
(106 lbfin) Loctite
243
R1503motr57S
SMR2002_070_05-06A.FM 05-06-1
GENERAL A tube is to be inserted to siphon oil out of PTO

housing. To ensure tube will be inserted far in
Always perform the electric tests before removing enough, measure 381 mm (15-3/8 in) from tube
or installing any components. end (the end that will be inserted in engine) and
Clean threads before using Loctite when installing trace a mark or put tape on the tube at this loca-
the screws. tion.
Insert the tube along timing chain as shown until
PTO HOUSING you reach the mark (or tape). Then, siphon the oil
out using the oil VAC (P/N 529 035 880).
Removal
1
NOTE: When drive shaft will be removed, some
oil will flow out. To prevent it, start engine, run at
4000 RPM for 10 seconds and stop engine at this
RPM. This will move oil out of PTO housing into
oil tank.
If engine cannot be started, up to 1L (34 oz) could
flow out at PTO housing removal. To prevent this,
follow instructions REMOVING OIL IN PTO HOUS-
ING WHEN ENGINE CANNOT BE STARTED be-
low. Otherwise, skip to instructions PTO HOUSING
REMOVAL below.
Removing Oil in PTO Housing when Engine
cannot be Started
F18D2KA A
Remove chain tensioner plug screw and tensioner.
Refer to ENGINE BLOCK subsection. PTO HOUSING AND MAGNETO REMOVED FOR EXPLANATION
A. 381 mm (15-3/8 in) from tube end
1. Siphon tube
3 2
PTO Housing Removal
Drain engine oil. Refer to LUBRICATION in ENGINE
section.
Place rags under PTO housing to prevent spillage.
Up to 250 mL (8 oz) of oil could flow out when
removing PTO housing. If spillage occurs, clean
immediately with the Pulley flange cleaner (P/N
413 711 809) to prevent oil stains.
Disconnect CPS and magneto generator from wir-
ing harness.
 WARNING
R1503motr39A 1 Always disconnect battery or starter cables
1. Plug screw
exactly in the specified order, BLACK nega-
2. Gasket ring tive cable first. Disconnect electrical connec-
3. Chain tensioner tions prior to disconnecting fuel lines.
Remove valve cover. Refer to CYLINDER HEAD
AND VALVES subsection.
05-06-2 SMR2002_070_05-06A.FM
Remove: NOTE: Carefully separate the PTO housing from

– jet pump (refer to JET PUMP in PROPULSION the engine using two flat screwdrivers prying
SYSTEM) equally at the same time. Proceed slowly so that
starter gear disc springs no. 6 and washer no. 7
– drive shaft (refer to DRIVE SYSTEM in PRO- do not fall down.
PULSION SYSTEM)
– PTO housing no. 5
– slightly lift rear part of engine and safely block
in this position. Remove rear LH side engine CAUTION: Ensure to use prying lugs to sepa-
support no. 1. rate PTO housing to prevent damaging contact
surface.
1 2
R1503motr50A
1. Engine support R1503motr58A
Remove: 1. Disc springs

2. Washer
– thru-hull fitting boot 3. Starter drive gear
– gasket no. 9.
2
Inspection
Check PTO housing for cracks or other damages.
Replace if necessary.
Installation
NOTE: Clean all metal component in a non-ferrous
metal cleaner.
 WARNING
Wear safety glasses and work in a well venti-
lated area when working with strong chemical
products. Also wear suitable non-absorbent
F18J0BA 1 gloves to protect your hands.
1. Thru-hull fitting boot
2. Remove this collar For installation, reverse the removal procedure.
However, pay attention to the following.
– coolant pump housing no. 2 (refer to COOLING
SYSTEM) NOTE: Turn the oil/coolant pump shaft in the right
position to fit into the balance shaft.
– screws nos. 3 and 4
SMR2002_070_05-06A.FM 05-06-3
Position the disc springs no. 6 and washer no. 7

2 1 2 2
as per the following illustration.
1 2 3 4
R1503motr46A
1. Washer
2. Disc spring
3. Flange washer
4. Starter drive ass’y 1 2
CAUTION: Ensure the starter drive gear shaft is 1
well engaged in its bore. R1503motr15A 2
Gently install PTO housing. 1. Screws M6 x 35
2. Screws M6 x 85
CAUTION: While installing housing, pay partic- Tightening sequence for screws on PTO housing
ular attention that gasket does not get pinched is as per following illustration.
or slide out of its contact surface in the area
shown in the following illustration. Never force 15 14 1 13 12 11 10
to install cover. If there is a strong resistance,
remove housing and check oil/coolant pump
alignment and starter gear alignment.
1
16
9
17
18
8
19 7
20 6
R1503motr15B
21 2 3 4 5
Reinstall LH engine support. Apply Loctite 243 (blue)

on screw threads then torque to 24 N•m (17 lbf•ft).
Remove block under engine.
F18D2LA Properly reinstall chain tensioner. Refer to ENGINE
1. Pay attention that gasket remains properly positioned on this BLOCK subsection.
surface.
Properly reinstall valve cover. Refer to CYLINDER-
Refer to the following illustration for proper instal- HEAD AND VALVES subsection.
lation of screws. Refill engine with oil and cooling system with coolant.
Refer to ENGINE and COOLING SYSTEM sections.
Check engine alignment. Refer to REMOVAL AND
INSTALLATION in ENGINE section.
05-06-4 SMR2002_070_05-06A.FM
PTO SEAL COUPLING

Inspection Removal
Check the PTO seal no. 10 on the PTO housing. If Lock crankshaft with locking tool (P/N 529 035 821).
brittle, hard or damaged, or if you see a sign of oil Refer to CRANKSHAFT LOCKING in ENGINE BLOCK
leakage, replace it. subsection.
Remove:
Removal
– jet pump
oil will flow out. To prevent it, start engine, run at – drive shaft
4000 RPM for 10 seconds and stop engine at this – PTO seal as described above
RPM. This will move oil out of PTO housing into – coupling no. 12 using impeller remover/installer
oil tank. (P/N 529 035 820).
CAUTION: Never run engine without supplying CAUTION: Apply some oil on the tool to protect
water to the exhaust cooling system when wa- the seal located in the PTO coupling.
If spillage occurs, clean immediately with the Pul-
ley flange cleaner (P/N 413 711 809) to prevent oil
stains.
Remove:
– Oetiker clamp no. 11 located close to the PTO
housing
– jet pump (refer to JET PUMP in PROPULSION
SYSTEM)
– drive shaft (refer to DRIVE SYSTEM in PRO-
PULSION SYSTEM)
R1503motr48A
– PTO seal no. 22.
2
Inspection
Check if seal no. 13 is brittle, cracked or hard.
Check coupling for worn splines.
If damaged, replace faulty part.
R1503motr47A 1
1. Oetiker clamps
2. PTO seal
Installation R1503motr49A
Reinstall removed parts in the reverse order.
SMR2002_070_05-06A.FM 05-06-5
Installation 1 2
For installation, reverse the removal procedure.
Torque PTO coupling to 250 N•m (184 lbf•ft). Ap-
ply Loctite anti-seize on threads.
STATOR
Removal
Remove:
– PTO housing (refer to PTO HOUSING REMOVAL
elsewhere in this section)
– holding plate no. 14 with CPS no. 15
R1503motr26A
1. Stator screws
2. Stator
Inspection
Check stator and CPS condition. If damaged re-
place the faulty part.
For electrical inspection, refer to CHARGING SYS-
TEM for the stator and to ENGINE MANAGE-
MENT for the CPS.
3
Installation
R1503motr21A 1 2 NOTE: There is only one position for the stator
1. CPS screws
(notch in the magneto housing cover).
2. Holding plate
3. CPS
– screws no. 16
– stator no. 17.
R1503motr51A 1
1. Notch for stator
05-06-6 SMR2002_070_05-06A.FM
Place the rubber grommets on both cables in the Inspection

proper notches at the PTO housing.
Check rotor, bent teeth and encoder wheel condi-
2 1 tion. If damaged, replace faulty part.
Installation
Encoder wheel position has to be located with the
location pin on the crankshaft gear.
IMPORTANT: If rotor has balancing holes, never
install it so that they are inside the large gap be-
tween encoder wheel teeth. This would create a
non-starting condition of the engine.
R1503motr52A
1. Grommet on CPS cable

2. Grommet on stator cable
Apply Loctite 243 on threads.Torque stator and 4

CPS screws to 10N•m (88 lbf•in).
ROTOR AND ENCODER WHEEL

Removal
Lock crankshaft with locking tool (P/N 529 035
821). Refer to CRANKSHAFT LOCKING in ENGINE
BLOCK subsection.
F18D0AA 2 1 3
Remove:
WRONG INSTALLATION
– PTO housing 1. Rotor
2. Balancing holes
– hexagonal screws no. 18 retaining rotor. 3. Encoder wheel
4. Large gap
Withdraw rotor no. 19 with encoder wheel no. 20.
Apply Loctite 243 on threads.Torque rotor screws
3
RING GEAR
2 Removal
1
Lock crankshaft with locking tool (P/N 529 035 821).
Refer to CRANKSHAFT LOCKING in ENGINE BLOCK
subsection.
Remove:
– PTO housing cover
1
– hexagonal screws no. 18.
R1503motr53A
1. Hexagonal screws
2. Rotor
3. Encoder wheel
SMR2002_070_05-06A.FM 05-06-7
Withdraw rotor no. 19, encoder wheel no. 20 and STARTER DRIVE ASS’Y
starter ring no. 21.
Removal
4
Remove:
3
– PTO housing and ring gear as described above
2 – starter drive ass’y no. 8.
R1503motr54A
1. Hexagonal screws
2. Rotor
3. Encoder wheel
4. Ring gear 1
Inspection
Check ring gear condition, especially teeth condi- R1503motr55A
tion. If damaged, replace faulty part. 1. Starter drive ass’y
Installation CAUTION: Be careful not to lose the distance

washer, disc springs no. 6 and washer no. 7 lo-
For installation, reverse the removal procedure. cated on the starter drive shaft.
Ring gear and encoder wheel position has to be lo-
cated with the location pin on the crankshaft gear.
3
1
2
R1503motr58A
R1503motr54B 1. Disc springs

2. Washer
1. Location pin 3. Starter drive gear
2. Location pin holes
Apply Loctite 243 on threads.Torque rotor screws

05-06-8 SMR2002_070_05-06A.FM
Inspection
Check condition of the teeth, shaft, etc. and if the
sprag clutch operates well. If damaged, replace
faulty part.
Installation
Apply some Isoflex Topas NB52 grease (P/N 293
550 021) on the starter drive bearing located in the
engine block and on the starter drive support in the
PTO housing cover.
R1503motr56A
1. Starter drive bearing
R1503motr45A
1. Starter drive support
CAUTION: Be sure not to forget the distance

washer, disc springs and washer on the starter
drive shaft when assembling.
SMR2002_070_05-06A.FM 05-06-9
Subsection 07 (LUBRICATION SYSTEM)
LUBRICATION SYSTEM 0
10 Nm
10 Nm (88 lbfin)
(88 lbfin) 1
2 Engine oil
4
Loctite 3 10 Nm Multi purpose
243 (88 lbfin) grease
28 Nm
(21 lbfft)
24 Nm
(17 lbfft)
Loctite
19 243
3 Nm (26 lbfin) 32
20 10 Nm
Left handed threads 25 (88 lbfin)
26
Engine oil
33
31
10 Nm (88 lbfin) 6
Loctite
Loctite 243 5 243
18
17 39 Loctite 5910
Engine oil 16
23
15 24
21
Loctite 243 22 10 Nm
12 Nm (88 lbfin)
18 Nm
(106 lbfin) (159 lbfin) Engine Loctite
oil 243
R1503motr112S
SMR2002_071_05_07A.FM 05-07-1
Oil
18 Nm
(159 lbfin)
10 Nm
Loctite 243 Loctite 243 (88 lbfin)
41 18 Nm
(159 lbfin) 8
10 Nm
(88 lbfin)
10 Nm
Oil 7 (88 lbfin)
34 10 Nm Loctite 243
Loctite
(88 lbfin) 243
Loctite 243
Oil
35 Loctite 243
Oil
Loctite 243 Horizontal
to exhaust side
14
13 9
Oil 27
38 28 29 5-25 Nm
37
Oil (44-221 lbfin)
36 40 30 Oil
10 Nm Loctite 243 18 Nm 10
(88 lbfin) (159 lbfin) Loctite 243 10 Nm
(88 lbfin)
42 12
10 Nm 10 Nm Loctite 243
(88 lbfin) (88 lbfin) 11
R1503motr113S
05-07-2 SMR2002_071_05_07A.FM
GENERAL Check the oil level as follows:

1. Watercraft must be level. Check oil level either
Prior to change the oil, ensure vehicle is on a level
with watercraft in water or out of water. Engine
surface.
should be warm.
Oil and oil filter must be replaced at the same time.
Oil change and oil filter replacement should be done
with a warm engine.
 WARNING 2. If out of water, raise trailer tongue and block in
position when bumper rail is level. Install a gar-
The engine oil can be very hot. Wait until en-
den hose to the flushing connector. Refer to
gine oil is warm.
Flushing in MAINTENANCE and follow the pro-
Dispose oil and filter as per your local environmen- cedures.
tal regulations. CAUTION: Failure to flush exhaust cooling sys-
tem, when engine is out of water, may severely
OIL LEVEL VERIFICATION damage engine and/or exhaust system.
3. Warm-up engine then let idle for 30 seconds
CAUTION: Check level frequently and refill if before stopping.
necessary. Do not overfill - it would make the
engine smoke and reduce its power. Operating 4. Stop engine.
the engine with an improper level may severely 5. Wait at least 30 seconds then pull dipstick out
damage engine. Wipe off any spillage. and wipe clean.
 WARNING
Engine oil may be hot. Certain components in
the engine compartment may be very hot. Di-
rect contact may result in skin burn.
CAUTION: Never run engine longer than 5 min-

utes. Drive line seal has no cooling when water-
6. Reinstall dipstick, push in completely.
F18D04A
1. Dipstick
SMR2002_071_05_07A.FM 05-07-3
7. Remove dipstick and read oil level. It should be

between marks.
F18G03A 1 2
2
1. Oil filter housing
2. Pressure test plug
F18D05A
NOTE: Oil pressure switch works between 180 kPa
(26 PSI) and 220 kPa (32 PSI).
1. Full
2. Add The engine oil pressure should be within the follow-
3. Operating range
ing values.
8. Otherwise, add oil up to have the level between
marks as required. OIL PRESSURE TEST
9. To add oil, unscrew oil cap. Place a funnel into ENGINE RPM PRESSURE kPA (PSI)
the opening and add the recommended oil to
Idle (cold) 300 - 400 (44 - 58)
the proper level. Do not overfill.
Idle (at 80°C (176°F) min. 160 (23)
ENGINE PRESSURE TEST 4000 - 7500 300 - 400 (44 - 58)
NOTE: The engine pressure test should be done
with a warm engine and the recommended oil. If the engine oil pressure is out of specifications,
check the points described in TROUBLESHOOT-
Remove plug below oil filter housing.
ING section.
Use oil pressure gauge (P/N 529 035 709) and hose
Reinstall plug.
adaptor (P/N 529 035 652) and install where shown.
Start engine and read pressure at different RPM Oil change
as per following table.
Engine in vehicle
NOTE: If water is found in oil (oil will be milky),
refer to submerged engine in MAINTAINANCE
section and follow the procedure to flush it.
Bring engine to its normal operating temperature.
05-07-4 SMR2002_071_05_07A.FM
CAUTION: Failure to flush exhaust cooling sys- Pull siphon tube out of dipstick hole then crank
tem, when engine is out of water, may severely engine (do not start) while in engine drown mode
damage engine and/or exhaust system. (fully depress throttle lever and HOLD, then crank
engine).
 WARNING Crank engine for 10 seconds. Siphon oil again. Re-
Engine oil may be hot. Certain components in peat the crank-siphon cycle 2-3 times.
the engine compartment may be very hot. Di-
Engine removed
rect contact may result in skin burn.
There are two separate drain plugs on the engine.
CAUTION: Never run engine longer than 5 min- One is located in the lower crankcase half and the
utes. Drive line seal has no cooling when wa- other one in the PTO housing.
Run engine for 10 seconds at 4000 RPM and shut
it off at this RPM. This will move oil from PTO
housing to oil tank to allow maximum oil draining.
Remove oil filler cap and dipstick.
Using the oil VAC (P/N529 035 880), siphon oil
through dipstick hole.
CAUTION: Never crank or start engine when si-
phon tube is in dipstick hole. Never start engine
when there is no oil in engine. R1503motr211A 1
NOTE: So that siphon tube is located at the proper 1. Drain plugs
height to siphon oil, it is suggested to put some Place a drain pan under the engine drain plug area.
electrical tape on siphon tube at 475 mm (18.7 in)
from its end. Then, insert siphon tube until you Clean the drain plug area.
reach the tape. Unscrew drain plugs no. 39 and no. 40 then remove
dipstick.
2
CAUTION: Pay attention not to lose gasket rings
on drain plug.
– Wait a while to allow oil to flow out of oil filter.
Change gasket ring on drain plug if damaged.
Inspection
Oil condition gives information about the engine
condition. See TROUBLESHOOTING section.
Installation
Reinstall removed parts and fill in the new engine oil.
Oil Type and System Capacity

Refer to TECHNICAL DATA. For refilling procedure,
refer to OIL LEVEL VERIFICATION above.
R1503motr150A 1
1. Oil vac
2. Siphon tube in dipstick hole
SMR2002_071_05_07A.FM 05-07-5
OIL FILTER Inspection

Removal Check oil filter cover O-ring no. 4 and oil filter screw
O-ring, change if necessary.
Remove:
Check and clean the oil filter inlet and outlet area
– engine oil (refer to OIL CHANGE) for dirt and other contaminations.
– oil filter screw no. 1
– oil filter cover no. 2
– oil filter no. 3.
3 2 1
R1503motr115A 2 1
1. Inlet bore from the oil pump to the oil filter
2. Outlet bore to the engine oil providing system
R1503motr114A
Installation
The installation is the opposite of the removal pro-
1. Oil filter screw
2. Oil filter cover cedure. Pay attention to the following details.
3. Oil filter
Install a new oil filter.
Place rags in fillet area to prevent spillage. If spillage Install O-ring on oil filter cover.
occurs, clean immediately with the pulley flange
cleaner (P/N 413 711 809) to prevent stains.
 WARNING
gloves to protect your hands.
R1503motr116A
Torque oil filter screw to 9 N•m (80 lbf•in).
05-07-6 SMR2002_071_05_07A.FM
OIL STRAINERS
The oil strainers do not need to be cleaned at every
oil change. Clean them during other inspections,
especially when the engine is disassembled.
PTO - Oil strainer

Removal
Remove:
– engine oil (refer to OIL CHANGE)
– PTO cover no. 5
(refer to PTO COVER/MAGNETO section)
– oil strainer no. 6.
1 R1503motr118A 1
1. Oil inlet to the oil pump
Installation
Refill engine at the proper level with the recom-
mended oil. Refer to TECHNICAL DATA for capacity
and OIL LEVEL VERIFICATION above for procedure.
Suction Pump - Oil strainer

Removal
– Remove blow-by ventilation hose no. 7.
R1503motr117A
1
1. Oil strainer
Cleaning and Inspection

Clean oil strainer with a part cleaner then use an air
gun to dry it.
 WARNING
Always wear eye protector. Chemicals can
cause a rash break out in and an injury to your
eyes.
Check and clean the oil outlet area for dirt and oth-
er contaminants.
R1503motr133A
1. Blow-by ventilation hose
– Disconnect wiring harness from blow-by valve

no. 8 and blow-by pressure switch no. 9.
– Detach air silencer box from throttle body.
SMR2002_071_05_07A.FM 05-07-7
– Disconnect battery cables and vent tube then re- Inspect rubber rings no. 13 and no. 14.
move battery. Refer to BATTERY in CHARGING
SYSTEM section for proper procedures.
– Remove retaining screws no. 10 and no. 11. 1
– Place rags under cover to prevent spillage. If
spillage occurs, clean immediately with the pul-
ley flange cleaner (P/N 413 711 809) to prevent
stains.
 WARNING 2
R1503motr121A
– Remove suction pump cover with oil separator.
1. O-ring
– Remove oil strainer no. 12. 2. Rubber ring gasket
If rubber rings are brittle, cracked or hard, replace

them.
Clean both contact surfaces of oil strainer cover.
Check and clean the oil inlet and outlet area for dirt
and other contaminations.
R1503motr120A 1
1. Oil strainer
Cleaning and Inspection

Clean oil strainer with a part cleaner then use an
air gun to dry it.
R1503motr122A 1
 WARNING 1. Oil inlet to the oil pump
Always wear eye protector. Chemicals can

cause a rash break out in and an injury to your
eyes.
05-07-8 SMR2002_071_05_07A.FM
Installation
Position screw length as shown.
R1503motr123A
1. Oil pressure regulator
NOTE: The oil pressure regulator system opens

when the oil pressure exceeds 400 kPa (58 PSI).
R1503motr119A 1 2 Removal
1. Screws M6 x 25
2. Screws M6 x 85 Remove:
Torque suction pump cover screws to 10 N•m (88 – engine oil (refer to OIL CHANGE)
lbf•in) as per sequence illustrated below. Apply – oil pressure regulator plug no. 15, compression
Loctite 243 on threads. spring no. 16, valve piston no. 17 and valve pis-
ton guide no. 18.
6
 WARNING
Oil pressure regulator plug on oil pump housing
1 is spring loaded.
2
3
R1503motr144A 4
ENGINE OIL PRESSURE

REGULATOR
The oil pressure regulator is located on the bottom
of the PTO housing.
R1503motr124A 4 3 2 1
1. Valve piston guide
2. Valve piston
3. Compression spring
4. Oil pressure regulator plug
SMR2002_071_05_07A.FM 05-07-9
Inspection – oil pump cover no. 22

Inspect valve piston and valve piston guide for scor- 2
ing or other damages.
Check compression spring for free length.
COMPRESSION SPRING FREE LENGTH
NEW NOMINAL 60 mm 2.362 in)
SERVICE LIMIT 50.3 mm (1.980 in)
Replace parts if important wear or damage are

present.
Clean bore and threads in the PTO housing from
metal shavings and other contaminations.
Installation R1503motr125A 1
1. Screws
Pay attention to the following details. 2. Oil pump cover
Be careful that the O-Ring on plug screw is in place. – outer oil pump rotor no. 23
Torque plug screw to 12 N•m (106 lbf•in) maxi-
1
mum. Apply Loctite 243 on threads.
OIL PRESSURE PUMP

The oil pressure pump is located in the PTO hous-
ing and is driven by the balance shaft.
Removal
Remove:
– engine oil (refer to OIL CHANGE)
– PTO housing
(refer to PTO HOUSING/MAGNETO section)
– Coolant pump housing no. 19 and impeller no. 20.
(refer to COOLING SYSTEM section) R1503motr126A
– screws no. 21 1. Outer oil pump rotor
– Extract the coolant/oil pump shaft no. 24 from

outside PTO housing with a pusher.
05-07-10 SMR2002_071_05_07A.FM
– Remove rotary seal no. 25 with a screwdriver.
R1503motr129A 1
1. Pittings on the teeth
Using a feeler gauge, measure the clearance be-

tween inner and outer rotors.
R1503motr127A
CAUTION: Be careful not to damage the surface

of the rotary seal bore in PTO housing cover. B
– oil seal no. 26.
A
1
R1503motr130A 2 1
1. Outer rotor
2. Inner rotor
R1503motr128A
1. Oil seal OUTER AND INNER ROTOR CLEARANCE

mm (in)
Inspection SERVICE LIMIT
Inspect oil pump shaft assembly, housing and cov- A
er for marks or other damages. B 0.25 mm (.009 in)
Check inner rotor for corrosion pin-holes or other C
damages. If so, replace oil pump shaft assembly.
Ensure to also check oil pump housing and cover If clearance between inner and outer rotors ex-
and replace if damaged. ceeds the tolerance, replace coolant/oil pump shaft
assembly. Ensure to also check oil pump housing
and cover and replace if damaged.
If clearance between outer rotor and its bore in oil
pump exceeds the tolerance, replace the complete
oil pump and the PTO housing.
SMR2002_071_05_07A.FM 05-07-11
Using a vernier depth gage, measure side wear as Installation

shown.
For installation, reverse the removal procedure. Pay
attention to the following details.
NOTE: Never use oil in the press fit area of the ro-
tary seal.
Push coolant/oil pump shaft seal in place by using
thumb.
1
R1503motr131A 2 1
1. PTO housing surface
2. Vernier depth gauge
R1503motr128A
1. Oil seal
Install the new rotary seal by using the rotary seal

pusher (P/N 529 035 823).
CAUTION: Never use a hammer for the rotary
seal or coolant/oil pump shaft installation. Only
use a press to avoid damaging the ceramic com-
ponent.
R1503motr132A 2 1
1. Oil pump outer rotor surface
2. Vernier depth gage
Difference between pump housing and outer rotor

should not exceed 0.1 mm (.004 in). If so, replace
replace the complete oil pump assembly.
NOTE: When the axial clearance of the oil pump
shaft assembly increases, the oil pressure de-
creases.
Check the inside of oil pump housing and its cover
for scoring or other damages and replace if dam-
aged.
R1503motr141A 2 1
1. Rotary seal
2. Rotary seal pusher
05-07-12 SMR2002_071_05_07A.FM
Install the coolant/oil pump shaft using the rotary OIL SUCTION PUMP
seal pusher (P/N 529 035 823) on the opposite
side to support the rotary seal. Use the oil seal The oil suction pump is located on the front side
guide (P/N 529 035 822) with a press. of the engine at the bottom of the oil separator.
Removal
– Remove blow-by ventilation hose no. 7.
1
R1503motr142A 2 1
1. Oil seal guide
2. Coolant/oil pump shaft
R1503motr133A
1. Blow-by ventilation hose
– Disconnect wiring harness from blow-by pres-

sure switch no. 9 and blow-by valve no. 8.
– Detach air silencer from throttle body.
– Disconnect battery cables and vent tube then
remove battery. Refer to BATTERY in CHARG-
ING SYSTEM section for proper procedures.
– Remove retaining screws no. 42.
R1503motr143A 2
1. Coolant/oil pump shaft with oil seal guide
2. Rotary seal pusher spillage occurs, clean immediately with the pul-
ley flange cleaner (P/N 413 711 809) to prevent
Tighten oil pump cover screws and torque to 10 N•m stains.
(88 lbf•in). Apply Loctite 243 on threads.
Final Test  WARNING

After engine is completely reassembled, start en- lated area when working with strong chemi-
gine and make sure oil pressure is within specifi- cal products. Also wear suitable non-absor-
cations. bent gloves to protect your hands.
– Remove oil suction pump housing with oil sep-

arator.
SMR2002_071_05_07A.FM 05-07-13
– Remove oil pump screws no. 27 and cover no. 28.

1
R1503motr137A
1. Pittings on the teeth
Using a feeler gauge, measure the clearance be-

R1503motr135A 1 tween inner and outer rotors.
1. Oil pump cover
– Remove oil pump shaft ass’y no. 29.

– Remove outer rotor no. 30. A
B
C
R1503motr138A 2 1
1. Outer rotor
2. Inner rotor
OUTER AND INNER ROTOR CLEARANCE

R1503motr136A 1 2 mm (in)
1. Oil pump shaft ass’y SERVICE LIMIT
2. Outer rotor
A
Inspection B 0.25 mm (.009 in)
Inspect oil pump shaft assembly, housing and cov- C
er for marks or other damages.
If clearance between inner and outer rotors ex-
Check inner rotor for corrosion, pin-holes or other
ceeds the tolerance, replace oil pump shaft as-
damages. If so, replace oil pump shaft assembly.
sembly. Ensure to also check oil pump housing
Ensure to also check oil pump housing and cover
and cover and replace if damaged.
and replace if damaged.
If clearance between outer rotor and its bore in oil
pump exceeds the tolerance, replace the com-
plete oil pump and the PTO housing.
05-07-14 SMR2002_071_05_07A.FM
Using a vernier depth gage, measure side wear as Installation

shown.
For installation, reverse the removal procedure. Pay
1
R1503motr139A 1 2
1. Oil pump housing surface
2. Vernier depth gage
R1503motr134A 2 2
1. Screws M6 x 85
2. Screws M6 x 25
Torque oil pump cover screws to 10 N•m (88 lbf•in).

Tighten suction pump screws as per following se-
quence and torque to 10 N•m (88 lbf•in). Apply
Loctite 243 (blue) on threads.
1
R1503motr140A 1 2
1. Oil pump outer rotor surface
2. Vernier depth gage 7
Difference between pump housing and outer rotor 3

should not exceed 0.1 mm (.004 in). If so, replace 6
the complete oil pump assembly. 4
NOTE: When the axial clearance of the oil pump
shaft assembly increases, the oil pressure de- R1503motr145A 2 5
creases.
Check the inside of oil pump housing and its cover
for scoring or other damages and replace if dam-
aged.
SMR2002_071_05_07A.FM 05-07-15
OIL FILTER BYPASS OIL COOLER

The oil filter bypass valve is located in the PTO The oil cooler is located below the air intake man-
housing below the oil filter. ifold.
Removal
Remove the PTO housing. Refer to PTO HOUSING/
MAGNETO section.
Remove plug screw no. 31 and pull out the oil fil-
ter bypass valve ball no. 32 and spring no. 33.
3 2 1
R1503motr110A
1
1. Oil cooler
Removal
Remove:
– cooling hoses no. 34 and no. 35
– retaining screws no. 36
R1503motr146A
– oil cooler no. 37
1. Plug screw
2. Compression spring 2 1
3. Ball
Inspection
Inspect ball for scoring or other damages.
Check compression spring for free length.
COMPRESSION SPRING FREE LENGTH
NEW NOMINAL 21.5 mm (0.846 in)
SERVICE LIMIT 21 mm (0.826 in)
Replace parts if important wear or damage are

R1503motr147A 1
present.
1. Screws
Clean bore and threads in the PTO housing from 2. Oil cooler
metal shavings and other contaminations.
Installation
Pay attention to the following details.
Torque plug screw to 28 N•m (21 lbf•ft). Apply Loc-
tite 243 (blue) on threads.
05-07-16 SMR2002_071_05_07A.FM
– O-rings no. 38.

1
R1503motr148A 1
1. O-Rings
R1503motr133A
Inspection 1. Blow-by ventilation hose

If O-rings are brittle, cracked or hard, replace them.
– Disconnect wiring harness from blow-by valve
Clean both contact surfaces of oil cooler. no. 8 and blow-by pressure switch no. 9.
Check and clean the oil inlet and outlet area for dirt – Detach air silencer box from throttle body.
and other contaminations.
– Disconnect battery cables and vent tube then
remove battery. Refer to BATTERY in CHARG-
Installation ING SYSTEM section for proper procedures.
For installation, reverse the removal procedure. – Remove retaining screws no. 42.
Apply grease on O-rings. spillage occurs, clean immediately with the pul-
Torque oil pump cover screws to 10 N•m (88 lbf•in). ley flange cleaner (P/N 413 711 809) to prevent
Apply Loctite 243 (blue) on threads. stains.
OIL SEPARATOR  WARNING

Pressure Test Wear safety glasses and work in a well venti-
Refer to ENGINE MANAGEMENT section. products. Also wear suitable non-absorbent
Removal
– Remove blow-by ventilation hose no. 7. – Remove suction pump cover with oil separator
ass’y.
– Remove blow-by valve no. 8 from oil separator.
Refer to BLOW-BY VALVE in ENGINE MANAGE-
MENT section.
– Completely disassemble oil separator ass’y.
SMR2002_071_05_07A.FM 05-07-17
Inspection
If O-rings and rubber rings are brittle, cracked or
hard, replace them.
Clean all contact surfaces of oil separator.
Check and clean the oil and blow-by channels for
dirt and other contaminations.
Installation
R1503motr119A 1 2
1. Screws M6 x 25
2. Screws M6 x 85
Apply grease on O-rings and rubber rings.

Torque screws to 10 N•m (88 lbf•in). Apply Loctite
243 (blue) on threads.
05-07-18 SMR2002_071_05_07A.FM
Subsection 08 (CYLINDER HEAD AND VALVES)
CYLINDER HEAD AND VALVES 0

NOTE: For cylinder head removal, it is not necessary to remove engine from vehicle.
10 Nm
1 (88 lbfin)
Engine oil
10 5
Grease Klueber 6
Isoflex Topas NB52 11
9
10
Engine 7 20 Nm (14.5 lbfft) + 90°
Loctite oil 8
243 18 Nm
6 Nm 24 (159 lbfin)
(53 lbfin) 10 Nm
12 25 10 Nm (88 lbfin)
14 22 (88 lbfin)
23 2
Loctite
243
13 21 28
29 16 Loctite
10 Nm 15 30 10 Nm
243
20 Engine
oil
Loctite 243
40 Nm (29.5 lbfft)
+ 120° + 90°
17
6 Nm
(53 lbfin)
18 Nm
(159 lbfin) 18
Engine oil
Engine oil
19
26
Loctite 243
27
10 Nm (88 lbfin)
R1503motr43S
SMR2002_072_05_08A.FM 05-08-1
GENERAL Unscrew spark plug no. 2 then use the single-

spark ignition coil to take spark plug out of spark
NOTE: When diagnosing an engine problem, al- plug hole.
ways perform a cylinder leak test. This will help
pin-point a problem. Refer to the instructions in- 1
cluded with your leak tester and LEAK TEST sec-
tion for procedures. 2
Always place the vehicle on level surface.
NOTE: For a better understanding, the following
illustrations are taken with engine out of vehicle.
To perform the following instructions, it is not nec-
essary to remove engine from vehicle.
Always disconnect the negative wire from the bat-
tery before working on the engine.
Even if the removal of many parts is not necessary
to reach another part, it is recommended to re- R1503motr44A
move these parts in order to check them.
1. Single-spark ignition coil
For installation, use the torque values and Loctite 2. Spark plug
products as mentioned. Clean threads before us-
ing Loctite product when installing screws. Inspection
When disassembling parts that are duplicated in Check spark plug and single-spark ignition coil con-
the engine, (e.g.: valves, bushings), it is strongly dition (refer to ENGINE MANAGEMENT SYSTEM).
recommended to note their position (cylinder 1, 2
or 3) and to keep them as a “group”. If you find a Installation
defective component, it would be much easier to For installation, reverse the removal procedure.
find the cause of the failure among its group of Pay attention to the following details.
parts (e.g.: you found a worn valve guide. A bent
spring could be the cause and it will be easy to Check spark plug gap.
know which one among the springs is the cause Place spark plug into single-spark ignition coil,
to replace it if you grouped them at disassembly). screw spark plug then remove the single-spark ig-
Besides, since used parts have matched together nition coil. Torque spark plug. Reinstall the single-
during the engine operation, they will keep their spark ignition coil.
matched fit when you reassemble them together NOTE: Prior to inserting the ignition coil to its lo-
within their “group”. cation, apply some BOMBARDIER LUBE lubricant
SPARK PLUG hole. After installation, ensure the seal seats prop-
erly with the engine top surface.
Removal
Remove fuel rail cover from engine. VALVE COVER
Unplug the single-spark ignition coil connector on
the spark plug you need to remove.
Removal
Remove the single-spark ignition coil no. 1. Remove:
Clean spark plug and single-spark ignition coil area – valve cover shield no. 3
before disassembly. – valve cover screws no. 4
05-08-2 SMR2002_072_05_08A.FM
3 1 5
R1503motr81A
1. Valve cover screws

R1503motr159A 8 2 4 6
– valve cover no. 5 and profile sealing ring no. 6.
Torque screws first to 40 N•m (29 lbf•ft) and in a
second sequence to 55 N•m (40 lbf•ft).
2
ROCKER ARM
Removal
Lock crankshaft with crankshaft locking tool
(P/N 529 035 821), refer to CRANKSHAFT LOCK-
ING in ENGINE BLOCK section.
1 Remove:
R1503motr82A – spark plug
1. Valve cover – valve cover
2. Profile sealing ring
– spark plug tube no. 7
Inspection
1
Check the profile sealing ring on the valve cover
and the rubber bushing on the valve cover screws
if they are brittle, cracked or hard. If so, replace the
profile sealing ring or the valve cover screw accord-
ingly.
Installation
NOTE: Install the valve cover screws according to
following sequence.
R1503motr83A
1. Spark plug tube
SMR2002_072_05_08A.FM 05-08-3
– rocker arm shaft screws no. 8. Discard screws. Inspection

Spark Plug Tube
1
Check seals on spark plug tube. If seals are brittle,
cracked or hard, replace spark plug tube.
R1503motr93B 2 1 3
R1503motr86A
1. Rocker arm shaft screws

1. Spark plug tube
2. Seal to the valve cover
– rocker arm shaft no. 9 with rocker arm assem- 3. Seal to the cylinder head
bly (exhaust side no. 10 and intake side no. 11).
Rocker Arm
1 Inspect each rocker arm for cracks and scored fric-
tion surfaces. If so, replace rocker arm assembly.
3 Check the rocker arm rollers for free movement,
wear and excessive radial play. Replace rocker
arm assembly as necessary.
R1503motr84A 2
1. Rocker arm shaft
2. Rocker arms (exhaust side)
3. Rocker arm (intake side)
1
A
1 2
R1503motr87A
1. Rocker arm (intake side)

2. Roller
A. Bore for rocker arm shaft
R1503motr85A
1. Oil supply from the camshaft to the rocker arm shaft, then to the
rocker arms and finally to the valve adjustment
05-08-4 SMR2002_072_05_08A.FM
Measure rocker arm shaft diameter.
ROCKER ARM SHAFT DIAMETER
NEW MINIMUM 19.980 mm (.7866 in)
NEW MAXIMUM 20.007 mm (.7877 in)
SERVICE LIMIT 19.965 mm (.7860 in)
A
1
R1503motr88A 2
1. Rocker arm (exhaust side)
2. Roller
A. Bore for rocker arm shaft
Measure rocker arm bore diameter. If diameter is R1503motr90A A

out of specification, change the rocker arm assem- A. Measure rocker arm shaft diameter here
bly.
Any area worn excessively will require parts replace-
ROCKER ARM BORE DIAMETER
ment.
NEW MINIMUM 20.007 mm (.7877 in) Installation

NEW MAXIMUM 20.020 mm (.7881 in) For installation, reverse the removal procedure. Pay
SERVICE LIMIT 20.035 mm (.7887 in) Apply engine oil on rocker arm shaft.
Press the hydraulic lifter with your thumb. If the IMPORTANT: The rocker arm shaft can only be
hydraulic lifter groove disappears inside rocker installed in one specific position. Therefore crank-
arm casting, replace rocker arm assembly. Lifter shaft as well as camshaft has to be positioned
must turn freely in rocker arm bore. Otherwise, with their locking pins when the piston of cylinder
replace. no. 3 is on ignition TDC. Refer to CRANKSHAFT
LOCKING in ENGINE BLOCK section for crank-
shaft and the following for the camshaft locking.
Use camshaft locking tool (P/N 529 035 839). Ro-
tate camshaft so that tool can be pushed in cam-
shaft hole and lock camshaft in place.
R1503motr89A
1. Hydraulic lifter groove
Rocker Arm Shaft

Check for scored friction surfaces, if so, replace parts. R1503motr111A
1. Camshaft locking tool
SMR2002_072_05_08A.FM 05-08-5
Then, the camshaft sprocket lines should be lined – Torque screws at first to 10 N•m (88 lbf•in) ac-
up as shown in the following illustration. cording to following sequence.
1 1 1 3 4
5 2
6
R1503motr93A
R1503motr95A
– Torque screws to 20 N•m (177 lbf•in).

1. Position lines
– Finish tightening screws turning an additional
Position the rocker arm shaft with the notches on 90° rotation with a torque angle gauge.
top.
2
1
2
1
R1503motr92A
R1503motr91A 1. Rocker arm shaft screw

2. Torque angle gauge
1. Rocker arm shaft
2. Rocker arm shaft notches
CAMSHAFT TIMING GEAR
Install NEW rocker arm shaft screws no. 8. Torque
as per following procedure: NOTE: Although it is not necessary to position
crankshaft to TDC for disassembly, it is a good
CAUTION: This assembly use stretch screws. practice to do it, as a troubleshooting step, to
As the screws have been stretched from the know before disassembly if valve timing was ap-
previous installation, it is very important to use propriate.
new screws at assembly. Failure to replace
screws and to strictly follow the torque proce-
dure may cause screws to loosen and lead to
engine damage.
05-08-6 SMR2002_072_05_08A.FM
Removal Install the camshaft timing gear with the writing

visible, i.e. to be able to see the position lines when
looking from outside of engine.
ING in ENGINE BLOCK section. 1
Remove:
– valve cover
– chain tensioner. Refer to CHAIN TENSIONER
REMOVAL in ENGINE BLOCK section
– chain guide no. 12
– Allen screws no. 13
– camshaft timing gear no. 14.
NOTE: Secure timing chain no. 15 with a retaining
wire.
Inspection
2
Check camshaft timing gear for wear or deteriora-
tion.
If gear is worn or damaged, replace it as a set
(camshaft timing gear and timing chain).
For crankshaft timing gear, refer to ENGINE BLOCK
section.
Installation
R1503motr97A
A
Using the camshaft locking tool (P/N 529 035 839),
lock camshaft on TDC position. 1. Good (with 1503 aligned)
2. Never
Install timing chain. Refer to ENGINE BLOCK sec-

tion.
1
Ensure chain guides are in place.
Loosely install screws.
Install chain tensioner.
Tighten screws and torque to 10 N•m (88 lbf•in)
Remove locking tools.
2 CAUTION: Crankshaft and camshaft must be
locked on TDC position to place camshaft tim-
ing gear and timing chain in the proper posi-
tion. To double check, take a look at the timing
R1503motr94A
gear lines. They must be parallel to the cylinder
1. Camshaft locking tool head surface.
2. Camshaft on TDC position
SMR2002_072_05_08A.FM 05-08-7
1 1
R1503motr95A R1503motr110A
1
1. position lines 1. Blow-by ventilation hose
CAUTION: Ensure to remove locking tools when – coolant hose

finished.
TIMING CHAIN
Refer to ENGINE BLOCK section.
CYLINDER HEAD
Removal
ING in ENGINE BLOCK section.
Drain coolant (refer to COOLING SYSTEM).
Disconnect coolant temperature and cam position
sensors (CTS and CAPS). R1503motr120A 1
Remove: 1. Blow-by ventilation hose
– exhaust manifold (refer to EXHAUST MANI- – chain tensioner (refer to CHAIN TENSIONER
FOLD REMOVAL elsewhere in this section) REMOVAL in ENGINE BLOCK section)
– engine coolant outlet hose – valve cover shield
– valve cover and profile sealing ring
(see VALVE COVER REMOVAL above)
– camshaft timing gear
– cylinder head screws M6 no. 16
05-08-8 SMR2002_072_05_08A.FM
Installation
Ensure dowel pins are in place.
1
Install new cylinder head gasket.
CAUTION: Each installation of the cylinder head
requires a new cylinder head gasket. Using a
gasket twice will cause engine damage, even if
the engine had not run.
Install cylinder screws M11 no. 17. Torque screws
as per following procedure.
R1503motr98A
CAUTION: This assembly use stretch screws.
As the screws have been stretched from the
1. Cylinder head screws M6
previous installation, it is very important to
– cylinder head screws M11 no. 17 retaining cyl- measure each screw at assembly. If screw is
inder head to engine block. out of specification, replace by a new. Failure
to replace screws and to strictly follow the
torque procedure may cause screws to loosen
1 and lead to engine damage.
CYLINDER SCREW M11
Torque screws according to following sequence.

First torque to 40 N•m (30 lbf•ft).
Then tighten screws turning an additional 120° ro-
tation with a torque angle gauge and finish tight-
ening with a 90° rotation. Torque screws no. 16 to
R1503motr99A
10 N•m (88 lbf•in).
1. Cylinder head screws M11
Pull up cylinder head no. 18. 1

2
Remove gasket no. 19.
Cleaning
Remove carbon deposits from combustion cham-
ber, exhaust port and piston top.
Inspection
Check for cracks between valve seats, if so, replace
cylinder head.
Check mating surface between cylinder and cylin-
der head for contamination. If so, clean both sur-
faces. R1503motr100A
1. Cylinder screws M11

2. Angle torque wrench
Remove crankshaft locking tool then install plug

with sealing ring.
SMR2002_072_05_08A.FM 05-08-9
CAMSHAFT CAMSHAFT LOBE - EXHAUST VALVE
Removal NEW MINIMUM 31.699 mm (1.248 in)

Remove: NEW MAXIMUM 31.809 mm (1.252 in)
– valve cover SERVICE LIMIT 31.670 mm (1.247 in)
– rocker arms
CAMSHAFT LOBE - INTAKE VALVE
– chain tensioner (refer to CHAIN TENSIONER
REMOVAL in ENGINE BLOCK section) NEW MINIMUM 31.480 mm (1.239 in)
– camshaft timing gear NEW MAXIMUM 31.590 mm (1.244 in)
– camshaft lock no. 20
– camshaft no. 21.
CAMSHAFT BEARING JOURNAL
1
NEW MINIMUM 39.892 mm (1.5705 in)
2
NEW MAXIMUM 39.905 mm (1.5711 in)
CAMSHAFT BEARING JOURNAL - ENGINE FRONT
R1503motr101A CAMSHAFT BORE

MEASURED IN DIAMETER
1. Camshaft lock
2. Camshaft
Inspection NEW MAXIMUM 40.016 mm (1.5754 in)
Check each lobe and bearing journal of camshaft
for scoring, scuffing, cracks or other signs of wear. SERVICE LIMIT 40.050 mm (1.5767 in)
Measure camshaft bearing journal diameter and CAMSHAFT BORE - ENGINE FRONT
lobe height using a micrometer. MEASURED IN DIAMETER
Measure clearance between both ends of cam- NEW MINIMUM 25.000 mm (.9842 in)
shaft and cylinder head.
D A B A C C A B A C C A B A C SERVICE LIMIT 25.050 mm (.9862 in)
Replace parts that are not within specifications.
Installation
R1503motr102A
A. Camshaft lobe (exhaust valves) Pay attention to the following details.
B. Camshaft lobe (intake valves)
C. Camshaft bearing journal Grease the camshaft bearing journals well by us-
D. Camshaft bearing journal — engine front
ing the grease Klueber Isoflex (P/N 293 550 021)
or a similar product.
Install camshaft then place the camshaft lock no. 20
in the slot.
05-08-10 SMR2002_072_05_08A.FM
1
2
R1503motr101B
1. Camshaft lock position
For other parts, refer to proper installation proce-

dure.
R1503motr103A
VALVE SPRING 1. Valve spring compressor clamp

2. Valve spring compressor cup
Removal
Remove:
– rocker arms
– cylinder head.
Compress valve springs no. 22 and no. 23. Use
valve spring compressor clamp (P/N 529 035 724)
and valve spring compressor cup (P/N 529 035
725).
 WARNING
Always wear safety glasses when disassem-
bling valve springs. Be careful when unlock-
ing valves. Components could fly away be-
cause of the strong spring preload. R1503motr104A
LOCATE VALVE SPRING COMPRESSOR CLAMP IN CENTER OF

THE VALVE
Remove valve cotters no. 24.
SMR2002_072_05_08A.FM 05-08-11
Withdraw valve spring compressor, valve spring Installation

retainer no. 25 and valve springs.
1 Pay attention to the following details.
2 Colored area of the valve spring must be placed on
3 top.
NOTE: Valve cotters must be properly engaged in
valve stem grooves.
R1503motr105A
1. Valve spring retainer

2. Inner valve spring
3. Outer valve spring
Inspection
Check valve springs for rust, corrosion or other vis- R1503motr105B
ible damages. If so, replace faulty valve springs.
1. Position of the valve spring
Check valve springs for free length and straight-
ness. VALVE
Replace valve springs if not within specifications.
Removal
Remove valve spring.
Push valve stem then pull valves no. 26 and
no. 27 out of valve guides.
A
R610motr122A
2
A. Valve spring length
OUTER VALVE SPRING FREE LENGTH
NEW NOMINAL 45.45 mm (1.789 in)

R1503motr106A
SERVICE LIMIT 43 mm (1.693 in)
1. Intake valve 38 mm
INNER VALVE SPRING FREE LENGTH 2. Exhaust valve 31 mm
NEW NOMINAL 41.02 mm (1.615 in) Remove valve stem seal no. 28 with special pliers
such as Snap-on YA 8230.
05-08-12 SMR2002_072_05_08A.FM
R610motr126A
A. Valve stem diameter

R610motr125A
VALVE STEM DIAMETER mm (in)

Inspection NEW MINIMUM
Valve Stem Seal
Exhaust 5.946 mm (.2341 in)
Inspection of valve stem seals is not needed be-
cause new seals should always be installed when- Intake 5.961 mm (.2347 in)
ever cylinder head is removed.
NEW MAXIMUM
Valve
Exhaust 5.960 mm (.2346 in)
Inspect valve surface, check for abnormal stem
wear and bending. If so, replace by a new one. Intake 5.975 mm (.2352 in)
Valve Stem and Valve Guide Clearance SERVICE LIMIT
Measure valve stem and valve guide in three places,
Exhaust
using a micrometer and a small bore gauge. 5.93 mm (.233 in)
NOTE: Clean valve guide to remove carbon depos- Intake
its before measuring.
Change valve if valve stem is out of specification
or has other damages such as wear or friction sur-
face.
SMR2002_072_05_08A.FM 05-08-13
Replace valve guide if it is out of specification or Measure valve seat width, using a caliper.
has other damages such as wear or friction sur-
face. VALVE SEAT CONTACT WIDTH mm (in)
VALVE GUIDE DIAMETER mm (in) NEW
NEW MINIMUM 1.25 to 1.55 mm

Exhaust
(.049 to .061 in)
Exhaust
5.994 mm (.2359 in) 1.10 to 1.30 mm
Intake
Intake (.043 to .051 in)
NEW MAXIMUM SERVICE LIMIT
Exhaust Exhaust 2 mm (.078 in)

6.018 mm (.2369 in)
Intake Intake 1.8 mm (.07 in)
SERVICE LIMIT If valve seat contact width is too wide or has dark
Exhaust
spots, replace the cylinder head.
6.060 mm (.2386 in)
Intake
A B
Valve Face and Seat
2 3
V01C1HA
A. Valve face contact width

B. Valve seat contact width
Installation
R1503motr107A 1 For installation, reverse the removal procedure.
1. Valve seat
2. Exhaust valve contaminated area Install thrust washer no. 30, valve spring guide
3. Valve face (contact surface to valve seat)
no. 29 then valve stem seal no. 28.
– Check valve face and seat for burning or pittings
and replace valve or cylinder head if there are
signs of damage.
Ensure to seat valves properly. Apply some lap-
ping compound to valve face and work valve on its
seat with a lapping tool.
Measure valve face contact width.
NOTE: The location of contact area should be in
center of valve seat.
05-08-14 SMR2002_072_05_08A.FM
R1503motr108A 2 1
1. Thrust washer
2. Valve spring guide
3. Valve stem seal
Apply engine oil on valve stem and install it.

CAUTION: Be careful when valve stem is passed
through sealing lips of valve stem seal.
R1503motr108B
1. Sealing lips of valve stem seal
To ease installation of cotters, apply oil or grease

to them so that they remain in place while releas-
ing the spring.
After spring is installed, ensure it is properly locked
by tapping on valve stem end with a soft hammer
so that valve opens and closes a few times.
CAUTION: An improperly locked valve spring will
cause engine damage.
SMR2002_072_05_08A.FM 05-08-15
Subsection 09 (ENGINE BLOCK)
ENGINE BLOCK 0
Grease Klueber Isoflex Topas NB52 Grease

Loctite 243 Engine
oil
10 Nm
24 Nm 21 (88 lbfin)
(17 lbfft)
22 Loctite 243
Engine
oil 20
Loctite 243 19
18 Nm
(159 lbfin)
18
Engine
10 Nm oil
24 Nm (88 lbfin)
(17 lbfft)
Engine
oil Loctite 243
16
Loctite 243
18 Nm 24 Nm
17 (159 lbfin)
(17 lbfft)
Loctite 243
24 Nm
(17 lbfft)
Engine
oil Loctite 243
3 18 Nm
(159 lbfin)
2
7 24 Nm
(17 lbfft)
10 Nm 1 40 Nm + 55 Nm
(88 lbfin) (30 lbfft) (41 lbfft)
Loctite 243 24 Nm
(17 lbfft)
R1503motr01S
SMR2002_073_05_09A.FM 05-09-1
9 Engine
8
oil 10
Engine Engine
oil oil
Engine
oil
Engine
260 Nm oil
(191 lbfft) Engine
4 oil
Loctite
Engine anti-seize 4 12
oil
Engine
oil
Engine
oil 45 Nm
11 (33 lbfft) + 90°
6
13
Engine
oil
6
Engine 5
oil
Engine
15 oil
14
Engine Engine
Engine oil
oil oil
15
R1503motr02S
05-09-2 SMR2002_073_05_09A.FM
GENERAL 1
When disassembling parts that are duplicated in
the engine, (e.g.: pistons, connecting rods etc.), it
is strongly recommended to note their position
(Cylinder 1, 2 or 3) and to keep them as a “group”.
If you find a defective component, it would be
much easier to find the cause of the failure among
its group of parts (e.g.: you found a worn valve
guide. A bent spring could be the cause and it will
be easy to know which one among the springs is
the cause to replace it if you grouped them at dis-
assembly). Besides, since used parts have
matched together during the engine operation,
they will keep their matched fit when you reas-
semble them together within their “group”. R1503motr03A
1. Screwdriver
CRANKSHAFT LOCKING In this position, the crankshaft can be locked by
Remove: using crankshaft locking tool P/N 529 035 821.
– seat and vent tube support When finished, reinstall all removed parts.
– air intake manifold (refer to AIR INTAKE MANI-
FOLD REMOVAL in ENGINE section) CRANKSHAFT
– fuel rail cover
Removal
– spark plugs
Remove:
– plug screw.
– engine oil
2 1 (refer to OIL CHANGE in LUBRICATION section)
– engine from vehicle
(refer to REMOVAL AND INSTALLATION)
– cylinder head (refer to CYLINDER HEAD RE-
MOVAL in CYLINDER HEAD section)
in PTO HOUSING/MAGNETO section)
– starter gear (refer to STARTER GEAR REMOV-
AL in PTO HOUSING/MAGNETO section)
– starter drive ass’y
– oil suction pump with oil separator ass’y (refer
to SUCTION PUMP REMOVAL in LUBRICA-
TION section)
R1503motr04A
– engine mounting brackets
1. Plug screw
2. Gasket ring
Put a screwdriver or similar into the spark plug

hole of cylinder no. 3 and feel when the piston
reaches TDC.
SMR2002_073_05_09A.FM 05-09-3
– oil tank plug screws no. 1 with O-ring no. 2 NOTE: Before removing the connecting rod bear-
ing caps, mark them to remember the right posi-
1 tion when reassembling.
R1503motr05A
ENGINE UPSIDE DOWN

1. Oil tank plug screw with O-ring
– engine block screws no. 3 and no. 7

R1503motr07A 1
1. Mark on connecting rod
– thrust washers no. 4
1
R1503motr06A
BOTTOM VIEW OF ENGINE

1. Screws
– bottom engine block half

– connecting rod screws R1503motr09A
1 1. Thrust washer
R1503motr08A
1. Connecting rod screws
05-09-4 SMR2002_073_05_09A.FM
– crankshaft no. 5.
1 2
1
R1503motr12A
R1503motr10A
1. Crankshaft
1. Crankshaft 2. Feeler gauge
Inspection CONNECTING ROD BIG END

Replace crankshaft if the gears are worn or other- mm (in)
wise damaged. NEW MINIMUM 0.150 mm (.06 in)
2 NEW MAXIMUM 0.302 mm (.01 in)
Crankshaft Radial Play

Measure all crankshaft journals. Compare to inside
diameter of crankshaft bushings (elsewhere in this
section).
1
1
R1503motr11A
1. Balancer gear
2. Crankshaft timing gear

Using a feeler gauge, measure distance between 2
butting face of connecting rod and crankshaft
counterweight. If the distance exceeds specified
tolerance, replace the worn part.
R1503motr13A
1. Micrometer
2. Crankshaft area for bushing
SMR2002_073_05_09A.FM 05-09-5
CRANKSHAFT JOURNAL DIAMETER Installation

mm (in) For installation, reverse the removal procedure.
NEW MINIMUM 49.91 mm (1.9650 in) Pay attention to following details.
NOTE: Before installing the crankshaft, make sure
that the timing chain is on the crankshaft and the
SERVICE LIMIT 49.88 mm (1.9637 in) chain tension guide has been installed first. Those
parts cannot be installed as soon as the crankshaft
CRANKSHAFT JOURNAL RADIAL CLEARANCE is in place.
mm (in) CAUTION: Crankshaft has to be aligned with
SERVICE LIMIT 0.07 mm (.0028 in) balance shaft. Grooves on crankshaft and bal-
ance shaft.
Crankshaft Pin
Measure all crankshaft pin diameters. Compare to
inside diameter of connecting rod bushings (else-
where in this section).
1 2
R1503motr17A 1 2
1. Groove on balance shaft
2. Groove on crankshaft
For correct installation of the connecting rods refer

R1503motr14A
to CONNECTING ROD INSTALLATION elsewhere
in this section.
1. Micrometer
2. Crankshaft pin area for bushing CAUTION: It is absolutely necessary to follow
this procedure. Otherwise several engine dam-
CRANKSHAFT PIN DIAMETER age can occur.
mm (in)
CAUTION: Never forget thrust washers no. 4
NEW MINIMUM 45.032 mm (1.7729 in) for axial adjustment on crankshaft center.
CRANKSHAFT PIN RADIAL CLEARANCE

mm (in)
05-09-6 SMR2002_073_05_09A.FM
Insert thrust washers as soon as crankshaft is in Install the crankshaft cover before mounting the
place according to following illustration. engine bracket. Put some oil on O-ring and press
the cover in. The crankshaft cover has to be even
with the engine block surface.
1
R1503motr09A
THRUST WASHER INSERT DIRECTION

1. Thrust washer
CAUTION: Thrust washers has to be even with R1503motr19A 2

the engine block sealing surface.
1. O-ring
1 2. Crankshaft cover
CAUTION: Install crankshaft locking tool (P/N 529

035 821) right away to put crankshaft in TDC
position before installing the camshaft and rock-
2
ers (refer to CYLINDER AND HEAD).
1
R1503motr16A
1. Thrust washer
2. Sealing surface
Install lower engine block half. Refer to ENGINE

BLOCK ASSEMBLY elsewhere in this section for
proper procedure to clean surfaces, apply Loctite
5910 and proper torquing sequence. R1503motr18A
1. Crankshaft locking tool
SMR2002_073_05_09A.FM 05-09-7
TIMING CHAIN CHAIN TENSIONER

Inspection Removal
Check timing chain on camshaft timing gear for ex- NOTE: Removal of the air intake manifold allows
cessive radial play. easier access to the chain tensioner, but is not
Check chain condition for wear and rollers condition. necessary. Refer to AIR INTAKE MANIFOLD RE-
MOVAL in INTAKE section.
Remove:
– chain tensioner plug screw no. 18 with gasket
ring no. 19
– chain tensioner no. 20.
R610motr201A 1 3 2
1. Timing chain
If chain is excessively worn or damaged, replace

it as a set (camshaft timing gear and timing chain).
Removal
Remove:
– engine oil (refer to OIL CHANGE in LUBRICA-
TION section)
– engine from vehicle (refer to REMOVAL AND
INSTALLATION)
MOVAL in CYLINDER HEAD section) R1503motr39A 1
– PTO housing (refer to PTO HOUSING REMOV- 1. Plug screw
AL in PTO HOUSING/MAGNETO section) 2. Gasket ring
3. Chain tensioner
– crankshaft (refer to CRANKSHAFT REMOVAL
elsewhere in this section) Inspection
– timing chain. Check chain tensioner for excessive wear or
cracks. Also check free movement of the chain ten-
Installation sioner piston.
The installation is essentially the reverse of the re-
moval procedure but, pay attention to the follow- Installation
ing details. The installation is essentially the reverse of the re-
Ensure to perform proper valve timing. Lock crank- moval procedure but, pay attention to the follow-
shaft and camshaft at TDC (refer to CYLINDER ing details.
HEAD). Torque chain tensioner plug screw to 18 N•m
Install chain then, install chain tension. (160 lbf•in).
CAUTION: Improper valve timing will damage
engine components.
05-09-8 SMR2002_073_05_09A.FM
BALANCER SHAFT – engine block screws no. 3
Removal
Remove:
– engine oil (refer to OIL CHANGE in LUBRICA-
TION section)
INSTALLATION) 1
R1503motr06A
AL in PTO HOUSING/MAGNETO section) 1. Screws
– starter drive ass’y – bottom engine block half
– oil suction pump with oil separator ass’y (refer – thrust washers no. 6
TION section) 1
– engine mounting brackets
– oil tank plug screws no. 1 with O-ring no. 2
1
R1503motr05A
R1503motr20A
ENGINE UPSIDE DOWN

1. Thrust washer
1. Oil tank plug screw with O-ring
– balance shaft.
SMR2002_073_05_09A.FM 05-09-9
Inspection Installation
Check balancer shaft and replace if damaged. For installation, reverse the removal procedure.
If the gear on the balancer shaft is damaged, re- Pay attention to following detail.
place balancer shaft. CAUTION: Balance shaft has to be aligned with
Check gear(s) on the crankshaft the same time and crankshaft. Grooves on crankshaft and balance
replace crankshaft if necessary (refer to CRANK- shaft.
SHAFT above).
Balance Shaft Bushing Seat Play
Measure all balance shaft bushing seats. Compare
to inside diameter of balance shaft bushings (else-
where in this section).
1
2
R1503motr17A 1 2
1. Groove on balance shaft
2. Groove on crankshaft
CAUTION: Never forget thrust washers no. 6

for axial adjustment on balance shaft PTO side.
R1503motr23A
Insert thrust washers as soon as balance shaft is
1. Micrometer in place according to following illustration.
2. Balance shaft area for bushings
1
BALANCE SHAFT SEAT DIAMETER
mm (in)
BALANCE SHAFT SEAT RADIAL CLEARANCE

mm (in)
R1503motr20B
THRUST WASHER INSERT DIRECTION

1. Thrust washer
05-09-10 SMR2002_073_05_09A.FM
CAUTION: Thrust washers has to be even with CAUTION: Install crankshaft locking tool (P/N
the engine block sealing surface. 529 035 821) right away to put crankshaft in TDC
position before installing the camshaft and rock-
2 ers (refer to CYLINDER AND HEAD).
1
R1503motr22A
1. Thrust washer
2. Sealing surface
R1503motr18A
Install lower engine block half. Refer to ENGINE 1. Crankshaft locking tool
BLOCK ASSEMBLY elsewhere in this section for
proper procedure to clean surfaces, apply Loctite
5910 and proper torquing sequence.
ENGINE BLOCK
Install the crankshaft cover before mounting the Removal
engine bracket. Put some oil on O-ring and press
the cover in. The crankshaft cover has to be even Remove:
with the engine block surface. – engine oil (refer to OIL CHANGE in LUBRICA-
TION section)
1
INSTALLATION)
AL in PTO HOUSING/MAGNETO section)
– starter drive ass’y
– oil suction pump with oil separator ass’y (refer
TION section)
– balance shaft (refer to BALANCE SHAFT RE-
R1503motr19A 2 MOVAL elsewhere in this section)
1. O-ring – crankshaft (refer to CRANKSHAFT REMOVAL
2. Crankshaft cover
elsewhere in this section)
– piston with connecting rod (refer to PISTON RE-
MOVAL elsewhere in this section).
SMR2002_073_05_09A.FM 05-09-11
Bushings – hammer CJ125-6

When bushings need to be removed from the en- – claws CJ93-4.
gine block, mark them to identify the correct posi-
tion at installation. See the following illustration for
an example:
1
F01J0ZA
Close puller claws so that they can be inserted in

against bearing.
Inspection
Cylinder
R1503motr37A 2
Check cylinder for cracks, scoring and wear ridges
1. Mark on balance shaft bushings on the top and bottom of the cylinder. If so, replace
2. Mark on crankshaft bushings
cylinder.
Starter Drive Bearing
Cylinder Taper
Check bearing no. 21 of starter drive assembly
no. 22 in engine block and replace it if damaged. Measure cylinder bore and if it is out of specifica-
tions, rehone cylinder sleeve and replace piston
ass’y with first oversize.
NOTE: It is not necessary to have all cylinders re-
honed if they are not all out of specification. Mixed
standard size and oversize cylinders are allowed.
Measure cylinder bore at 3 recommended posi-
tions. See the following illustration.
1 B
R1503motr40A 1 3
1. Bearing of starter drive assembly
Starter drive bearing can be easily removed from

lower crankcase half using the following suggest-
R1503motr24A
ed tool or equivalent:
1. First measuring diameter
– Snap-on hammer puller including: 2. Second measuring diameter
3. Third measuring diameter
– handle CJ93-1 A. 60 mm (2.362 in)
B. 110 mm (4.331 in)
05-09-12 SMR2002_073_05_09A.FM
CYLINDER TAPER IN DIAMETER

mm (in)

1
Distance between measurements should not ex-
ceed the service limit mentioned above.
Cylinder Out of Round
Measure cylinder diameter in piston axis direction
from top of cylinder. Take an other measurement
90° from first one and compare.
NOTE: Take the same measuring points like de-
R1503motr33A
scribed in CYLINDER TAPER above.
ENGINE UPSIDE DOWN
1. Radial gauge
CRANKSHAFT BUSHING INSIDE DIAMETER

mm (in)
A
B
R1503motr25A
A. Perpendicular to crankshaft axis

B. Parallel to crankshaft axis
CYLINDER OUT OF ROUND

mm (in)

R1503motr34A 1
ENGINE UPSIDE DOWN
Bushings
1. Radial gauge
To measure the wear of the crankshaft bushings
no. 13 and no. 14 and balance shaft bushings BALANCE SHAFT BUSHING INSIDE DIAMETER
no. 15, both engine block halves with OLD bush- mm (in)
ings have to be screwed together according to SERVICE LIMIT 32.11 mm (1.2642 in)
tightening procedure described below.
Measure the inside diameter of the bushings with Replace bushings if they are out of specifications.
a radial gauge.
SMR2002_073_05_09A.FM 05-09-13
Oil Spray Nozzles Put bushings correctly in place. Top crankshaft

Remove oil spray nozzle no. 16 and banjo screw bushing halves have a bore which has to be placed
no. 17 from engine block. in the upper engine block.
1 2
2 3
R1503motr35A
R1503motr38A
1. Upper engine block half
2. Oil bore in engine block
1. Banjo screw 3. Oil bore in bushing
2. Oil spray nozzle
Bushings have to be even with the engine block
Check free movement of ball inside the banjo
split surface and their protrusions have to fit in the
screw. Clean Nozzle and banjo screw from dirt and
notched areas in the engine block seat.
debris.
1
Installation
Torque oil spray nozzle to 18 N•m (160 lbf•in).
To install starter drive bearing no. 21 of starter
drive assembly, use pusher (P/N 290 876 502) and
handle (P/N 420 877 650).
R1503motr36A
1. Bushing protrusion in engine block notch
2 Apply engine oil on all bushings, in the bottom area

F06D32A of the cylinder bore and also on the band of the
piston ring compressor tool.
1. Handle
2. Pusher For proper installation of pistons, refer to PISTON
Use NEW bushings when diameters are out of INSTALLATION elsewhere in this section.
specification. NOTE: Before installing the crankshaft, make sure
If OLD bushings can be used again, make sure that the timing chain is on the crankshaft and the
they are at the same position as they were before. chain tension guide has been installed first. Those
parts cannot be installed after as the crankshaft is
in place.
05-09-14 SMR2002_073_05_09A.FM

clogged.
Engine block mating surfaces are best cleaned us-
ing a combination of the chisel gasket remover
(P/N 413 708 500) and a brass brush. Brush a first
pass in one direction then make the final brushing
perpendicularly (90°) to the first pass (cross hatch).
CAUTION: Do not wipe with rags. Use a new
clean hand towel only.
torquing should be done within 10 minutes. It is sug-
gested to have all you need on hand to save time.
F12R17A
sealant as described here to get an uniform appli- Do not apply in excess as it will spread out inside
cation without lumps. If you do not use the roller crankcase.
tribute the sealant (unlike the Drei Bond sealing NOTE: Do not use Loctite Primer N with this seal-
compound, using a finger will not affect the adhe- ant. The sealant curing time is similar to the Loc-
sion). tite 518 without using the Primer N, which is 4 to
24 hours.
Use the silicone-based Loctite 5910 (P/N 293 800
081) on mating surfaces. Tighten engine block screws according to follow-
ing sequence.
CAUTION: Do not use Loctite 515 or 518 to seal
crankcase. Do not use Loctite Primer N with the 6 16 15 14 4 9 2 10 11 12 13 8
Loctite 5910. Using these products or non sili-
cone-based sealant over a previously sealed
crankcase with Loctite 5910 will lead to poor ad-
hesion and possibly a leaking crankcase. These
products are chemically incompatibles. Even af-
ter cleaning, the Loctite 5910 would leave incom-
patible microscopic particles.
Use a plexiglas plate and apply some sealant on it.
Use a soft rubber roller (50 - 75 mm (2 - 3 in))
(available in arts products suppliers for printmak-
ing) and roll the sealant to get a thin uniform coat
on the plate (spread as necessary). When ready,
apply the sealant on crankcase mating surfaces.
5 23 22 3 21 17 18 1 19 20 7
R1503motr06B
Apply Loctite 243 (blue) on threads. Torque engine

block screws no. 3 at first to 40 N•m (29 lbf•ft)
and in a second sequence to 55 N•m (41 lbf•ft).
Torque engine block screws no. 7 to 22 N•m
(17 lbf•ft).
SMR2002_073_05_09A.FM 05-09-15
Before continuing the installation process, the ax- Install the crankshaft cover before mounting the
ial clearance of balance shaft and crankshaft has engine bracket. Put some oil on O-ring and press
to be checked the cover in. The crankshaft cover has to be even
with the engine block surface.
1
1
R1503motr41A 2
1. Dial gauge
2. Crankshaft R1503motr19A 2
1. O-ring
CRANKSHAFT AXIAL CLEARANCE mm (in) 2. Crankshaft cover
NEW MINIMUM 0.08 mm (.003 in) CAUTION: Install crankshaft locking tool (P/N 529
035 821) right away to put crankshaft in TDC
NEW MAXIMUM 0.22 mm (.009 in) position before installing the camshaft and
SERVICE LIMIT 0.35 mm (.014 in) rockers (refer to CYLINDER AND HEAD).
1
1
R1503motr42A 2 R1503motr18A
1. Crankshaft locking tool

1. Dial gauge
2. Balance shaft
Install cylinder head, PTO housing and the other
BALANCE SHAFT AXIAL CLEARANCE mm (in)
parts in accordance with the proper installation
procedures.
05-09-16 SMR2002_073_05_09A.FM
PISTON/CONNECTING ROD 1 2 3
Removal
Disassemble engine block according to ENGINE
BLOCK REMOVAL above.
Remove connecting rod screws.
R1503motr27A
1. Piston
2. Piston pin
3. Circlip
Detach piston no. 10 from connecting rod.
Inspection
Connecting Rod/Piston Pin Clearance
R1503motr08A
Measure piston pin. Compare to inside diameter
1. Connecting rod screws of connecting rod no. 5.
NOTE: Before removing the connecting rod bear-
ing caps, mark them to remember the right posi-
tion when reassembling.
Pull piston with connecting rod out of the cylin-
ders.
Remove one piston circlip no. 8 and discard it.
2
1
R610motr134A 1 R610motr73A
1. Piston circlip 1. Bore gauge

2. Connecting rod
NOTE: The removal of both piston circlips is not
necessary to remove piston pin.
Push piston pin no. 9 out of piston.
SMR2002_073_05_09A.FM 05-09-17
To measure the connecting rod big end diameter,

use the OLD screws no. 11.
Install the OLD bushings no. 12 as they were
mounted initially.
Do the torque procedure as described below.
R610motr137A A
A. Piston pin diameter in the area of the bushing
CONNECTING ROD SMALL END DIAMETER

mm (in)
A
PISTON PIN DIAMETER
mm (in)
NEW MAXIMUM 23.000 mm (.9055 in) R610motr76A
SERVICE LIMIT 22.990 mm (.904 in) A. Connecting rod big end bushing
CONNECTING ROD BIG END DIAMETER

PISTON PIN BORE CLEARANCE
mm (in) mm (in)
SERVICE LIMIT 0.080 mm (.0035 in) SERVICE LIMIT 45.080 mm (1.774 in)
If the connecting rod small end diameter is out of CONNECTING ROD BIG END CLEARANCE
specification, replace connecting rod. mm (in)
Connecting Rod Big End Radial Play SERVICE LIMIT 0.09 mm (.0035 in)
Measure inside diameter of connecting rod big Use NEW bushings no. 12, when connecting rod
end. Compare to crankpin. big end diameter is out of specification.
05-09-18 SMR2002_073_05_09A.FM
Piston With the micrometer set to the dimension, adjust

Inspect piston for scoring, cracking or other dam- a cylinder bore gauge to the micrometer dimen-
ages. Replace piston and piston rings if necessary. sion and set the indicator to 0 (zero).
Using a micrometer, measure piston at 18 mm
(.709 in) perpendicularly (90°) to piston pin axis.
2 1
F00B09A

2. Dial bore gauge
R610motr136A 1
A. 18 mm (.709 in)
The measured dimension should be as described

in the subsequent table. If not, replace piston.
PISTON MEASUREMENT
mm (in)
99.951 to 99.969 mm
NEW NOMINAL
(3.935 to 3.936 in)
1
F00B0AA
Piston/Cylinder Clearance TYPICAL

1. Indicator set to 0 (zero)
Adjust and lock a micrometer to the piston dimen-
sion. Position the dial bore gauge 62 mm (2.44 in) above
cylinder base, measuring perpendicularly (90°) to
1 piston pin axis.
The result is the exact piston/cylinder wall clear-
ance.
PISTON/CYLINDER CLEARANCE mm (in)
0.0 24 to 0.056 mm
NEW NOMINAL
(.0009 to .0022 in)
F00B08A
NOTE: Make sure used piston is not worn. See PIS-

1. Micrometer set to the piston dimension
TON MEASUREMENT above.
SMR2002_073_05_09A.FM 05-09-19
If clearance exceeds specified tolerance, rehone Replace connecting rod if diameter of connecting
cylinder sleeve and replace piston ass’y by over- rod small end is out of specifications. Refer to
size. CRANKSHAFT AND BALANCER SHAFT for removal
NOTE: It is not necessary to have all pistons re- procedure of connecting rod.
placed with an oversize if they are not all out of
specification. Mixed standard size and oversize Installation
piston are allowed. For installation, reverse the removal procedure.
NOTE: Make sure the cylinder bore gauge indica- Pay attention to the following details.
tor is set exactly at the same position as with the Apply engine oil on the piston pin.
micrometer, otherwise the reading will be false. Insert piston pin into piston and connecting rod.
Piston Pin Use the piston circlip installer (P/N 529 035 765) to
assemble the piston circlip.
Using synthetic abrasive woven, clean piston pin
from deposits. CAUTION: Secure piston pin with new piston cir-
clips.
Inspect piston pin for scoring, cracking or other dam-
ages. NOTE: Take care that the hook of the piston circlip
is positioned properly.
Measure piston pin. See the following illustration
for the proper measurement positions. 1
Piston Pin/Connecting Rod Bushing Clearance
Measure inside diameter of connecting rod.
2
CONNECTING ROD SMALL END DIAMETER
mm (in)

R1503motr28A
1. Sleeve with piston circlip inside

2. Assembly jig from piston clip installer
2
1
R610motr134B
CORRECT POSITION OF THE PISTON CIRCLIP
R610motr73A
1. Bore gauge
2. Connecting rod
05-09-20 SMR2002_073_05_09A.FM
Using a piston ring compressor plier, such Snap-

3 1 2
ON RC-980, slide piston into cylinder.
R1503motr29A
R610motr79A
1. Half bushing of connecting rod big end

CAUTION: Take care that piston will be in- 2. Split surface of the connecting rod
stalled with the punched arrow on piston top to 3. Protrusion of bushing in line with connecting rod groove
the exhaust side.
Torque NEW connecting rod screws no. 11 as per
1 following procedure:
– Install screws and torque to 45 N•m (33 lbf•ft).
Do not apply any thread locker product.
– Finish tightening the screws with an additional
90° turn using an angle torque wrench.
dure may cause screw to loosen and lead to en-
gine damage. Besides, as the screws have been
stretched from the previous installation, it is
very important to use new screws at assembly.
R1503motr30A
1. Arrow should indicate to the exhaust side 1

Put bushings correctly in place and clean the split
surface on both sides (cracked area) carefully.
R1503motr31A
1. Angle torque wrench
SMR2002_073_05_09A.FM 05-09-21
PISTON RINGS Ring End Gap
RING END GAP

Removal mm (in)
Remove piston ass’y as described above.
NEW MINIMUM
Remove rings.
RECTANGULAR 0.15 mm (.006 in)
Inspection
TAPER-FACE 0.15 mm (.006 in)
Ring/Piston Groove Clearance
Using a feeler gauge measure each ring/piston OIL SCRAPER RING 0.15 mm (.006 in)
groove clearance. If the clearance is too large, the NEW MAXIMUM
piston and the piston rings should be replaced.
RECTANGULAR 0.35 mm (.014 in)
RING/PISTON GROOVE CLEARANCE
mm (in) TAPER-FACE 0.35 mm (.014 in)
NEW MINIMUM OIL SCRAPER RING 0.30 mm (.012 in)
RECTANGULAR 0.025 mm (.001 in) SERVICE LIMIT
TAPER-FACE 0.015 mm (.0006 in) ALL 1 mm (.04 in)
OIL SCRAPER RING 0.020 mm (.0008 in) Measure position for ring end gap in the area of 8
NEW MAXIMUM
to 16 mm (.315 to .630 in) from top of cylinder.
NOTE: In order to correctly position the ring in the
RECTANGULAR 0.070 mm (.0028 in) cylinder, use piston as a pusher.
TAPER-FACE 0.060 mm (.0024 in) Using a feeler gauge, check ring end gap. Replace
ring if gap exceeds above described specified tol-
OIL SCRAPER RING 0.055 mm (.0021 in) erance.
SERVICE LIMIT
Installation
ALL 0.15 mm (.006 in) For installation, reverse the removal procedure.
Install the oil scraper ring first, then the taper-face
ring with the word “TO” facing up, then the rectan-
gular ring with the word “T” facing up.
2
1
3
R1503motr32A 1 A31C2NA
1. Rectangular ring
1. Piston
2. Taper-face ring
2. Filler gauge 3. Oil scraper ring
05-09-22 SMR2002_073_05_09A.FM
CAUTION: Ensure that top and second rings are

not interchanged.
NOTE: Use a ring expander to prevent breakage
during installation. The oil ring must be installed by
hand.
Check that rings rotate smoothly after installation.
Space the piston ring end gaps 120° apart and do
not align the gaps with the piston pin bore or the
thrust side axis.
A
A A
A31C2OA
1. DO NOT align ring gap with piston trust side axis

2. DO NOT align ring gap with piston pin bore axis
A. 120°
SMR2002_073_05_09A.FM 05-09-23
TABLE OF CONTENTS 0
OVERVIEW............................................................................................................................. 06-02-1
OPERATING PRINCIPLE .................................................................................................... 06-02-2
AIR INDUCTION................................................................................................................. 06-02-2
AIR COMPRESSOR SYSTEM............................................................................................ 06-02-2
BASIC OPERATION ........................................................................................................... 06-02-2
AIR/FUEL RAIL ASSEMBLY .............................................................................................. 06-02-2
FUEL PUMP MODULE....................................................................................................... 06-02-3
MPEM (multi-purpose electronic module) ...................................................................... 06-02-4
IGNITION SYSTEM............................................................................................................ 06-02-8

GENERAL ........................................................................................................................... 06-03-1
FUEL SYSTEM ................................................................................................................... 06-03-1
AMP CONNECTOR PIN-OUT ............................................................................................ 06-03-3
QUICK FUEL PRESSURE TEST ........................................................................................ 06-03-4
THROTTLE BODY .............................................................................................................. 06-03-5
AIR COMPRESSOR............................................................................................................ 06-03-8
PRESSURE TEST ............................................................................................................... 06-03-8
REPAIR ............................................................................................................................... 06-03-9
FUEL DELIVERY................................................................................................................. 06-03-12
FUEL INJECTOR ................................................................................................................ 06-03-14
AIR/FUEL RAIL ................................................................................................................... 06-03-15
DIRECT INJECTOR ............................................................................................................ 06-03-16
FUEL PUMP ....................................................................................................................... 06-03-17
MPEM REPLACEMENT ..................................................................................................... 06-03-21
KNOCK SENSOR (KS) ....................................................................................................... 06-03-28
RAVE SOLENOID ............................................................................................................... 06-03-29
IGNITION COIL .................................................................................................................. 06-03-30
TDC SETTING .................................................................................................................... 06-03-32
SPARK PLUGS ................................................................................................................... 06-03-35
CRANKING SYSTEM ......................................................................................................... 06-03-36
DI SYSTEM TEST SUMMARY .......................................................................................... 06-03-36
SMR2002-095_06-01ATOC.FM 06-01-1

GENERAL............................................................................................................................ 06-04-1
DESS SYSTEM ................................................................................................................... 06-04-1
FAULT DETECTION AND COMPENSATORY ACTIONS .................................................. 06-04-3
COMPONENT FAILURE WARNING SYSTEM .................................................................. 06-04-3
VCK (VEHICLE COMMUNICATION KIT) ........................................................................... 06-04-5
DI SYSTEM FAULT CODES ............................................................................................... 06-04-6
06-01-2 SMR2002-095_06-01ATOC.FM
OVERVIEW 0
F12F03T
SMR2002-074_06-02A.FM 06-02-1
OPERATING PRINCIPLE
The Orbital Combustion Process (OCP) provides a
stratified combustion process resulting from the
direct injection of a finely atomized fuel spray (less
than 10 microns). This is achieved by using a pneu-
matically assisted direct injection system, a
unique combustion chamber geometry and a pre-
cise control of the combustion process by the
MPEM (Multi-Purpose Electronic Module).
AIR INDUCTION
Air for combustion is drawn directly at the base of
F12D01A
the engine through two 46 mm throttle bodies.
The air flow is controlled by two throttle plates.
The air continues through the reed valves into the FUEL DELIVERY SYSTEM
crankcase.
BASIC OPERATION
When the piston reaches the correct position, the
MPEM opens the fuel injector and fuel is dis-
charged into a cavity inside the direct injector.
Next, the direct injector opens and the fuel is dis-
charged into the combustion chamber by the com-
pressed air which breaks the fuel up into a very
fine mist in the process. This air/fuel mixture is
then ignited by the spark plug.
AIR/FUEL RAIL ASSEMBLY

F12F05A 1 1 2 4 3 2 6
TWIN 46 mm THROTTLE BODIES
AIR COMPRESSOR SYSTEM

The air compressor supplies the compressed air
required for fuel atomization in the air injector. It is
integrated with the engine and mechanically driv-
en by the counterbalance shaft. It also supplies the
air pressure required to operate the RAVE valves.
F12F06A 5 7 1 8
TYPICAL
1. Air/fuel rail
2. Fuel injector
3. Fuel pressure regulator
5. Air inlet hose
6. Fuel inlet
7. Air return
8. Fuel return
06-02-2 SMR2002-074_06-02A.FM
The air/fuel rail assembly is mounted on top of the FUEL PUMP MODULE
cylinder head. It provides support for the air/fuel
injectors and both air and fuel regulators. It also
contains passages for the air and the fuel. The rail
is a small reservoir for the injectors that keeps
enough fluid at the proper pressure to supply the
injectors demand.
Fuel Injector
Fuel injectors are used to provide fuel from the
fuel rail to the to the direct injector.

A fuel pressure regulator controls the pressure in-
side the fuel rail, and allows the excess of fuel to
return to the fuel tank. The fuel pressure regulator
regulates the fuel pressure at approximately
185 kPa (27 PSI) higher than the air pressure in the
fuel rail. The back side of the diaphragm is ex- F12D0AA
posed to the air rail pressure. As the air pressure

increases in the fuel rail, the fuel pressure needed The fuel pump module is located inside the fuel
to open the regulator will increase equally. tank. The module includes the fuel pump and the
fuel level sensor.
The differential pressure regulation utilizes the air
pressure reference signal to maintain constant Fuel Pump
pressure drop across fuel injector orifice.
It operates at a nominal pressure of approximately
The initial operating pressure of the regulator is 735 kPa (107 PSI).
Fuel Filter
Direct Injector
Also called air injector, two direct injectors (one pump module inside the fuel tank. An inline fuel
per cylinder) are used to inject air/fuel mixture into filter is also installed on the fuel line going to the
the combustion chamber. fuel rail.
Air Pressure Regulator
An air pressure regulator regulates the pressure of
air delivered by the air compressor.
It regulates the pressure developed inside the air
passage to approximately 550 kPa (80 PSI).
The initial operating pressure of the regulator is
SMR2002-074_06-02A.FM 06-02-3
ELECTRONIC MANAGEMENT The MPEM is directly powered by the battery. It is

responsible for the following engine management/
MPEM electrical functions:
(multi-purpose electronic module) – interpreting information
The electronic fuel injection is equipped with a – distributing information
MPEM. It is also called ECU (Electronic Control – start/stop function
Unit). It is the brain of the electrical system/fuel – timer
injection system.
1 – ignition timing maps
– injection maps (fuel injector and direct injector)
– MPEM contains a total of 34 maps (injection
and ignition) for optimum engine operation in all
conditions
– etc.
will keep the programmed safety lanyard(s) active,
fault codes and other vehicle information, even
when the battery is removed from the watercraft.
MPEM — General Functions

F12D0EA Automatic Power Shut-Down
TYPICAL The MPEM is equipped with an automatic power
1. Multi-purpose electronic module (MPEM) shut-down. This feature prevents the battery from
The MPEM is mounted in the front of the water- losing its charge if the safety lanyard cap is left on
craft. the post when the engine is not running.
After connecting the safety lanyard cap, the
MPEM will remain in standby mode during the
next 10 minutes, waiting for a starting. If the start/
stop button is not depressed, then the MPEM will
be automatically powered down.
Antistart Feature
safety lanyard(s) that has been programmed to op-
DESS system. See below for details.
Digitally Encoded Security System (DESS)
post.
06-02-4 SMR2002-074_06-02A.FM
The safety lanyard cap contains a magnet and a Gauges Current Supply
ROM chip. The magnet actually closes the reed The purpose of this function is to allow reading of
switch inside the post which is the equivalent of a gauges without the engine running. It will give ac-
mechanical ON/OFF switch. The chip has a unique cess to most functions of the information center
digital code. gauge without starting the engine.
The DESS circuitry in the watercraft MPEM is ac- Gauges are supplied with current for 33 seconds
tivated at the factory. Therefore, a safety lanyard when connecting the safety lanyard cap on its post
must be programmed to start the engine. or when pressing the start/stop switch without
NOTE: Actually, it is the memory of the MPEM the safety lanyard on the DESS post.
which is programmed to recognize the digital code NOTE: The fuel pump will be activated for 2 sec-
of the safety lanyard cap. This is achieved with the onds to build up pressure in the fuel injection sys-
MPEM programmer (P/N 529 035 878) or the VCK tem, only when connecting the safety lanyard cap
(Vehicle Communication Kit) (P/N 529 035 844). to the post.
Refer to their operation manual or help system to
program a safety lanyard. Engine Starting
The system is quite flexible. Up to 8 safety lan- If the MPEM recognizes a valid safety lanyard, it
yards may be programmed in the memory of the allows engine to start when the start/stop switch
watercraft MPEM. They can also be erased indi- is pressed.
vidually. If the safety lanyard is left on the DESS post for
The MPEM also offers a special safety lanyard — the more than 10 minutes after stopping the engine,
Sea-Doo LK™ (learning key) — which can be pro- the MPEM may send out 1 long beep when press-
grammed so that the vehicle can be run only at a ing the start/stop switch. The current supply to
limited speed — approximately 48 km/h (30 MPH). gauges will be stopped as explained in the ANTI-
Such feature is ideal for first time riders or renters. START FEATURE section. A light pressure on the
safety lanyard or removing and reinstalling the
 WARNING safety lanyard is required to allow the MPEM to
read and validate the safety lanyard, the engine
When programming a Sea-Doo LK™ (learning
can then be started.
key), use only a lanyard that is identified for
that purpose. Otherwise, a customer could use If start/stop button is held after engine has started,
a vehicle with a greater speed than he was ex- the MPEM automatically stops the starter when
pecting. the engine speed reaches 1000 RPM.
NOTE: If desired, a safety lanyard can be used on is depressed more than 70%, the engine will not
other watercraft equipped with the DESS. It only be allowed to start.
needs to be programmed for that watercraft.
Engine RPM Limiter
When connecting a safety lanyard cap on the post,
the DESS is activated and will emit audible signals: The MPEM will limit the maximum engine speed.
– 2 short beeps indicate a working safety lanyard. Engine Stopping
Engine starting can take place. There are 2 ways to stop the engine.
– 1 long beep indicates a wrong safety lanyard is Press and hold start/stop switch or remove the
being used or that something is defective. En- safety lanyard cap from its post.
gine starting is not allowed.
If the engine is stopped by removing the safety lan-
The memory of the MPEM features two self- yard, it is possible to restart the engine as explained
diagnostic modes for the DESS operation. Refer in the ENGINE STARTING section.
to DIAGNOSTIC PROCEDURES subsection for
more information. If safety lanyard cap is reconnected within 6 sec-
onds, the current supply to gauges is cut for a brief
The memory of the MPEM is permanent. If the moment and comes back on with the audible sig-
battery is disconnected, no information is lost. nal of safety lanyard validation.
SMR2002-074_06-02A.FM 06-02-5
Low-Fuel and Low-Oil Level Warning Device Power Distribution

When the fuel level in the reservoir is low, the fuel The MPEM distributes power from battery to all
level sensor transmits a signal to the MPEM. The accessories. Accessories are protected by fuses
MPEM sends out signals for the beeper and to the integrated in the MPEM. Fuses are identified be-
information center gauge. sides their holder.
When the oil level is low in the reservoir, the IMPORTANT: The sensors and injectors are con-
MPEM sends out a signal to the information center tinuously powered with the supply from the bat-
gauge and the pilot lamp on the gauge will turn on. tery. The MPEM switches the ground to com-
plete the electrical circuits it controls. Take this
into account when troubleshooting the electrical
system.
MPEM — Engine Management Functions
F12D0CS
06-02-6 SMR2002-074_06-02A.FM
This engine management system controls both Flooded Engine (drowned mode)
the fuel injection and the ignition timing. If the engine does not start and it is flooded, pro-
As shown in the DI CONTROL SYSTEM illustra- ceed as follows:
tion, the MPEM is the central point of the fuel in- Remove spark plug cables and connect them on
jection system. It reads the inputs, makes compu- the grounding device.
tations, uses pre-determined parameters and
sends the proper signals to the outputs for proper Remove spark plugs and dry them using a rag.
engine management. Cover spark plug holes with a rag.
The MPEM also stores the fault codes and general While engine is stopped, depress and HOLD the
information such as: operating conditions, vehicle throttle lever at full throttle position for cranking.
hours, serial numbers, customer and maintenance Crank the engine several times.
information.
A 1 second beep every second indicates the drowned
Electronic Fuel Injection mode is active.
The MPEM receives the signals from different sen- NOTE: Proceeding in this order, no fuel is injected,
sors which indicate engine operating conditions at no ignition occurs and the accumulated fuel in the
milli-second intervals. engine will be expelled.
Signals from sensors are used by the MPEM to In case of water-flooded engine, if water does not
determine the injection parameters (fuel maps) re- completely go out, it may be necessary to remove
quired for optimum air-fuel ratio. the air intake silencer then to lean the vehicle so
The CPS and both TPS are the primary sensors that water can flow out from throttle bodies.
used to control the injection and ignition timing. Reinstall spark plugs and connect cables.
Other sensors are used for secondary input.
Start engine normally without applying the throttle.
NOTE: The EGT sensor does not provide control
inputs to the MPEM. Its sole purpose is to protect Monitoring System
the exhaust system components by emitting a The MPEM monitors the electronic components
warning signal in the event of overheating. of the fuel injection system and some compo-
nents of the electrical system. When a fault oc-
Ignition Timing
curs, it sends visual messages through the infor-
The MPEM is programmed with data (it contains mation center and/or audible signals through a
ignition mappings) for optimum ignition timing un- beeper to inform you of a particular condition. Re-
der all operating conditions. Using engine operat- fer to the DIAGNOSTIC PROCEDURES subsec-
ing conditions provided by the sensors, the MPEM tion for the displayed messages and the beeper
controls the ignition timing for optimum engine coded signals chart.
operation.
Limp Home Modes
Knock Sensor
Besides the signals as seen above, the MPEM
A knock sensor is mounted on top of the cylinder may automatically set default parameters to the
head. It detects specific vibration that would be engine management to ensure the adequate op-
typically generated by engine detonation. If deto- eration of the watercraft if a component of the fuel
nation occurs, the knock sensor detects it and the injection system is not operating properly.
MPEM retards the ignition advance temporarily (it
Depending on the severity of the malfunction, the
goes in a specific mode) until detonation stops.
watercraft speed may be reduced and not allowed
Engine Modes of Operation to reach its usual top speed as usual.
The MPEM controls different operation modes of The engine RPM may be limited to idle if some
the engine to allow proper operation for all possi- critical components fail. In this case, removing and
ble conditions: Cranking, flare, idle, warm up, nor- reinstalling the safety lanyard on its post may al-
mal operation, Sea-Doo LK™ (learning key) (limit- low retrieving normal operation.
ed vehicle speed), engine speed limiter, drowned
engine and limp home (see below).
SMR2002-074_06-02A.FM 06-02-7
These performance-reduced modes allow the rid- Ignition Coil

er to go back home which would not be possible
Ignition coil induces voltage to a high level in the
secondary windings to produce a spark at the
NOSTIC PROCEDURES for a complete chart.
spark plug.
operation, the DI system will reduce engine RPM
MPEM. Each coil provides high voltage to its cor-
gradually to the proper level.
responding spark plug.
Diagnostic Mode This ignition system allows spark plugs to spark
The malfunctions are recorded in the memory of independently.
the MPEM. The memory of the MPEM can be CAUTION: Do not interchange spark plug ca-
checked using the VCK (Vehicle Communication bles. The white tape on the ignition coil should
Kit) (P/N 529 035 844) to see the fault codes. Refer match the white tape on the high tension cable.
to the DIAGNOSTIC PROCEDURES subsection.
Both coils are located inside the electrical box.
IGNITION SYSTEM 2 1
The ignition system consist of different sub-systems
neto. Part of the AC current is rectified and regu-
lated for the charging system.
The following type of ignition system is used:
Magneto System F12R0UC
The magneto is the primary source of electrical TYPICAL

energy. It transforms magnetic field into electric 1. PTO side ignition coil
2. MAG side ignition coil
current (AC).
The magneto has a 3 phases, delta wound stator
06-02-8 SMR2002-074_06-02A.FM

ADJUSTMENT 0
GENERAL  WARNING
Engine problems are not necessarily related to the Fuel lines remain under pressure at all times. Al-
electronic fuel injection system. ways proceed with care and use appropriate
It is important to ensure that the mechanical integrity safety equipment when working on pressurized
of the engine/propulsion system is present: fuel system. Wear safety glasses and work in a
– fuel pump connection and fuel lines without leaks. fuel line connections. Use the VCK (Vehicle Com-
munication Kit) to release fuel pressure prior to
Check the chart in TROUBLESHOOTING section removing a hose. Cover the fuel line connection
to have an overview of problems and suggested with an absorbent shop rag. Slowly disconnect
solutions. the fuel hose to minimize spilling. Wipe off any
When replacing a component, always check its fuel spillage in the bilge. Fuel is flammable and
operation after installation. explosive under certain conditions. Always work
in a well ventilated area. Always disconnect bat-
 WARNING tery prior to working on the fuel system. After
Air compressor hose may be hot. Use a rag performing a pressure test, use the valve on the
or gloves or let hose cool down. fuel pressure gauge to release the pressure (if so
equipped).
FUEL SYSTEM – Always disconnect battery properly prior to

 WARNING When the job is done, ensure that hoses from fuel
The fuel system of a fuel injection system holds rail going to fuel pump are properly secured in their
much more pressure than on a carbureted wa- support. Then, pressurize the fuel system. Perform
tercraft. Prior to disconnecting a hose or to re- the high pressure test as explained in this section
moving a component from the fuel system, fol- and pressurize the fuel tank and fuel lines as ex-
low the recommendation described here. Pay plained in FUEL SYSTEM section.
attention that some hoses may have more than Properly reconnect the battery.
same quantity of clamps at assembly.  WARNING
– Use the VCK (Vehicle Communication Kit) (P/N 529
age and that NO fuel line is disconnected prior to
035 844) to release the fuel pressure in the sys-
installing the safety lanyard on the DESS post.
tem. Look in the ACTIVATION section of the soft-
Always perform the high pressure test if any
ware B.U.D.S.
component has been removed. A pressure test
must be done before connecting the safety lan-
yard. The fuel pump is started each time the safe-
ty lanyard is installed and it builds pressure very
quickly.
SMR2002-075 _06-03A.FM 06-03-1

CAUTION: Never use injector cleaning products. Pay particular attention to ensure that pins are not
They may contain additive that could damage in- out of their connectors or out of shape. The trou-
jector components. A copper wire brush may be bleshooting procedures cover problems not re-
used to clean the tip of the direct injectors if nec- sulting from one of these causes.
essary.
To check air/fuel rail for leaks, first pressurize the  WARNING
system then spray soapy water on all hose con- Ensure all terminals are properly crimped on
nections, regulators and injectors. Air bubbles will wires and connector housings are properly
show the leaking area. Check also for leaking fuel fastened.
or fuel odor.
Before replacing a MPEM, always check electrical
 WARNING connections. Make sure that they are very tight and
Never use a hose pincher on high pressure they make good contact and that they are corrosion-
hoses. free. A “defective module” could possibly be re-
MPEM. The voltage and current might be too
ELECTRICAL SYSTEM weak to go through dirty wire pins. Check carefully
It is important to check that the electrical system they look dull. Clean pins properly and then coat
is functioning properly: them with silicon-based dielectric grease or other
– battery appropriate lubricant (except if otherwise speci-
– fuses fied) when reassembling them. If the newly re-
placed MPEM is working, try the old one and re-
– DESS check if it works.
– ignition (spark) Ensure that all electronic components are genu-
– ground connections ine — particularly in the ignition system. Installing
– wiring connectors. resistive caps, non-resistive spark plug cables (or
modified length) or non-resistive spark plugs may
It is possible that a component seems to operate lead to generate fault codes or bad operation.
in static condition but in fact, it is defective. In this
case, the best way to solve this problem is to re- NOTE: Diagnostics Communication Kit. See DIAG-
move the original part and replace it with one NOSTIC PROCEDURES section.
which is in good condition. After a problem has been solved, ensure to clear
Never use a battery charger to replace temporarily the fault(s) in the MPEM using the VCK. Refer to
the battery, as it may cause the MPEM to work DIAGNOSTIC PROCEDURES section.
fuse solidity and condition with an ohmmeter. Vi- Communication Errors Between
sual inspection could lead to false results. B.U.D.S. and the MPEM
Remember that if there has not been active com-
 WARNING munication between B.U.D.S. and the MPEM for
All electrical actuators (injectors, fuel pump, more than 10 minutes, the MPEM automatically
RAVE solenoid, ignition coil and starter sole- shuts down. This causes false “communication
noid) are permanently connected to the bat- errors”. This occurs quite frequently and confuses
tery positive terminal, even when the safety many technicians. Whenever this occurs, simply
lanyard is removed. Always disconnect the remove and replace the lanyard to restart the
battery prior to disconnecting any electric or MPEM. In fact, one should get into the habit of
electronic parts. resetting the MPEM with the lanyard whenever
the MPEM does not seem to respond. It must be
To perform verifications, a good quality multimeter kept “awake”.
such as Fluke 111 (P/N 529 035 868) should be
used.
06-03-2 SMR2002-075 _06-03A.FM

Resistance Measurement Also remember this validates the operation of the

date the over temperature functionality. To test it,
the sensor could be removed from the engine/
connected to the harness to see if the MPEM will
ate a fault code.
our temperature sensors are NTC types (Negative
Temperature Coefficient) and work the opposite When working with injectors, the resistance value
which means that the resistance value decreases might test good while the complete current would
as the temperature increases. Take it into account not flow through the wire when pulsating current
when measuring at temperatures different from is supplied to the injector in its normal operation.
20°C (69°F). Use this table for resistance variation A solution would be to use a jumper wire to direct-
relative to temperature for temperature sensors. ly supply the injector from the MPEM. If it now
works, replace the defective wire. A Noid light
TEMPERATURE RESISTANCE (ohms) (available from after-market tool/equipment sup-
°C °F NOMINAL LOW HIGH pliers) may also be used to validate the injector
operation.
- 30 - 22 12600 11800 13400
- 20 -4 11400 11000 11800 AMP CONNECTOR PIN-OUT
- 10 14 9500 8000 11,000
0 32 5900 4900 6900 AMP connector no. 3 and no. 4 of the wiring har-
10 50 3800 3100 4500 ness when performing tests.
20 68 2500 2200 2800
18 19 20 21
30 86 1700 1500 1900
40 104 1200 1080 1320
50 122 840 750 930
60 140 630 510 750
70 158 440 370 510
80 176 325 280 370
90 194 245 210 280
100 212 195 160 210
110 230 145 125 160
120 248 115 100 125
F07F15A
AMP CONNECTOR PIN-OUT (WIRING HARNESS SIDE)
new sensor.
SMR2002-075 _06-03A.FM 06-03-3

QUICK FUEL PRESSURE TEST

 WARNING
Read PRESSURE TEST under AIR/FUEL RAIL
farther in this section for precautions and
setup to take care of, before performing this
test. The procedure here is a quick summary.
Disconnect outlet hose (the one with the fuel fil-

Connect adapter to pressure gauge as shown.
3
1
1 F12R09A
1. Fuel filter
2. Fuel line going to air/fuel rail

Do not crank engine.
2
185 ± 14 kPa (27 ± 2 PSI)
If pressure is within limits, air/fuel rail is working

F12R08A
adequately. Proceed with the fuel pressure test
1. Pressure gauge (P/N 529 035 709) below.
2. T-adapter (P/N 529 035 710)
If pressure is out of limits, go to FUEL DELIVERY
Install pressure gauge between disconnected hose part and proceed with the tests described there.
(inline installation).
FUEL PRESSURE
(when cranking engine
or when engine is running)
738 ± 14 kPa (107 ± 2 PSI)

If pressure is out of limits, proceed with all the tests.
06-03-4 SMR2002-075 _06-03A.FM

AIR INDUCTION SYSTEM Remove TPS, throttle lever, spring and guide from
the old throttle body.
THROTTLE BODY Installation
Mechanical Inspection Reinstall removed parts on the new throttle body.
Check that the throttle plates moves freely and For TPS replacement procedures, refer to THROT-
smoothly when depressing throttle lever. Take this TLE POSITION SENSOR (TPS) in ELECTRONIC
opportunity to lubricate the throttle cable. MANAGEMENT below.
IMPORTANT: The throttle bodies are designed to Properly attach throttle bodies together if previ-
be tamper proof. Changing the idle stop or modi- ously detached.
fying them in any way will not increase perfor-
mance or change the idle speed. Adjustment
Before replacing any parts, check the following as Throttle Body Synchronization
these could be causing the fault. Perform the test NOTE: If both throttle bodies are replaced togeth-
while the engine is not running. er with new ones, no synchronization is required
– Throttle cable adjustment too tight. Not return- as it has already been set at the factory. However,
ing fully to idle stop. proceed with throttle cable and closed TPS adjust-
ments as described below. If only one throttle body
is replaced, proceed with the complete following
– Throttle linkage between the two throttles has adjustments. Ensure to perform all the adjust-
moved. ments prior to starting the engine. Otherwise, en-
– TPS is loose. gine may run at a limited RPM in limp home mode.
– Corroded or damaged wiring or connectors. IMPORTANT: The throttle body synchronization
is required only when replacing one throttle body.
– Throttle body has been replaced and the closed
Otherwise, do not tamper with it as this is NOT a
TPS reset has not been performed.
regular maintenance procedure.
– MPEM has been replaced and the closed TPS
The master throttle body is the one driven by the
reset has not been performed.
throttle cable. The slave throttle body follows the
master and must me synchronized with the master.
Electrical Inspection
Refer to THROTTLE POSITION SENSOR (TPS) in 1 7
ELECTRONIC MANAGEMENT below.
Replacement
Removal
To remove throttle bodies from engine, proceed
as follows:
– Remove air intake silencer. Refer to AIR INTAKE
section.
– Disconnect TPS connectors.
– Disconnect throttle cable and oil injection pump
cable.
– Detach hoses and remove fasteners retaining 4 5 8 6 2 3
F12R0XA
throttle bodies and pull out together.
If only one throttle body replacement is required, 2. Master throttle body
detach them and remove the sealant on idle set 3. Master throttle plate
4. Slave throttle body
screw head. Gently remove the plastic cap from 5. Slave throttle plate
the synchronization screw. 6. Idle set screw
7. Lock nut
8. Synchronizing screw with its tamper proof cap
SMR2002-075 _06-03A.FM 06-03-5

NOTE: In the following illustrations, the lower link

plate has been removed for clarity purposes only.
It does not have to be removed to perform the
adjustment.
Loosen lock nut of idle set screw.
Unscrew idle set screw so that master throttle
plate completely closes in the throttle body. En-
sure screw end clears the lever stopper.
F12R1BA 2 1
2. Turn screw clockwise to increase resistance
Tighten lock nut.
 WARNING
Do not apply any threadlocker to the screw
F12R0YA 2 1 threads. The threadlocker may leak off the
1. Unscrew until master throttle plate is fully closed in throttle body screw and onto the throttle mechanism and
2. Unscrew here cause the throttle to stick.
3. Gap here
Remove synchronizing screw and spring between Recheck reading and readjust as necessary.
levers. Slave TPS
NOTE: The 175 Ω below is used to open the throt- Install a new synchronizing screw. Screw in and
tle plates the same amount on each throttle body ensure screw end clears the lever stopper. Ensure
to obtain the proper synchronization. It is the also to keep slave throttle plate completely closed
equivalent of using a drill bit in the throttle bore to in the throttle body.
open throttle plate on carburetors.
Master TPS  WARNING
Snap throttle plate a few times to ensure it is com- Ensure to use a new screw which is coated
pletely closed. with the proper threadlocker to avoid further
loosening. Do not use the removed screw
Using an ohmmeter, measure resistance between
even if you were applying any threadlocker.
pins 2 and 3. Note the resistance value. Add
The threadlocker may leak off the screw and
175 Ω to that value.
flow onto the throttle mechanism and cause
Turn idle set screw clockwise until ohmmeter the throttle to stick.
reading reaches the computed value above ± 20 Ω.
06-03-6 SMR2002-075 _06-03A.FM

Ensure spring is still well positioned on stoppers.

2
Properly reinstall the plastic cap to the synchroni-
zation screw.
Apply Loctite 5900 (P/N 293 800 066) flange sealant
on idle set screw head.
1
F12R1DA
1. Gap here
2. Spring removed
Snap throttle plate a few times to ensure it is com-

pletely closed.
Measure resistance between pins 2 and 3. Note
the resistance value. Substract 175 Ω from that
value.
Properly reinstall the spring. Ensure that master
throttle plate is still closed.
Turn synchronizing screw clockwise until read- F12R10A 2
ing reaches the computed value above ± 20 Ω. 1. Plastic cap
2. Wider spaced tabs here
1 3. Loctite 5910 flange sealant
 WARNING
Ensure no Loctite product protrudes screw head.
F12R1CA 2
2. Turn screw clockwise to decrease resistance
SMR2002-075 _06-03A.FM 06-03-7

Throttle Cable Adjustment Closed TPS Adjustment

Mechanically adjust the throttle cable using the ad- Perform the CLOSED TPS ADJUSTMENT as de-
justing device underneath body, below steering. scribed in THROTTLE POSITION SENSOR (TPS)
Slacken lock nut to allow adjuster rotation. Free- in ELECTRONIC MANAGEMENT below.
play on lever should be between 2 and 3.5 mm
Injection Oil Pump Cable Adjustment
(1/16 and 1/8 in). When done, tighten lock nut.
As oil injection cable is throttle dependent, always
proceed with the oil injection pump cable adjust-
1 ment after throttle cable adjustment. Refer to OIL
2 INJECTION PUMP subsection.
CAUTION: Improper oil injection pump synchro-
nization with throttle bodies can cause serious
engine damage.
AIR COMPRESSOR
PRESSURE TEST
from the air compressor.
First ensure there is no leak from compressor gas-
kets, hoses and fittings. Soapy water can be sprayed
on components. Repair any leak.
Disconnect hose outlet from air compressor.
F12R1GB
1. Slacken nut
2. Turn adjuster
NOTE: On GTX DI models, vent tube removal in

front storage compartment may be necessary to
reach the adjusting device.
strain on cable and/or damage cable bracket or
throttle lever at handlebar.
Use the vehicle communication kit (VCK) with the F12R02A
B.U.D.S. software to perform this adjustment.
Choose the Monitoring tab. Connect adapters and pressure relief valve to pres-
Press throttle lever to reach full throttle. sure gauge as shown.
Turn cable adjustment until throttle opening meter
indicates between 95% and 99%.
06-03-8 SMR2002-075 _06-03A.FM

If pressure is within limits, air compressor is work-

1
ing adequately.
If pressure is below limits, ensure inlet hose is not
obstructed, bent or kinked. Otherwise, repair the
air compressor.
Remove pressure gauge and reinstall air compres-
sor hose.
REPAIR
Top End
Lift cover then remove compressor head.
corrosion damage.
Check reed valve plates for cracks, deformation,
F12R03A 4 3 2 dirt or other defects. The reed plates must lie com-
pletely flat against the reed valve body.
2. Adapter for air compressor (P/N 529 035 712) Inspect plane surfaces for warpage.
3. T-adapter (P/N 529 035 710)
4. Pressure relief valve (P/N 529 035 711) If reed valve is found defective, it is suggested to
replace it then to temporarily reassemble the com-
CAUTION: Ensure to install the pressure relief pressor to then make a pressure test. If it fails,
valve to allow excess pressure to go out. Note check bottom end.
the arrow on the valve. Otherwise, air compres-
sor components might be damaged. When changing reed valve, ensure to position ring
plate opening so that 2 holes align inside the open-
Install pressure gauge to air compressor. ing. Holes must not be obstructed by the opening
NOTE: To prevent fuel to be injected and thus go- edges.
ing out the disconnected hose, use the drowned
engine mode to crank engine. While engine is
stopped, depress and HOLD the throttle lever at
full throttle position for cranking.
Ensure the battery is in good condition to get the
normal cranking speed.
Crank engine and observe air pressure.
 WARNING
Be careful of pressure relief valve outlet. Com-
pressed air may flow out there.
F12R04A 1 2
MINIMUM AIR PRESSURE (at cranking) 1. Reed valve opening
2. Rotate opening to align 2 holes inside without obstructing the
holes
621 ± 14 kPa (90 ± 2 PSI)
SMR2002-075 _06-03A.FM 06-03-9

Ensure to position O-ring, around top of cylinder Bottom End

sleeve.
To gain access to piston, rings and connecting rod,
engine PTO flywheel must be removed. Refer to
ENGINE section.
Remove engine support and slightly lift engine to
allow access. Block engine in this position.
Remove top end as explained above.
Remove access plug of air compressor connect-
ing rod.
Remove connecting rod retaining screw.
As a puller, use a M7 x 1.0 x 50 mm screw to re-
lease connecting rod “crankpin”.
IMPORTANT: Trace a mark on “crankpin” (bush-
ing) outer end. This is needed for reinstallation.
F12R05A 1
1. O-ring on top of cylinder sleeve
Ensure to position screw from the bottom up as

show. Torque nut to 2.7 N•m (24 lbf•in).
2.7 Nm
(24 lbfin)
F12R06A 1
1. Use a M7 x 1.0 x 50 mm screw as a puller
Push piston upward with or without the cylinder

sleeve.
Remove rubber plug then push piston pin end to
remove from connecting rod.
1
F12D0BA Inspection
1. Screw from bottom up Clean all parts in a solvent and visually inspect for
corrosion damage.
CAUTION: Failure to properly position screw
head will lead piston to hit it. Clean piston ring grooves with a groove cleaner
If pressure is still low then continue with BOT-
TOM END. Otherwise, remove components Check bearings and pins for wear and heat discol-
again. Install a new gasket, new O-ring, compres- oration. Check connecting rod for straightness.
sor head and cover. Apply synthetic grease below Replace damaged components.
screw head and Loctite 243 on threads. Install Inspect piston for damage. Light scratches can be
screws then torque to 5 N•m (44 lbf•in) to then sanded with a fine sand paper.
finalize to 11 N•m (97 lbf•in). If you find aluminum dust or debris in this area,
they may have flowed toward the injection oil res-
ervoir. In this case, the oil reservoir and lines must
be flushed and the filter replaced.
06-03-10 SMR2002-075 _06-03A.FM

CAUTION: Failure to properly clean the oil sys- Assembly

tem will result in serious engine damage. Apply injection oil in cylinder and on rings prior to
The inspection of top end should include the fol- installing.
lowing measurements. Install the oil ring with the “TOP” marking on top.
Identify the correct position by looking at beveled
TOLERANCES
ENGINE edge of oil ring and while installation, make sure
MEASUREMENT NEW PARTS WEAR that the beveled edge should be towards the top
(min.) (max.) LIMIT of the piston.
Piston/cylinder wall 0.12 mm 0.2 mm
N.A. 1
clearance (.005 in) (.008 in)
0.1 mm 0.25 mm 0.5 mm

Ring end gap
(.004 in) (.010 in) (.020 in)

Clearance can be quickly checked with a feeler
gauge. Insert feeler gauge in cylinder then slide 1
piston (without piston rings installed). If clearance
exceeds tolerance, check cylinder top area with
your finger to feel if there is a ridge. If so, the cyl-
inder sleeve is worn and needs replacement. Oth-
erwise, replace piston.
Ring End Gap F12R1OA
Position ring close to top of cylinder top. 1. Beveled edge

Position ring openings 180° apart.
Using a feeler gauge, check ring end gap. If gap 1
placed.
F12R15A 2
1. Ring openings 180° apart
2. TOP marking on this side
F12R07A 2 1
1. Top of cylinder Use ring compressor (P/N 529 035 713) and insert
2. Ring end gap piston in cylinder.
NOTE: Cylinder may be removed from crankcase
to install piston more easily on the bench from the
bottom if desired.
SMR2002-075 _06-03A.FM 06-03-11

When attaching connecting rod to “crankpin”, strict-

ly follow this procedure:
1. Block counterbalance shaft to prevent any rota-
tion.
2. Install the “crankpin” (bushing) with the previ-
ously marked end outside. If the mark is not
present anymore, place a straight edge against
bushing end to find the tapered end (concave).
A very small gap between the edge and the
bushing will identify the tapered end to be in- 1
stalled against the counterweight.
3. Install a NEW screw and torque to 6.5 N•m
(58 lbf•in). Do not apply any thread locker product.
4. Turn the screw clockwise an additional 80 de-
grees ± 5 degrees.
dure may cause screw to loosen and lead to 2
engine damage. The bushing tapered end must
be against the counterweight. Besides, as the
“crankpin” screw has been stretched from the
previous installation, it is very important to use F12R08A
a new screw at assembly. Also, the new screw

will have the proper threadlocking coating. 2. T-adapter (P/N 529 035 710)
Ensure to correctly position O-ring on access cov- Install pressure gauge between disconnected hose
er and install cover. (inline installation).
Reinstall remaining removed parts. Ensure to
check engine alignment.
FUEL DELIVERY
FUEL PRESSURE REGULATOR
Pressure Test
at the air/fuel rail. It validates the pressure regula-
tor and leaks in the system.
IMPORTANT: Before checking air/fuel rail pres-
sure, make sure the fuel pressure from the fuel
pump and the air pressure from the air compres- 2
sor are within specifications. See the procedures
Also ensure there is no leak from hoses and fit-
tings. Repair any leak.
3
Ensure there is enough gas in fuel tank. 1
Disconnect outlet hose (the one with the fuel fil- F12R09A
1. Fuel filter
Connect adapter to pressure gauge as shown. 2. Fuel line going to air/fuel rail
06-03-12 SMR2002-075 _06-03A.FM


Do not crank engine. 1

185 ± 14 kPa (27 ± 2 PSI)
If pressure is within limits, fuel pressure regulator

is working adequately.
A rapid pressure drop indicates leakage either
from the air/fuel rail or from the fuel pump check
valve. Check air/fuel rail for leaks. If it is not leaking
then replace fuel pump.
leaking then replace fuel pressure regulator.
NOTE: Fuel in air compressor outlet line is an indica-
tion of a leaking fuel pressure regulator diaphragm.
F12R0DA
installation apply engine oil on O-ring. 1. Push clip toward injector to release connector

 WARNING
Wipe off any fuel spillage in the bilge. Fuel is 1 1
Fuel Pressure Regulator Replacement

Removal
Disconnect spark plug cables from spark plugs.
Disconnect the fuel injector wires, if necessary. F12R19A
1. Retaining screws
SMR2002-075 _06-03A.FM 06-03-13

Gently pull rail up by hand, working each side slight- Electrical Test
ly at a time.
Pull rail out.
Unscrew retaining plate screws. the B.U.D.S. software, energize the fuel injector
from the ACTIVATION section.
4 2 5
harness.
This will validate the injector mechanical and elec-
trical operation.
If it does not work, replace it.
F12R1AA 2 3 1 3 2 Otherwise, check the resistance of the fuel injec-
1. Retaining plate tor circuit.
2. Screws
3. Fuel injector Reconnect the injector and disconnect the AMP
4. Fuel pressure regulator and cover plug connector number 4 on the MPEM.
NOTE: If needed, use a small screwdriver to lift tween terminals as follows.
the fuel pressure regulator.
To remove fuel pressure regulator, pull the fuel COMPONENT CONTACT LOCATION
regulator and the cover out of rail.
Fuel injector MAG 7 and 13
Installation
Fuel injector PTO 8 and 14
but pay attention to the following. The resistance should be between 1.7 and 1.9 Ω.
If the same regulator is reinstalled, it is recommend- If resistance value is correct, try a new MPEM.
ed to change the O-rings. Refer to MPEM REPLACEMENT procedures else-
Insert the fuel pressure regulator into the cover where in this section.
then install both regulators together in place with If resistance value is incorrect, repair the wiring
your hand. Do not use any tool. harness/connectors between AMP plug connec-
NOTE: A thin film of injection oil may be applied tor and fuel injector.
Apply Loctite 243 on rail retaining screws then Fuel Injector Replacement
torque to 25 N•m (18 lbf•ft). When one fuel injector is defective, both have to
be replaced at the same time. Be sure to check
FUEL INJECTOR the other one. Also replace direct injectors.
Removal
Leakage Test
See FUEL PRESSURE REGULATOR REPLACE-
Testing the fuel injector operation can be per- MENT above for procedure. However, do not re-
formed with the air/fuel rail installed. move any regulator.
The leakage test is validated when performing the To remove fuel injector, pull it out of rail.
CHART elsewhere in this section.
06-03-14 SMR2002-075 _06-03A.FM

Installation Air/Fuel Rail Replacement

For the installation, reverse the removal proce- Removal
If the same injector is reinstalled, it is recommend-
Disconnect air compressor supply hose from rail.
Disconnect fuel hoses (supply and return) at their
Insert the fuel injector in place with your hand. Do
inline connectors.
not use any tool.
Temporarily connect those hose ends together to
NOTE: A thin film of injection oil may be applied prevent rail draining.
Disconnect spark plug cables from spark plugs
Apply Loctite 243 on rail retaining screws then torque and fuel injector wires. Cut locking ties of wiring.
AIR/FUEL RAIL 3 1 4 2
Pressure test
FUEL PRESSURE
(when cranking engine or when engine is running)
738 ± 14 kPa (107 ± 2 PSI)

Remove pressure gauge and reinstall fuel hose. At F12R0CA
1. Air/fuel rail
If pressure is out of limits, check air/fuel rail for 2. Air supply hose
3. Fuel supply hose
leaks. If it is not leaking then replace air regulator 4. Retaining screws
A higher pressure may be an indication of a
pinched or clogged air regulator outlet line. 1
Air Pressure Regulator Replacement

Removal
See FUEL PRESSURE REGULATOR REMOVAL
above for procedure.
Remove the fuel regulator then the air regulator.
Installation
but pay attention to the following.
F12R0DA
1. Push clip toward injector to release connector

SMR2002-075 _06-03A.FM 06-03-15
Gently pull rail up by hand, working each side slight- Leakage Test
ly at a time.
If direct injector leaks through its large top O-ring,
Pull rail out. there will be an air/fuel leak between the injector
Disconnect hose ends at their inline connectors and the air/fuel rail. Replace O-ring of both injectors.
and drain fuel rail. If there is an injector internal leak, the high tempera-
Disconnect air and fuel hoses from rail. ture from the combustion chamber will make visible
overheated area. Replace damaged components.
2 Electrical Test
1 the B.U.D.S. software, energize the direct injector
in the ACTIVATION section.
harness.
This will validate its mechanical and electrical op-
eration.
If it does not work, replace the direct injector.
Otherwise, check the resistance of the direct in-
jector circuit.
F12R0FA
Reconnect the injector and disconnect the AMP
1. Air and fuel return hoses
2. Fuel supply hose Using a multimeter, check resistance value be-
NOTE: When lifting/removing air/fuel rail, we rec-
ommend replacing carbon dams on direct injec- COMPONENT CONTACT LOCATION
tors that have been running for 50 hours or more.
Remove fuel injector, fuel pressure regulator and Direct injector MAG 5 and 15
air pressure regulator. Direct injector PTO 6 and 21
Installation
For installation, reverse the removal process but The resistance should be between 1 and 1.6 Ω.
pay attention to the following. If resistance value is correct, try a new MPEM.
A thin film of injection oil may be applied to O-rings Refer to MPEM REPLACEMENT procedures else-
of fuel injectors to ease rail installation. where in this section.
Apply Loctite 243 on rail retaining screws then torque If resistance value is incorrect, repair the wiring
to 25 N•m (18 lbf•ft). harness/connectors between AMP plug connec-
tor and direct injector.
When installing fuel or air hoses fitting to the air/
fuel rail, use Loctite Krylox (no. 29-719).
Direct Injector Replacement
DIRECT INJECTOR IMPORTANT: Do not remove direct injector need-
lessly. They are sealed with a carbon dam that may
When one direct injector is defective, both have expand when pulled out. A special tool is required
to be replaced at the same time. Be sure to check to compress it prior to reinstalling. Otherwise,
the other one. Also replace fuel injectors. sealing efficiency might be affected.
The direct injectors can be replaced by lifting the Remove air/fuel rail retaining screws. Partially lift
air/fuel rail. rail to allow direct injector removal.
06-03-16 SMR2002-075 _06-03A.FM

Disconnect direct injector connector then pull in- Carbon Dam Replacement
jector out of cylinder head. Remove direct injector. See procedure above.
1 NOTE: When replacing a carbon dam, it is recom-
mended to replace it on both injectors. It is also
recommended to replace all O-rings. When servic-
ing air/fuel rail or direct injectors, we recommend
replacing carbon dams that have been running for
50 hours or more.
CAUTION: Never reuse a carbon dam after it has
been removed from the injector. Always install
a new one.
Remove carbon dam and O-ring using a small pick.
Install seal guide (P/N 529 035 715) on end of injec-
tor. Carefully slide carbon dam in injector groove.
Use carbon dam compressor (P/N 529 035 716) to
compress carbon dam evenly.
2
F12R0GA
FUEL PUMP
1. Air/fuel rail
2. Disconnect and pull injector out
Pressure Test
Compress the carbon dam using tool (P/N 529 035 The pressure test will show the available pressure
716).
from the fuel pump.
Carefully install direct injector in cylinder head pay-
ing attention to carbon dam insertion. Ensure to Ensure there is no leak from hoses and fittings.
position connector pointing toward bottom of cyl- Repair any leak.
inder head. Ensure there is enough gas in fuel tank.
NOTE: A thin film of injection oil may be applied Use the VCK (Vehicle Communication Kit) to re-
to carbon dam if necessary to ease insertion in cyl- lease the fuel pressure in the system. Look in the
inder head. ACTIVATION section of the software B.U.D.S.
Reconnect electrical connector. Disconnect inlet and outlet hoses from fuel pump
using tool (P/N 529 035 714).
2
F12R0HA 1
1. Carefully insert direct injector
2. Connector pointing toward bottom of cylinder head
Reinstall air/fuel rail.
SMR2002-075 _06-03A.FM 06-03-17

Connect adapters and pressure relief valve to

pressure gauge as shown.
2
1
1
3
4
F12R0BA
1. Fuel pump outlet hose (fuel filter side)

F12R0AA 3 2 2. Fuel pump return line
3. Fuel relief valve on the return line side
1. Pressure gauge (P/N 529 035 709) 4. Pressure gauge between disconnected hose (inline installation)
2. T-adapter (P/N 529 035 710)
3. Pressure relief valve (P/N 529 035 711) Install safety lanyard and observe fuel pressure.
CAUTION: Ensure to install the pressure relief MINIMUM FUEL PUMP PRESSURE
valve to allow excess pressure to flow back (when installing safety lanyard)
through return line. Note the arrow on the valve.
Otherwise, fuel pump components might be dam- 721 kPa (105 PSI)
aged.
Install pressure gauge between disconnected If pressure is within limits, fuel pump is working
hoses on fuel pump side (closed-loop installation adequately.
on fuel pump). Make sure the pressure-relief valve If pressure is below limits, ensure fuel filters are
is installed on the fuel pump return line side. not obstructed. There is one in-line fuel filter at the
fuel pump outlet hose and one filter at the inlet
underneath the pump. Otherwise, replace the fuel
pump.
Remove pressure gauge and reinstall fuel hoses.
At installation apply engine oil on O-ring.
06-03-18 SMR2002-075 _06-03A.FM

Electrical Test Disconnect electrical connector.

When connecting the safety lanyard to the DESS Disconnect vent tube from fuel pump.
post, the fuel pump should run for 2 seconds to Release the fuel pressure in the system.
Disconnect inlet and outlet hoses from fuel pump
If the pump does not work, disconnect the plug using tool (P/N 529 035 714).
Pull fuel pump toward front of vehicle. Wipe off
Install a temporary connector to the fuel pump any fuel spillage in the bilge.
test harness.
If pump does not run, replace the fuel pump.
Otherwise, check the continuity of the fuel pump
circuit.
the MPEM.
Using a multimeter, check continuity between ter-
minals of circuits 24 and 26.
in this section.
between AMP plug connector and fuel pump.
F12R0JA 1
Fuel Pump Replacement 1. Pull fuel pump toward front
Removal Installation
Open front storage compartment cover. For installation, reverse the removal process but
Remove the storage basket. pay attention to the following.
Remove glove box (see HULL/BODY section). Tighten fuel pump screws in a criss-cross sequence.i
Remove front vent tubes.
From glove box opening, remove fuel pump retain-
ing nuts.
F12R0IA 1 2
1. Fuel pump
2. Retaining screw
SMR2002-075 _06-03A.FM 06-03-19

FUEL DELIVERY SYSTEM DIAGNOSTIC FLOW CHART
NOTE: The tolerance for the pressure is ± 14 kPa (2 PSI).

Fuel pump runs
Fuel pump does not run Connect safety lanyard for 2 sec. then stops
Check fuses Install fuel pressure gauge on

Check lanyard connection fuel pressure line
Check pump module operation
Repair or replace if necessary

OK
Fuel pump runs Repair or replace
Fuel pressure Check for

Fuel pressure less more than blocked fuel
than 185 kPa (27 PSI) 185 kPa return line
(27 PSI)
Check fuel lines

Repair or yes for leaks Fuel pressure
replace Check fuel filters is 185 kPa Line OK
(27 PSI)
Replace Perform fuel

fuel pump fails
pump test Crank or start engine
module
Fuel pressure lower

test OK than 735 kPa (107 PSI)
Fast
pressure Replace
drop Perform fuel Check Fuel pressure Fuel pressure
fuel pump fails no yes
pump test for air greater than is 735 kPa
yes module leaks
no leaks 735 kPa (107 PSI)
(107 PSI)
Verify pass
fuel pump Repair
check valve Proceed to air leaks
fails compressor OK Check air Replace fuel
OK fails pressure test return pressure
line for regulator
Ensure Replace blockage
Air pressure less Air pressure more
air/fuel fuel pump than 621 kPa than 621 kPa
rail is not (90 PSI) (90 PSI)
leaking yes
no Check
Repair/replace
air/fuel rail RAVE no Check direct
fails OK line
Check fuel for air leaks injector
leaks OK
injector
Repair Repair air Direct
fails Replace
OK leaks compressor injector direct
OK injector
Replace fuel Replace air
injector pressure System OK
regulator
Check air/fuel rail for leaks OK
Replace fuel
fails
pressure NOTE: The tolerance for the Retest
regulator pressure is ± 14 kPa (2 PSI).
Repair/replace air/fuel rail
F12A06S
06-03-20 SMR2002-075 _06-03A.FM

ELECTRONIC MANAGEMENT Select the Activation tab.

Point the mouse cursor over the PTO TPS. Check
MPEM REPLACEMENT the ADC reading. It must be between 23 and 45.
General 1
Prior to replacing a suspected MPEM, ensure that Activation
all the recommendations in the general introduc-
tion of this section have been followed.
IMPORTANT: When MPEM is replaced, the safe-
ty lanyard(s), the TPS closed position and the TDC
their specific section for adjustment.
To allow transferring the previous recorded infor-
mation from the old MPEM to the new one, use the
vehicle communication kit (VCK) with the B.U.D.S.
software. Use Replace in the MPEM menu. Follows
instructions in its help system.
NOTE: If the old MPEM is working, it must be read
inside B.U.D.S. prior to removing it from the vehicle
to carry vehicle information and history to the new 30
MPEM. Besides, select the Setting tab and note
the Current Angle in the ignition offset area. When F12R1JA 3 2
installing the new MPEM, re-use this setting as a 1. “Activation” tab
preliminary setting. Then, proceed with the regular 2. Point on PTO TPS
3. ADC reading
procedure for the TDC setting. If the old MPEM is
not working, try to find a previous saved file from Point the mouse cursor over the MAG TPS. Check
B.U.D.S. the ADC reading. It must be between 37 and 59.
If either readings are not within those parameters,
Replacement they are out of range and the MPEM will be unable
Disconnect battery cables. to initialize. Proceed with THROTTLE BODY SYN-
CHRONIZATION as detailed in THROTTLE BODY.
 WARNING If the ADC’s are within range, proceed with the
Battery BLACK negative cable must always required resets.
be disconnected first and connected last. After performing the required resets, ensure to
clear all faults from the newly replaced MPEM.
Disconnect AMP connectors from MPEM. Now, all faults must be inactive (except the Diag-
Remove MPEM. nostic Cap Missing fault).
Install the new MPEM to the vehicle. Start the engine and increase engine speed above
Reconnect AMP connectors to MPEM then bat- 5000 RPM to be sure no fault appears.
tery cables.
Transfer the data from the previous MPEM to the
new one using B.U.D.S. then proceed with the re-
quired resets after the following verification has
been done.
SMR2002-075 _06-03A.FM 06-03-21

THROTTLE POSITION SENSOR NOTE: In this particular case, by comparing the

signals from both sensors, the MPEM will gener-
(TPS) ate a fault code when the TPS is malfunctioning
due to specific “spots”.
General
To isolate the faulty TPS, disconnect one and test
The throttle position sensor (TPS) is a potentiom- the other.
eter that sends a signal to the MPEM which is pro-
portional to the throttle shaft angle. On the DI sys- Voltage Test — Both TPS
tem, two sensors are used for redundancy purposes.
The MPEM compares the signals from both sensors Check the voltage output from MPEM to the desired
and determines if there is an error and uses the most throttle position sensor.
appropriate sensor to operate the system. Disconnect plug connector from throttle position sen-
sor and connect a voltmeter to the wiring harness.
Check the voltage readings on the PTO side as
follows.
CONNECTION VOLTAGE
Pin 2 with engine ground 0 - 0.5 V
Check the voltage readings on the MAG side as

follows.
F12F05A 1 1
CONNECTION VOLTAGE
IMPORTANT: Prior to testing the TPS, ensure that
mechanical components/adjustments are adequate Pin 2 with engine ground 0 - 0.5 V
according to THROTTLE BODY in AIR INDUCTION
Pin 3 with engine ground 4.75 - 5 V
SYSTEM above.
The MPEM may generate two types of fault codes Remove and reinstall the safety lanyard to activate
pertaining to the TPS. Refer to DI SYSTEM FAULT the MPEM. There should be 5 Vdc in each test.
CODES in DIAGNOSTIC PROCEDURES section If voltage test is good, replace the TPS.
for more information.
If voltage test is not good, check the resistance of
Wear Test the TPS circuit.
While engine is not running, activate throttle and Resistance Test
pay attention for smooth operation without physi-
cal stops of the cable. Reconnect the TPS.
Using the vehicle communication kit (VCK) with the NOTE: Resistance values are different at idle on
B.U.D.S. software, use the THROTTLE OPENING each TPS.
display under Monitoring. MAG Side
Slowly and regularly depress the throttle. Observe Disconnect the AMP plug connector number 3 on
the needle movement. It must change gradually the MPEM.
and regularly as you move the throttle. If the nee-
dle “sticks”, bounces, suddenly drops or if any dis- Using a multimeter, check resistance value be-
crepancy between the throttle movement and the tween terminal 10 and 14.
needle movement is noticed, it indicates a worn The resistance should be 1600 - 2400 Ω.
TPS that needs to be replaced. Check the resistance between terminal 5 and ter-
06-03-22 SMR2002-075 _06-03A.FM

The resistance should be 2500 Ω.

1 2
PTO Side
the MPEM.
tween terminal 3 and 18.
The resistance should be 1600 - 2400 Ω.
minal 18 with the throttle plate in idle position. F12R0LA
The resistance should be 2500 Ω. MAG SIDE THROTTLE BODY

1. Allen screws
Test Results — Both TPS 2. Throttle position sensor (TPS)
If resistance values are correct, try a new MPEM. Re- Apply Loctite 243 on screw threads, install the
fer to MPEM REPLACEMENT procedures else- new TPS.
NOTE: Both TPS do not need to be replaced at the
If resistance values are incorrect, repair the wiring same time.
tor and the TPS.
Proceed with the CLOSED TPS ADJUSTMENT.
Replacement See below.
Remove the air intake silencer. Closed TPS Adjustment
NOTE: Although this operation is called “adjust-
Disconnect the connector of the TPS. ment”, it is not really an adjustment. Rather, it per-
Loosen two Allen screws retaining the TPS. forms a reset of the values in the MPEM.
Remove TPS. This reset is very important. The setting of the TPS
will determine the basic parameters for all fuel
mapping and several MPEM calculations.
NOTE: Reset must be done each time the throttle
position sensor (TPS) is loosened or removed or
throttle body(ies) is(are) replaced or MPEM is re-
placed.
SMR2002-075 _06-03A.FM 06-03-23

CAUTION: An improperly adjusted TPS may Otherwise, validate the information center is
lead to poor engine performance and emission working by activating the tachometer using the
compliance could possibly be affected. software B.U.D.S. under Activation (first ensure
information center is in tachometer mode). If it
Use the vehicle communication kit (VCK) with the does not display 3000 RPM, the information cen-
B.U.D.S. software to perform this adjustment. ter may be faulty and needs to be tested.
Ensure the throttle body plate stop lever rest against If the information center correctly displayed 3000
its stopper. Open throttle approximately one quarter RPM, perform the following tests.
then quickly release. Repeat 2 - 3 times to settle
throttle plate. If stopper does not rest against its NOTE: Take into account that a CPS fault can be
stop lever, perform throttle cable adjustment. Refer triggered by bent or missing encoder wheel teeth.
to THROTTLE BODY in AIR INDUCTION SYSTEM Check the teeth condition. Also, bad connections
above. in magneto connector could generate electrical
noise that would make you wrongly think the CPS
Push the Reset button in the SETTING section of is faulty. Check pins and wires.
B.U.D.S.
NOTE: There is no idle speed adjustment to per- Encoder Wheel Inspection
form. The MPEM takes care of that. If TPS are not
To check the encoder wheel for bent teeth, pro-
within the allowed range while resetting the
ceed as follows.
closed TPS, the MPEM will generate a fault code
and not accept the setting. Remove magneto cover. Refer to MAGNETO SYS-
TEM in ENGINE section.
Start engine and make sure it operates normally
through its full engine RPM range. If fault codes ap- Install a dial indicator on crankcase casting. Posi-
pear, refer to DI SYSTEM FAULT CODES in DIAG- tion the gauge on a tooth and set it to zero (0).
NOSTIC PROCEDURES section for more informa- Rotate flywheel and check needle movement. The
tion. maximum allowed difference between teeth is
CRANKSHAFT POSITION or replace the encoder wheel.
SENSOR (CPS)
2 1
2
F12R1HA
F12R0OA
1. Magneto cover 1. Encoder wheel

2. CPS connector 2. Dial indicator
Check for RPM display at the information center Properly reinstall cover.
while cranking engine (first ensure information The encoder wheel for bent teeth can also be in-
center is in tachometer mode). If it displays ap- spected by the following alternative method.
proximately 300 RPM, the CPS circuitry is properly Remove magneto cover. Refer to MAGNETO SYS-
working. TEM in ENGINE section.
06-03-24 SMR2002-075 _06-03A.FM

Install a pointed wire on one of the threaded hole Voltage Test

of crankcase with the screw as shown in the fol-
Unplug magneto connector.
lowing illustration.
Check connector pins for corrosion or damage.
1 2 Remove and reinstall the safety lanyard to activate
the MPEM.
Check the voltage readings on the harness side as
follows:
CONNECTION VOLTAGE
0 V ± a small mV
Pin 4 with engine ground
tolerance
Pin 5 with engine ground 12 V
If voltage tests good, the CPS is defective and

needs replacement.
F12R1MA If voltage does not test good, perform the follow-
ing tests.
1. Pointed wire
2. Screw on the threaded hole
Resistance Test
Rotate the flywheel one time and adjust the point-
er so that it slightly touches the highest tooth. Us- Check the continuity of the wiring harness.
ing a feeler gauge, check and measure the clear- Disconnect the AMP plug connector number 2 on
ance between each tooth and pointer. the MPEM.
7 and 14.
If wiring harness is good, it could be either the CPS
or the MPEM. Try a new part one at a time. When
trying a new MPEM, refer to MPEM REPLACE-
MENT procedures elsewhere in this section.
2 1 between AMP plug connector and the CPS.
Replacement
Remove tuned pipe.
Unscrew front engine support and slightly lift en-
gine to have access to magneto cover screws.
Block engine in this position.
Disconnect connector and remove magneto cover.
F12R1NA
1. Pointed wire
2. Feeler gauge
The maximum allowed difference between teeth

is 0.15 mm (.006 in). Otherwise, straighten the
tooth or replace the encoder wheel.
SMR2002-075 _06-03A.FM 06-03-25

Remove CPS. If resistance tests good, reconnect the MATS and

disconnect the AMP plug connector number 4 on
the MPEM.
tor and the MATS.
Replacement
F12R0NA 1
1. CPS inside magneto cover
Pull MATS out while turning right and left.
Apply Loctite 243 on screw threads then install the Install the new MATS.
new CPS.
MANIFOLD AIR TEMPERATURE WATER TEMPERATURE SENSOR

SENSOR (MATS) (WTS)
F12R0MA 1 F12R0PA 1
PTO SIDE THROTTLE BODY 1. Water temperature sensor (WTS)

1. Manifold air temperature sensor (MATS)
Resistance Test
Resistance Test Disconnect the plug connector from the WTS and
Disconnect the plug connector from the MATS check the resistance of the sensor itself.
and check the resistance of the sensor itself. The resistance should be between 2280 Ω and
The resistance should be between 2280 Ω and 2740 Ω.
2740 Ω. Otherwise, replace the WTS.
Otherwise, replace the MATS. If resistance tests good, reconnect the WTS and
disconnect the AMP plug connector number 4 on
the MPEM.
06-03-26 SMR2002-075 _06-03A.FM

Using a multimeter, recheck resistance value be- Ensure sensor is correctly installed elbow adaptor.
tween terminals 9 and 11. Otherwise, the MAPS could generate a fault code
If resistance value is correct, try a new MPEM. Re- for an unexpected sensor range at idle when it
fer to MPEM REPLACEMENT procedures else- reads the atmospheric pressure. Ensure the cor-
where in this section. rect connector is plugged and not mixed with the
MAG TPS. Remove sensor and check for oil or dirt
If resistance value is incorrect, repair the wiring on its end and if problem persists, check throttle
harness/connectors between AMP plug connec- plate condition/position and the wiring harness.
tor and the WTS. Perform the following tests.
Replacement Voltage Test
Remove air/fuel rail retaining screws. Check the voltage output from MPEM to the mani-
Cut locking ties as necessary to allow lifting of fold air pressure sensor (MAPS).
air/fuel rail in order to give access to the tempera- Disconnect plug connector from throttle position
ture sensor. sensor and connect a voltmeter between pin 1 and
Disconnect WTS connector and remove WTS. 3 and also between pin 1 and 2 of wiring harness.
Apply Loctite 518 on threads of the WTS then in- Remove and reinstall the safety lanyard to activate
stall. the MPEM. There should be 5 Vdc in each test.
Reinstall remaining removed parts. If voltage test is good, replace the MAPS.
If voltage test is not good, check the continuity of
MANIFOLD AIR PRESSURE the MAPS circuit.
SENSOR (MAPS)
Resistance Test
the MPEM.
Using a multimeter, check continuity of circuits 3-3,
3-6 and 3-7.
in this section.
between AMP plug connector and the MAPS.
Replacement
Disconnect MAPS connector and remove the MPAS.
F12R0LB 1
MAG SIDE THROTTLE BODY tab into the adaptor notch.
NOTE: This sensor is a dual function device. When
engine is started and it runs at idle speed, the sen-
the MPEM. Thereafter, it takes the manifold air
pressure at operating RPMS.
SMR2002-075 _06-03A.FM 06-03-27

EXHAUST GAS TEMPERATURE KNOCK SENSOR (KS)

SENSOR (EGT)
1
F12R0QA 1
1. Knock sensor (KS)
F12R0SA 2
1. Muffler Dynamic Test
Resistance Test the B.U.D.S. software, monitor the knock sensor
using the FAULTS section.
check the resistance of the sensor itself. Start the engine and bring engine RPM above
The resistance should be between 2280 Ω and sor is good.
2740 Ω.
Ensure sensor and head contact surfaces are clean
If resistance tests good, reconnect the EGT and and mounting bolt and washer are correct and prop-
disconnect the AMP plug connector number 4 on erly torqued down.
the MPEM.
tween terminals 10 and 12. Disconnect the AMP plug connector number 4
from the MPEM module.
fer to MPEM REPLACEMENT procedures else- Static Resistance Test
terminal 2 and terminal 17 on the plug connector.
tor and the EGT. The resistance should be approximately 5 MΩ.
Otherwise, check the continuity of the knock sen-
Replacement sor circuit 4-2 and 4-17.
Disconnect EGT connector and remove EGT. If wiring harness is good, try a new MPEM. Refer
Apply Loctite 518 on threads of the EGT then in- to MPEM REPLACEMENT procedures elsewhere
stall. in this section.
Replug connector. Otherwise, repair the wiring harness/connectors
between AMP plug connector and knock sensor.
06-03-28 SMR2002-075 _06-03A.FM

Replacement Install leak test pump (P/N 529 021 800) on hose end
and pressurize air line to 69 - 103 kPa (10 - 15 PSI).
Wait some time to see if pressure drops. If so,
Clean contact surface, apply Loctite 243 in thread- check line for leaks. Otherwise, the solenoid is de-
ed hole then install the new knock sensor. fective and needs to be replaced.
Torque screw to 20 N•m (15 lbf•ft). Using the vehicle communication kit (VCK) with
CAUTION: Improper torque might prevent sen- the B.U.D.S. software, energize the RAVE sole-
sor to work properly and lead engine to severe noid from the ACTIVATION section.
damage of internal components. The pressure should drop when the solenoid is ac-
Re-plug connector. tivated. If the solenoid does not work, disconnect
the plug connector from the solenoid.
RAVE SOLENOID Install a temporary connector to the solenoid with
A quick check can be done as follows. When engine side the bilge and apply voltage (12 V) to this test
is being stopped, the RAVE valves will open and harness.
close. This can be heard or seen by carefully remov-
ing the cap and feeling the movement with a hand. If it does not work, replace the solenoid. Other-
wise, proceed with the resistance test below.
Another test can be done using the vehicle com-
munication kit (VCK) with the B.U.D.S. software, Reconnect hose to compressor.
using the MONITORING section. Start engine and Unplug the outlet hose from RAVE solenoid.
bring its RPM to approximately 6000 and look at
the RAVE solenoid LED. It should turn on, indicat- 4
ing the RAVE system is working on the electronic
side. However, pneumatic test still have to be per-
formed to validate the mechanical operation.
Leakage/Voltage Test
NOTE: The solenoid activates both RAVE valves
at the same time.
Unplug the RAVE solenoid supply hose from air
compressor.
F12R0TA 3 1 2
1. RAVE solenoid
2. Supply hose from air compressor
3. Check valve
4. Outlet hose to RAVE valves
Install leak test pump on hose end and apply pres-

sure. If pressure can not be held, check hoses for
leaks. If hoses test good, connect pump directly
to each RAVE valve nipple and pressurize. If pres-
sure drops, replace the defective seal inside RAVE
valve.
Take into account that the RAVE may be mechani-
F12R0RA 1 2 cally stuck in the cylinder slot. Open the RAVE and
check for free operation. Refer to ENGINE section
1. Air compressor
2. Disconnect RAVE supply hose and look in TOP END subsection.
SMR2002-075 _06-03A.FM 06-03-29

Pressure Relief Circuit IGNITION COIL

When RAVE valve is released, the pressure es-
NOTE: The MPEM energizes the primary side of
cape from this vented hose. If the RAVE valves
does not return when the solenoid is released, en-
and short circuit in the primary winding but it does
sure the return spring is in good condition, this
not check the secondary winding.
hose is not kinked or plugged and the solenoid al-
lows pressure to bleed there. Using the vehicle communication kit (VCK) with
the B.U.D.S. software, energize the ignition coil
Although it is not related with RAVE operation, we
from the ACTIVATION section.
suggest to verify the check valve operation which
prevent the pressure going down to crankcase. In- You should hear the spark occurring. In doubt, use an
stall a hose pincher after the T-fitting to adequately inductive spark tester or a sealed tester — available
pressurize the check valve portion. from after-market tool/equipment suppliers — to pre-
3 2 the following checks.
 WARNING
Never make a spark test with spark plug re-
the bilge and ignited which could cause an
explosion.
Primary Winding
Disconnect the plug connector from the ignition
coil and check the resistance of the primary circuit.
F12R0TB 1
1. RAVE solenoid
2. Pressure relief hose
3. Install hose pincher here
Resistance Test
Reconnect the solenoid and disconnect the AMP
If resistance value is correct, try a new MPEM. Refer F12R0UA 3 1
to MPEM REPLACEMENT procedures elsewhere in 1. PTO side ignition coil
2. Mag side ignition coil
this section. 3. Primary winding connector
tor and solenoid.
06-03-30 SMR2002-075 _06-03A.FM

The resistance should be between .45 - .55 Ω at Dynamic Test

20°C (68°F). Use an ignition coil tester, available from after-market
Otherwise, replace the ignition coil. tool/equipment suppliers.
If resistance tests good, reconnect the ignition
coil connector and disconnect the AMP plug con-  WARNING
nector number 3 on the MPEM. Do NOT use coil tester on metal work bench.
Using a multimeter, recheck resistance value be- Follow manufacturer instructions.
tween terminals 21 and 22 for MAG side and ter-
minals 20 and 23 for PTO side. 1. With ignition coil removed from craft, hook high
tension leads from tester to ignition coil high
If resistance value is correct, try a new MPEM. Re- tension cables.
where in this section. 2. Connect 2 smaller tester leads to primary of ig-
nition coil.
harness/connectors between AMP plug connec- 1
tor and the ignition coil.
Secondary Winding
Static Test
NOTE: An ignition coil with good resistance mea-
at high voltage level which is not detectable with
an ohmmeter. A dynamic test is more effective.
Remove high tension lead from ignition coil.
Using a multimeter, check the resistance between 2
the terminals C and the coil post.
F12H0UA
The resistance should be between 6800 and
10200 Ω at 20°C (68°F). TYPICAL
1. Lead to secondary
If not within specification, replace the ignition coil. 2. Leads to primary
Otherwise, perform the DYNAMIC TEST below.
3. Turn power switch to 12 volts and you should
Measure resistance of the high tension leads. observe spark jumping at a predetermined gap
They must be as follows. Otherwise, replace the of 7 to 8 mm (.276 to .311 in).
lead.
If there is no spark, if it is weak or intermittent, the
NOTE: It is not necessary to remove the spark coil is defective and should be replaced.
plug cap.
IMPORTANT: Always replace leads with genuine  WARNING
parts. Otherwise, fuel injection system operation Always reconnect spark plug cables at the same
may be impaired. spark plugs where they come from. The cable
coming out the edge of the electrical box must
MODEL SIDE VALUE OHM
be connected to the MAG side spark plug. Oth-
MAG 5700 erwise, severe backfire may occur with possible
GTX DI
PTO 4900 damage to exhaust system components. The
white tape on the ignition coil should match the
Check continuity between ignition coil ground cir- white tape on the high tension cable.
cuits and engine.
SMR2002-075 _06-03A.FM 06-03-31

Normally TDC setting should not be required. It

2 3 1 has been set at factory and it should remain cor-
rectly set since every part is fixed and not adjust-
able. The only time the TDC setting might have to
be changed would be when replacing the crank-
shaft, the magneto rotor, the CPS, the encoder
wheel or the MPEM. If the TDC setting is found
to be incorrect, you should first check for proper
crankshaft alignment. This might be the indication
of a twisted crankshaft.
With this ignition system, the TDC setting can be
checked with either the engine hot or cold. Also,
the TDC setting is to be checked at any RPM with
the timing light. The TDC setting is best checked
F12R0UB
at idle speed as it is more accurate and easier than
at higher speed, also it will keep the engine tem-
1. MAG side ignition coil at bottom
2. Mag side ignition coil wire on edge of electrical box perature lower for a longer time. Ensure to prop-
3. Edge of electrical box erly cool the engine through the flushing fitting.
NOTE: If PTO ignition coil is replaced, ensure to NOTE: When checking the TDC setting, the spark
reinstall the white tape on the new coil on if it is advance has to be locked to allow proper verifica-
not present. tion of the TDC marks. See TDC SETTING below.
TDC SETTING Static Test

1. Disconnect MAG side spark plug wire and con-
General nect wire to grounding device then remove spark
Before checking TDC setting with a stroboscopic plug.
timing light (dynamic test), it is mandatory to CAUTION: Never crank engine with spark plugs
scribe a timing mark on the PTO flywheel (static removed unless spark plug cables are connect-
test) corresponding to the specific engine. ed to the grounding device.
Also, the mark scribed on the PTO flywheel can 2. Remove PTO flywheel guard.
be used to troubleshoot a broken magneto woo- 3. Remove middle screw securing the engine to
druff key. the rear engine mount. Reinstall screw with tim-
CAUTION: The relation between the PTO flywheel ing mark pointer tool.
mark position and crankshaft position may
change as the PTO flywheel might move on crank- 1
shaft when engine is ran. This will result in a false
ignition timing reading. Always verify PTO fly-
wheel mark position before checking ignition tim-
ing with an appropriate timing light. If mark does
not align with tool, repeat static test to ensure fly-
wheel has not moved before changing the ignition
timing.
NOTE: Do not use the factory mark found on the
PTO flywheel to check TDC setting or troubleshoot
any problems.
F12R1IA
1. Timing mark pointer tool (P/N 295 000 135)
06-03-32 SMR2002-075 _06-03A.FM

4. Install and adjust a TDC gauge (P/N 295 000 143) NOTE: This specification is of the type “indirect
in MAG side spark plug hole. measurement” relative to the piston movement
5. Ensure to install its roller to allow proper reading since we are measuring at a 45° angle through the
of the gauge. Proceed as follows: spark plug hole.
– Rotate magneto flywheel clockwise until pis- 7. Scribe a thin mark on PTO flywheel aligned with
ton is just Before Top Dead Center. timing mark pointer tool.
1 2 3 using the stroboscopic timing light.
TDC setting procedure, therefore, always check
the TDC setting with a stroboscopic timing light.
8. Remove TDC gauge.
Dynamic Test
To check TDC setting, use Bombardier timing light
(P/N 529 031 900).
F12R0VA 5 4
1. Outer ring
2. Adaptor lock nut
3. Adaptor
4. Roller
5. Roller lock nut
– Install roller on dial gauge end. Ensure to posi-

tion roller edge parallel with the dial gauge A00B4FA
face. Secure in this position by tightening roller

lock nut. This will keep the roller in the proper 10. Connect timing light pick-up to MAG side spark
axis for measurement accuracy. plug wire.
– Loosen adaptor lock nut then holding gauge 1
with dial face directed toward you when you
are in line with the crankshaft, screw adaptor
in spark plug hole.
– Slide gauge far enough into adaptor to obtain
a reading then finger tighten adaptor lock nut.
– Since we are working with an indirect mea-
surement, ensure that dial gauge face is po-
sitioned in the same direction as the connect-
ing rod.
– Rotate magneto flywheel clockwise until pis-
ton is at Top Dead Center.
– Unlock outer ring of dial and turn it until “0”
(zero) on dial aligns with pointer. F00H1QA
– Lock outer ring in position. TYPICAL

1. Timing light pick-up
6. From this point, rotate magneto flywheel back 1/4
turn then rotate it clockwise to reach 7.87 mm
(.310 in).
SMR2002-075 _06-03A.FM 06-03-33
IMPORTANT: To check the TDC setting, the spark CAUTION: If the TDC setting is adjusted too ad-
advance curve must be locked first. This allows to vanced, this will cause serious damage to the
perform TDC setting at any RPM by keeping the engine.
ignition timing “frozen” so that it does not vary
Adjustment
with engine RPM. See TDC SETTING below for
more information. In this operation, the ignition timing light and
B.U.D.S. are used to synchronize the MPEM TDC
CAUTION: If the spark advance curve is not
reference with the engine crankshaft. This timing
locked using B.U.D.S. then a wrong ignition tim-
adjustment will affect the timing of ignition as well
ing will be seen as the ignition curve does not
as direct injector timings. The aim of the adjust-
match the locked ignition timing.
ment is to align the mark on the flywheel with the
11. Start engine and check marks at idle speed. pointer at idle using the timing light and B.U.D.S.
Point beam of timing light straight in line with When this is achieved, then the MPEM TDC refer-
timing mark pointer. ence is synchronized with the engine crankshaft.
NOTE: Look at the mark at the same angle as it
was scribed so that parallax error is minimized. 1
1
2
4
3 5
F12R0WA
F06H07A
1. “Setting” tab
2. Ignition offset section
3. “Locked” box
1. Timing light straight in line with pointer
4. Current angle in MPEM
5. Arrows to change the angle
CAUTION: If engine is to be run more than a few
seconds, engine must be cooled using the flush 1. Choose the Setting tab and look under IGNI-
kit. TION OFFSET.
NOTE: If mark on PTO flywheel is perfectly align- 2. Check the Locked box to “freeze” the timing at
ed with timing mark pointer, no adjustment is re- the correct value.
quired. If mark does not align with pointer, recheck 3. The VCK displays the number that is stored in
PTO flywheel mark before performing the TDC the MPEM.
setting to ensure PTO flywheel has not loosen or
tightened. 4. Now click the up or down arrow to change the
number of the current angle so that the TDC
TDC Setting setting marks align when checking with the tim-
ing light. Each step makes an adjustment of 1/4
General degree.
To correct the TDC setting, the data of the MPEM NOTE: Each time the setting is changed on the
is changed using the VCK (Vehicle Communication screen, the new value is also changed in the
Kit) (P/N 295 035 844). Look in SETTING section MPEM, so there may be a slow response, do not
of the software B.U.D.S. make changes too quickly.
NOTE: For more information on the VCK, refer to
its online help. The MPEM programmer will not
work to perform this operation on the DI engines.
06-03-34 SMR2002-075 _06-03A.FM

5. When marks align, uncheck the Locked box to Safety Lanyard Removed
finish. Connect test probes to switch BLACK and BLACK/
NOTE: This will write the new value immediately YELLOW wires. Measure resistance, there should
to the MPEM. There is no need to write the doc- be NO continuity (open circuit).
ument to the MPEM for the TDC setting unless Connect one test probe to the WHITE/GRAY wire
other changes were made. However, we recom- and the other test probe to the switch terminal.
mend to reset the service hours when you per- Measure resistance, it must be close to 0 ohm.
form a service action such as the TDC setting.
Connect one test probe to the BLACK wire and the
NOTE: The MPEM features a permanent (non- other test probe to the switch ring. Measure resis-
volatile) memory and keeps the TDC setting pro- tance, it must be close to 0 ohm.
grammed even when the watercraft battery is dis-
connected. Safety Lanyard on Switch
Engine Start/Stop Switch Verification YELLOW wires. Measure resistance, it must be
A quick operation test can be done using the vehi- close to 0 ohm.
cle communication kit (VCK) with the B.U.D.S. soft-
ware, using the MONITORING section. Press the SPARK PLUGS
start button and look at the Start button LED. It
should turn on, indicating the starting system is Disassembly
working on the input side (start button, MPEM and First unscrew the spark plug one turn.
wiring). You know now the problem is on the output
side (MPEM output signal to starting solenoid, wir- Clean the spark plug and cylinder head with pres-
ing harness going to the solenoid, starter motor. Re- surize air then completely unscrew.
fer to STARTING SYSTEM for testing procedures).
Otherwise, check the input side as follows. Heat Range
Disconnect the YELLOW/RED wire of the start/ The proper heat range of the spark plugs is deter-
stop switch. Using an ohmmeter, connect test mined by the spark plugs ability to dissipate the
probes to YELLOW/RED wire and to ground. heat generated by combustion.
Measure resistance, it must be an open circuit The longer the heat path between the electrode tip
(switch is normally open). Depress and hold switch, to the plug shell, the hotter the spark plug operat-
the ohmmeter should read close to 0 ohm. Other- ing temperature will be — and conversely, the
wise, replace switch. shorter the heat path, the colder the operating tem-
perature will be.
If the switch tests good, check continuity of cir-
cuits 2-8 and 2-11 using a multimeter. A “cold” type plug has a relatively short insulator
nose and transfers heat very rapidly into the cylin-
If wiring harness tests good, it could be the MPEM.
der head.
Try a new MPEM referring to MPEM REPLACE-
MENT procedures elsewhere in this section. Such a plug is used in heavy duty or continuous
high speed operation to avoid overheating.
Safety Lanyard Switch Verification
If 2 short beeps are not heard when installing the
safety lanyard, refer to DIAGNOSTIC PROCEDURES.
The following continuity tests can also be per-
formed using an ohmmeter:
Disconnect switch wires.
SMR2002-075 _06-03A.FM 06-03-35

The “hot” type plug has a longer insulator nose 3. Hand screw spark plug into cylinder head. Then,
and transfers heat more slowly away from its firing tighten the spark plug clockwise an additional
end. It runs hotter and burns off combustion de- 1/4 turn with a proper socket.
posits which might tend to foul the plug during
prolonged idle or low speed operation.
1 2
1 2
A00E0BA
1. Proper socket
A00E09A 2. Improper socket
1. Cold
2. Hot SPARK GAP
ENGINE TORQUE
PLUG mm (in)
CAUTION: Severe engine damage might occur
if a wrong heat range plug is used. NGK Hand tighten 1.1
DI + 1/4 turn with
A too “hot” plug will result in overheating and pre- ZFR4F-11 a socket (.043)
ignition, etc.
A too “cold” plug will result in fouling or may cre- CRANKING SYSTEM
ate carbon build up which can heat up red-hot and
cause pre-ignition or detonation. See above for start/stop switch and the DESS post
Fouling other tests.
Fouling of the spark plug is indicated by irregular
running of the engine, decreased engine speed DI SYSTEM TEST SUMMARY
due to misfiring, reduced performance, and in-
creased fuel consumption. This is due to a loss of Pressure Tests
compression. Other possible causes are: pro-
longed idling, or running on a too rich mixture or VALUE
COMPONENT
incorrect fuel. The plug face of a fouled spark plug kPa (PSI)
has either a dry coating of soot or an oily, glossy Air compressor 621 ± 14 (90 ± 2) at cranking
coating given by an excess either of oil or of oil
with soot. Such coatings form a conductive con- Fuel pressure 185 ± 14 (27 ± 2)
nection between the center electrode and ground. regulator when installing safety lanyard
738 ± 14 (107 ± 2)
Spark Plug Installation Fuel pressure inline test at cranking or
Prior to installation make sure that contact surfac- when engine is running
es of the cylinder head and spark plug are free of
grime. Fuel pump 721 (105) minimum at cranking
cording to the following chart.
06-03-36 SMR2002-075 _06-03A.FM

Electrical Tests
TERMINAL
NUMBER
26 and pin B PU/PK
Fuel pump AMP no. 4 0 ohm (continuity)
24 and pin D BK/PK
Fuel injector MAG 7 and 13 BL/PU and BL/BK
AMP no. 4 1.7 - 1.9 ohms
Fuel injector PTO 8 and 14 GY/PU and GY/BK
Direct injector MAG 5 and 15 BL/BW and BL/PK
AMP no. 4 1 - 1.6 ohms
Direct injector PTO 6 and 21 GY/BW and GY/PK
1 and engine ground PU/BW 5V
TPS 2 and engine ground BK/BW 0 - 0.5 V
Throttle position 3 and engine ground PU/BW 4.75 - 5 V
sensor MAG
(TPS) 10 and 14 PU/BW and BK/BW 1600 - 2400 ohms
AMP no. 3 5 and 14 WH/BW and BK/BW 2500 ohms at idle
5 and 10 WH/BW and PU/BW 1200 ohms at idle
1 and engine ground PU/RD 5V
TPS 2 and engine ground BK/RD 0 - 0.5 V
Throttle position 3 and engine ground WH/RD 0V
sensor PTO
(TPS) 3 and 18 BK/RD and PU/RD 1600 - 2400 ohms
AMP no. 4 1 and 3 WH/RD and BK/RD 1000 ohms at idle
1 and 18 WH/RD and BK/RD 2500 ohms at idle
0 V (with a small mV
Pin 4 and ground BK
CPS tolerance)
(Deutsche
Pin 5 and ground GY/RD 12 V
connector)
Pin 6 and ground GY/YL 5V
Crankshaft position
sensor Pin 7 and
GY/YL
(CPS) pin 6 of CPS
Pin 6 and
AMP no. 2 GY/RD 0 ohm (continuity)
pin 5 of CPS
Pin 14 and
BK
pin 4 of CPS
Manifold air
temperature sensor AMP no. 4 16 and 19 WH/GY and BK/WH 2280 - 2740 ohms
(MATS)
Water temperature
AMP no. 4 9 and 11 TA/OR and BK/OR 2280 - 2740 ohms
sensor (WTS)
Pin 3 and
PU/BL
pin 1 of MAPS
Manifold air
Pin 6 and
pressure sensor AMP no. 3 WH/BL 0 ohm (continuity)
pin 3 of MAPS
(MAPS)
Pin 7 and
BK/BL
pin 2 of MAPS
Exhaust gas
AMP no. 4 10 and 12 TA/GY and BK/TA 2280 - 2740 ohms
temperature (EGT)
SMR2002-075 _06-03A.FM 06-03-37

TERMINAL
NUMBER
Knock sensor (KS) AMP no. 4 2 and 17 BK/BL and YL/BL 5 M ohms
Rave solenoid (RS) AMP no. 4 20 and 23 PU/GY and BK/GY 24 ohms
.45 - .55 ohms
AMP no. 3 21 and 22 RE/GN and WH/GN
primary winding
Ignition coil MAG 6800 - 10200 ohms
Coil terminal C
and coil post
high tension leads
.45 - .55 ohms
AMP no. 3 20 and 23 RE/BL and WH/BL
primary winding
Ignition coil PTO 6800 - 10200 ohms
Coil terminal C
and coil post
high tension leads
GTX DI models PTO — White tape 4900 ohms lead alone
06-03-38 SMR2002-075 _06-03A.FM

GENERAL
Here is the basic order suggested to diagnose a suspected fuel injection related problem:
– Check the chart in TROUBLESHOOTING section to have an overview of problems and suggested
solutions.
– Check if there is a MAINT signal reported by the vehicle information center. If so, use the VCK (Vehicle
Communication Kit) and look for fault codes to diagnose the trouble.
– Check all fuses.
– Check air/fuel rail pressure.
– Check RAVE valves if stuck.
– Check air compressor pressure.
DESS SYSTEM
It is self-activated when the safety lanyard cap is being installed on the watercraft post. It gives immediate
monitoring. Some codes may occur only when pressing the start/stop button. Refer to the following chart.
SIGNAL CAUSE REMEDY
2 short beeps • Safety lanyard is recognized • Ignition is authorized, engine can be started normally.
(while installing safety by the MPEM.
lanyard on watercraft • Good contact between safety
post) lanyard cap and DESS post.
1 long beep • Bad connection between safe- • Remove and replace the safety lanyard on the post
(while installing safety ty lanyard cap and post. until 2 short beeps are heard to indicate the system
lanyard on watercraft is ready to allow engine starting.
post or when pressing
start/stop button) • Unprogrammed or defective • Use the safety lanyard that has been programmed for
safety lanyard. the watercraft. If it does not work, check safety lan-
yard condition with the programmer. Replace safety
lanyard if reported defective. If it still does not work,
enable advanced diagnostic mode to obtain more de-
tails about the failure.
• Salt water or dirt in safety • Clean safety lanyard cap to remove dirt or salt water.
lanyard cap.
• Improper operation of MPEM • Enable advanced diagnostic mode to obtain more de-
or defective wiring harness. tail about the failure.

(memory).
Other beeps • Refer to COMPONENT FAILURE WARNING SYSTEM

below.
SMR2002-076 _06-04A.FM 06-04-1


1. Remove safety lanyard cap from watercraft post.
3. Install safety lanyard on watercraft post.
SIGNAL CAUSE REMEDY
1 long and • No safety lanyard has ever been pro- • Use MPEM programmer or the VCK
1 short beeps grammed in watercraft MPEM. 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.
2 short beeps • MPEM can not read the digital code of • Check safety lanyard cap condition
the safety lanyard cap or the magnet is with the MPEM programmer or the
defective. VCK. Replace safety lanyard if report-
ed defective.
• Mixed wires at safety lanyard post • Check post wiring harness.

2 long beeps • Wrong safety lanyard or bad connec- • Use the safety lanyard that has been
tion of the DESS wires. programmed for the watercraft. If the
problem is not resolved, check safety
programmer or the VCK. Replace safe-
ty lanyard if reported defective.
3 short beeps • Wiring harness of DESS post is ground- • Check wiring harness and safety lan-
ed or there is a short circuit. yard post.
If you need to listen again to the coded beeps, remove safety lanyard and repeat the procedure to activate
06-04-2 SMR2002-076 _06-04A.FM

FAULT DETECTION AND COMPENSATORY ACTIONS

For a basic overview of the monitoring system and the limp home modes, see OVERVIEW section.
COMPONENT FAILURE WARNING SYSTEM

Sensor Failures
Refers to open or short circuit failures on sensors, drivers, injectors or ignition.
CODE ➀
Manifold air
pressure sensor “MAINT” ON OFF 6 Limited RPM
(MAPS)
Manifold air
temperature sensor “MAINT” ON OFF 6 Limited RPM
(MATS)
Limited RPM
Throttle position
“MAINT” ON ON 4 (idle speed if both
sensor (single TPS)
TPS’s fail)
Limited RPM
Water temperature
“MAINT” ON OFF/(ON) 6/(4) (code 4 if EGT also
sensor (WTS)
fails)
Direct injector
(single injector)
Fuel injector
(single injector)
Ignition
(no firing on one “MAINT” ON OFF 6 Limited RPM
cylinder)
RAVE solenoid “MAINT” ON OFF 6 Limited RPM
Starter solenoid “MAINT” ON OFF 6 Engine may not start.
Fuel pump “MAINT” ON OFF 6 Limited RPM
Exhaust gas Limited RPM
temperature sensor “MAINT” ON OFF/(ON) 6/(4) (code 4 if WTS
(EGT) also fails)
Fuel level sensor “MAINT” ON OFF 6 None
Diagnostic cap fault “MAINT” ON OFF 6 None
Knock sensor “MAINT” ON OFF 6 Limited RPM
Engine drowned
Engine will not run.
mode activated None None ON 2
Release throttle.
(it is not a fault)
SMR2002-076 _06-04A.FM 06-04-3

System Failures
Refers to operating conditions outside normal and/or safe ranges such as demand system failures, ex-
treme voltages, over temperature conditions or low fuel/oil levels.
CODE ➀
Manifold air pressure
sensor (MAPS),
ATM fault (bad “MAINT” ON OFF 6 Limited RPM
atmospheric
pressure reading)
Throttle position
“MAINT” ON ON 3 Limited RPM
sensor (single TPS)
Throttle position
“MAINT” ON ON 4 Idle RPM
sensor (dual TPS)
Throttle position
sensor None OFF OFF 6 None
(single adaption fault)
Throttle position
sensor “MAINT” ON OFF 6 Limited RPM
(dual adaption fault)
Limited RPM
Sensor supply fault
“MAINT” ON ON/OFF 4/(6) (code 6 and idle RPM
(TPS and MAPS)
if both in fault)
Encoder (CPS) fault
(bad pattern)
Low battery
“12 V LOW” ON OFF 6 None
voltage
Very low battery “12 V LOW”
ON ON 4 Limited RPM
voltage “MAINT”
High battery
“MAINT” ON OFF 6 None
voltage
Very high battery
“MAINT” ON OFF 6 Idle RPM
voltage
High water
temperature
Exhaust
over temperature
Low oil level “OIL-LOW” ON ON 5 None
Low fuel level “FUEL-LO” ON ON 4 None
Setup fault
(TDC or TPS not set “MAINT” ON OFF 6 Idle RPM
on a new MPEM)
MPEM fault “MAINT” ON OFF 6 Engine will not start.
➀ To see how the normal operation is recovered from the limp home mode, see the DI FAULT CODES
chart elsewhere in this section. Look in column “Normal operation resumes if fault removed and...”.
06-04-4 SMR2002-076 _06-04A.FM

Buzzer Code
BUZZER BUZZER PATTERN NOTE

CODE
ON
6 OFF Always OFF
2 SEC. 15 MIN.
5 ON
2 second beep every 15 minutes
OFF
2 SEC. 58 SEC.
4 ON
2 second beep every 58 seconds
OFF
2 SEC. 2 SEC.
3 ON 2 second beep every 2 seconds

OFF
1 SEC. 1 SEC.
2 ON 1 second beep every second
OFF
1 ON Always ON (continuously beep)

OFF
F12H13S
VCK  WARNING
(vehicle communication kit) If the computer you are using is connected to
The VCK (Vehicle Communication Kit) (P/N 529 the 110 Vac power outlet, there is a potential
035 844) is the primary tool to diagnose fuel injec- risk of electrocution when working in contact
tion related problems. with water. Be careful not to touch water
B.U.D.S. is designed for the DI model to allow sen-
sor inspection, diagnostic options and adjustment IMPORTANT: When using the software B.U.D.S.,
such as the Throttle Position Sensor (TPS) and the with the DI engines, ensure that the protocol “947
TDC setting. DI” is properly selected in “MPI” under “Choose
For more information pertaining to the use of the protocol”.
software B.U.D.S., use its help which contains de- Refer to the tables below for the fault codes you
tailed information on its functions. will find in the B.U.D.S.
SMR2002-076 _06-04A.FM 06-04-5

DI SYSTEM FAULT CODES – Electrical noise might also lead engine to occa-
General when engine is restarted. When looking at the
The faults registered in the MPEM are kept when the software B.U.D.S. A value between 1 and 9
the battery is disconnected. confirms an electrical noise problem. A value of
Be aware that a red light blinking with the MAINT 10 and above will generate a fault code.
message may not be for a fault code. It may be a – When installing a new MPEM. It is not properly
maintenance inspection reminder. Press and hold programmed from the factory. The MPEM must
the SET button of the information center for 2 sec- be returned to be properly “activated”.
onds. If the blinking continues, it is a fault code.
Use the VCK (Vehicle Communication Kit) to see – If everything is in good condition, replace the
it. Otherwise, it was a maintenance reminder. MPEM.
IMPORTANT: After a problem has been solved, When using the service action suggested in the Fault
ensure to clear the fault(s) in the MPEM using the section of B.U.D.S., the system circuits are referred
VCK. This will properly reset the appropriate as 4-23 for instance. It means AMP connector no. 4
counter(s). This will also records that the problem and the circuit wire no. 23 as found in the wiring dia-
has been fixed in the MPEM memory. gram.
Many fault codes at the same time is likely to be TPS (Throttle Position Sensor) Faults
burnt fuse(s). Faults which are reported in B.U.D.S. fall into two
For more information pertaining to the code faults groups TPS faults and adaption faults. These are
(state, count, first etc.) and report, refer to B.U.D.S. displayed on the B.U.D.S. system as TPS OUT OF
online help. RANGE and TPS ADAPTION FAILURE.

Specific Faults
ECU fault code P0606: This code may occur in
the following situations:
– Electrical noise is picked up by the MPEM. Ensure
that all connections are in good condition, also
grounds (battery, MPEM, engine and ignition sys-
tem), they are clean and well tightened and that all
electronic components are genuine — particularly
in the ignition system. Installing resistive caps,
non-resistive spark plug cables (or modified
length), non-resistive spark plugs or knock sensor
wiring/routing may lead to generate this fault code.
06-04-6 SMR2002-076 _06-04A.FM



Check if wrong connector is connected to TPS. Yes • Fix.
Check if sensor is loose. Yes • Fix and reset closed TPS.
Inspect sensor for damage or corrosion. Yes • Replace and reset closed TPS.
Inspect wiring (voltage test). Failed • Repair.

Inspect wiring and sensor (resistance test). Failed
• If bad TPS, replace and reset closed TPS.
Test sensor operation (wear test). Failed • Replace and reset closed TPS.


position not reset.

closed position not reset.
MPEM has been replaced and TPS closed

position not reset.
Throttle cable too tight. Yes • Fix and reset closed TPS.
Sensor is loose. Yes • Fix and reset closed TPS.
Throttle bracket is loose. Yes • Fix and reset closed TPS.

Idle screw or synchronization screw worn
Yes • Fix and reset closed TPS.
or loose.
SMR2002-076 _06-04A.FM 06-04-7

DI System Fault Code Chart
NORMAL OPERATION
RESUMES IF FAULT
FAULT DETECTED
FAULT DETECTED
SENSOR/CIRCUIT
REMOVED AND...
WHILE ENGINE
WHILE ENGINE
ECU INTERNAL
NOT RUNNING
COMPONENT/
FAULT CODE
DIAGNOSED
DETECTED
RUNNING
SERVICE ACTION
NAME
FAULT
AND
POSSIBLE CAUSES
Service action:
Direct Open or and 4-5. Check for + 12 volts on pin A of injector connector (color).
P1100 injector AIR_INJ_1 short Yes No Return to
Service action:
Direct Open or Return to and 4-6. Check for + 12 volts on pin A of injector connector (color).
P1101 injector PTO AIR_INJ_2 short Yes No idle
circuit Possible causes:
Service action:
Check for 1.7 - 1.9 ohm resistance between system circuits 4-13
Open or and 4-7. Check for + 12 volts on pin A of injector connector (color).
Service action:
Check for 1.7 - 1.9 ohm resistance between 4-14 and 4-8. Check
Open or for + 12 volts on pin A of injector connector (color).
PTO circuit idle Possible causes:
Ignition coil, short Check for .45 - .55 ohm resistance between system circuits 3-21
primary circuit on Return to and 3-22. Check for + 12 volts on pin A of coil connector (color).
P0351 winding IGN_CYL_1 ignition Yes No idle Possible causes:
MAG primary Damaged coil, damaged circuit wires, damaged connector, dam-
short Check for .45 - .55 ohm resistance between system circuits 3-20
Ignition coil, and 3-23. Check for + 12 volts on pin A of coil connector (color).
P0352 primary IGN_CYL_2 circuit on Yes No Return to
winding PTO ignition idle Possible causes:
primary Damaged coil, damaged circuit wires, damaged connector, dam-
Service action:
Check for 12 volts on pin 5 and 5 volts on 6 and 0 volts on pin 4 of
Wrong encoder harness connector. Check system circuits 2-6, 2-7, 2-14.
P0335 Encoder Encoder pattern Yes No Return to
(CPS) idle Possible causes:
sensed Damaged sensor, damaged circuit wires, damaged connector,
damaged ECU pins. ECU failure. Damaged tooth wheel. Check
correct rectifier regulator operation.
06-04-8 SMR2002-076 _06-04A.FM

NORMAL OPERATION
RESUMES IF FAULT
FAULT DETECTED
FAULT DETECTED
SENSOR/CIRCUIT
REMOVED AND...
WHILE ENGINE
WHILE ENGINE
ECU INTERNAL
NOT RUNNING
COMPONENT/
FAULT CODE
DIAGNOSED
DETECTED
RUNNING
SERVICE ACTION
NAME
FAULT
AND
POSSIBLE CAUSES
Service action:
Check for 5 volts on pin 1 and 0-0.5 volts on pin 3 and 0 volts on
pin 2. Check system circuits 4-1, 4-2, 4-18. Check with throttle
closed the resistance between 1 and 2 is 2000 ohms and between
2 and 3 is 1000 ohms and between 1 and 3 2500 ohms. Check for
Sensor out Return to linear resistance rise when opening throttles. Check physical stops
P0120 TPS, PTO TPI_1 of range Yes No idle for wear.
Possible causes:
Service action:
Check for 5 volts on pin 1 and 4.75-5.0 volts on 3 and 0volts on pin
2. Check system circuits 3-5, 3-10, 3-14. Check with throttle closed
the resistance between 1 and 2 is 2500 ohms and between 2 and
3 is 2500 ohms and between 1 and 3 1200 ohms. Check for linear
P0220 TPS, MAG TPI_2 Sensor out Yes No Return to resistance rise when opening throttles. Check physical stops for
of range idle wear.
Possible causes:
Service action:
Throttle Check cable adjustment. Check Idle stop for wear check throttle
Full reset. angles at idle.
P1102 TPS, PTO TPI_1_ADAP position Yes No Key off
adaption and on Possible causes:
failure No initialisation after throttle body or ECU changes throttle idle
stop drifted.
Service action:
Throttle Check cable adjustment. Check Idle stop for wear. Check throttle
position Full reset. angles at idle.
P1103 TPS, MAG TPI_2_ADAP adaption Yes No Key off
and on Possible causes:
failure No initialisation after throttle body or ECU changes throttle idle.
Stop drifted.
Service action:
P0116 WTS COOL_SENS of range Yes No idle
Possible causes:
Service action:
Check for debris or blockage in cooling system. Check for resis-
Overheat As soon as tance approx. 2280 ohms to 2736 ohms at temperature of 19 to
P0217 WTS COOL_RED warning Yes No fault is not 21°C (66 to 70°F) between system circuits 4-9 and 4-11.
present
Possible causes:
Engine overheated, damaged sensor.
Service action:
P0110 MATS MCT_SENS of range Yes No idle
Possible causes:
SMR2002-076 _06-04A.FM 06-04-9

NORMAL OPERATION
RESUMES IF FAULT
FAULT DETECTED
FAULT DETECTED
SENSOR/CIRCUIT
REMOVED AND...
WHILE ENGINE
WHILE ENGINE
ECU INTERNAL
NOT RUNNING
COMPONENT/
FAULT CODE
DIAGNOSED
DETECTED
RUNNING
NAME SERVICE ACTION
FAULT
AND
POSSIBLE CAUSES
Service action:
volts on pin 1 and 0 volts on pin 3 and 0 volts on pin 2. Check
Sensor out Return to Sensor housing is correctly inserted into manifold.
P0106 MAPS MAP Yes No
of range idle Possible causes:
Check sensing port for dirt or blockage. Sensor failure, unexpect-
ed reading at idle. Sensor fallen out of housing. Leaking Inlet
system, ECU failure.
Service action:
Bad Full reset. volts on pin 1 and 0 volts on pin 3 and 0 volts on pin 2.
P0105 MAPS MAP_ATM atmospheric Yes No Key off Possible causes:
reading and on Check sensing port for dirt or blockage, damaged sensor, dam-
aged circuit wires, damaged connector, damaged ECU pins. ECU
failure.
Service action:
P1400 EGT EXH_SENS of range Yes No idle
Possible causes:
Service action:
Check for debris or blockage in cooling system. Check tune pipe
Overheat As soon as injection valve.
P1401 EGT EXH_RED warning Yes No fault is not
present Possible causes:
Exhaust system overheated, damaged sensor damaged circuit
wires.
Service action:
As soon as TBD.
Fuel level Sensor out
P0460 sensor FUEL_SENS of range Yes No fault is not Possible causes:
present Damaged sensor, damaged circuit wires, damaged connector,
Service action:
Check for resistance of 6-8 ohms between system circuits 4-24
Open or Yes, Yes, Return to and 4-26.
P0230 Fuel pump FUEL_PUMP short short open idle
circuit circuit circuit Possible causes:
Damaged pump, damaged circuit wires, damaged connector,
Service action:
Yes, Check for resistance of 30 ohms between system circuits 4-23
Open or open Yes, and 4-20.
P0475 RAVE RAVE short and open Return to
solenoid circuit short circuit idle Possible causes:
circuit Damaged solenoid, damaged circuit wires, damaged connector,
Service action:
Starting Yes, Check for resistance of 6ohms between system circuits 3-19 and
system Open or open Yes, As soon as 3-15.
P1300 solenoid CRANK short and open fault is not
circuit short circuit present Possible causes:
(winding) Damaged solenoid, damaged circuit wires, damaged connector,
circuit
Battery Battery As soon as Possible causes:
P0563 voltage BV_HI_WARN voltage Yes Yes fault is not Battery failure, rectifier failure, battery terminal connection.
high present
06-04-10 SMR2002-076 _06-04A.FM
NORMAL OPERATION
RESUMES IF FAULT
FAULT DETECTED
FAULT DETECTED
SENSOR/CIRCUIT
REMOVED AND...
WHILE ENGINE
WHILE ENGINE
ECU INTERNAL
NOT RUNNING
COMPONENT/
FAULT CODE
DIAGNOSED
DETECTED
RUNNING
SERVICE ACTION
NAME
FAULT
AND
POSSIBLE CAUSES
Battery Battery Full reset. Possible causes:

P1500 voltage BV_HI_RED voltage Yes Yes Key off and Battery failure, rectifier failure, battery terminal connection.
very high on
Service action:
Check fuse.
Battery As soon as Check system circuits 3-25 to battery + terminal, 2-26 to regulator
P0562 Battery BV_LO_WARN voltage Yes Yes fault is not 2 pin connector pin A, 2-25 to regulator 2 pin connector pin B.
voltage low present Possible causes:
Service action:
Check fuse, check system circuits 3-25 to battery + terminal, 2-26
Battery to regulator 2 pin connector pin A, 2-25 to regulator 2 pin connec-
Battery Return to tor pin B.
P1501 voltage BV_LO_RED voltage Yes Yes idle
very low Possible causes:
Service action:
Sensor Sensor Check for shorts to ground or corrosion on the following system
supply (TPS, 5 volt Return to circuits 3-10 or 3-3.
P0122 MAG and XDRP_1 supply Yes Yes idle Possible causes:
MAPS) failure Damaged circuit wires, associated sensor failure (TPI 2 or MAP),
ECU fault.
Service action:
Sensor Check for shorts to ground or corrosion on system circuit 4-18.
Sensor 5 volt Return to
P0222 supply (TPS, XDRP_2 supply Yes Yes idle Possible causes:
PTO) failure Damaged circuit wires, associated sensor failure (TPI 1), ECU
fault.
Service action:
TDC and Reinitialise Initialize ECU.
P1600 ECU SETUP ECU not Yes Yes from
initialised B.U.D.S. Possible causes:
ECU not initialised, TDC not setup, throttle sensors not initalised.
Service action:
Internal Full reset. Check ignition leads, coils and correct spark plugs, replace ECU.
P0606 ECU ECU_FAULT ECU faults Yes Yes Key off Possible causes:
and on Incorrect software, ignition noise causing errors, internal EE-
PROM failure.
Service action:
Bring engine to 4500 RPM. If fault code appears, check for resis-
Knock Knock Yes, Return to tance approx. 4.8 ohms between system circuits 4-2 and 4-17.
P0325 sensor KNOCK_SENS sensor over No idle
failure 4500 Possible causes:
Diagnostic Service action:
Diagnostic cap is not As soon as Reinstall cap on wiring harness.
P1601 cap COMMS_CAP installed Yes Yes fault is not
on wiring present Possible causes:
harness Cap is not installed on wiring harness.
SMR2002-076 _06-04A.FM 06-04-11

Section 07 ENGINE MANAGEMENT (4-TEC)
TABLE OF CONTENTS 0
OVERVIEW............................................................................................................................. 07-02-1
COMPLETE ELECTRICAL SYSTEM OVERVIEW .............................................................. 07-02-2
MAGNETO SYSTEM AND POWER SUPPLY ................................................................... 07-02-3
OPERATING PRINCIPLE OF ENGINE MANAGEMENT ................................................... 07-02-3
AIR INDUCTION................................................................................................................. 07-02-4
BASIC OPERATION ........................................................................................................... 07-02-4
INTAKE MANIFOLD........................................................................................................... 07-02-4
FUEL PUMP MODULE....................................................................................................... 07-02-5
EMS (engine management system) ................................................................................ 07-02-5
EMS — GENERAL FUNCTIONS ....................................................................................... 07-02-6
EMS — ENGINE MANAGEMENT FUNCTIONS............................................................... 07-02-8
MPEM - MULTI-PURPOSE ELECTRONIC MODULE ........................................................ 07-02-11

GENERAL ........................................................................................................................... 07-03-1
FUEL SYSTEM ................................................................................................................... 07-03-1
ENGINE CONNECTOR PIN-OUT ...................................................................................... 07-03-3
CONNECTORS ON ENGINE ............................................................................................. 07-03-4
THROTTLE BODY .............................................................................................................. 07-03-5
FUEL DELIVERY................................................................................................................. 07-03-8
FUEL PUMP ....................................................................................................................... 07-03-9
FUEL RAIL .......................................................................................................................... 07-03-11
FUEL INJECTOR ................................................................................................................ 07-03-11
EMS ECU AND MPEM REPLACEMENT ........................................................................... 07-03-13
ENGINE WIRING HARNESS ............................................................................................. 07-03-14
IDLE BYPASS VALVE ........................................................................................................ 07-03-18
CAMSHAFT POSITION SENSOR (CAPS) ......................................................................... 07-03-20
COOLANT TEMPERATURE SENSOR (CTS)..................................................................... 07-03-22
KNOCK SENSOR (KS) ....................................................................................................... 07-03-24
OIL PRESSURE SWITCH (OPS) ........................................................................................ 07-03-25
OIL SEPARATOR PRESSURE SWITCH (OSPS) ............................................................... 07-03-25
TOPS VALVE (BLOW-BY) .................................................................................................. 07-03-27
SMR2002-095_07-01ATOC.FM 07-01-1
IGNITION COILS................................................................................................................. 07-03-29

TDC SETTING (TOP DEAD CENTER)................................................................................. 07-03-30
ENGINE START/STOP SWITCH VERIFICATION ............................................................... 07-03-30
SAFETY LANYARD SWITCH VERIFICATION.................................................................... 07-03-30
SPARK PLUGS.................................................................................................................... 07-03-31
CRANKING SYSTEM.......................................................................................................... 07-03-31

GENERAL............................................................................................................................ 07-04-1
SELF-DIAGNOSTIC MODE ................................................................................................ 07-04-3
VCK (vehicle communication kit) ..................................................................................... 07-04-4
4-TEC SYSTEM FAULT CODES......................................................................................... 07-04-4
07-01-2 SMR2002-095_07-01ATOC.FM
OVERVIEW 0
ENGINE MANAGEMENT SYSTEM OVERVIEW
ROTAX 4-TEC 1503
Cyl. 1 Cyl. 2 Cyl. 3
Con. B
MAGNETO Con. A
KS MAPS
CPS MATS
OPS TPS
CTS
CAPS EMS IDLE BYPASS VALVE
INJECTOR 1, 2, 3 ECU TOPS SWITCH

TOPS VALVE
OSPS
IGNITION COIL 1, 2, 3
EGT
MUFFLER
BATTERY ENGINE POWER SUPPLY
REGULATOR/
MPEM
RECTIFIER EMS ECU Engine Management System
Electronic Control Unit
MPEM Multi-Purpose Electronic Module
KS Knock Sensor
CPS Cranshaft Position Sensor
OSPS Oil Separator Pressure Sensor
CTS Coolant Temperature Sensor
CAPS Camshaft Position Sensor
EGT Exhaust Gas Temperature
MAPS Manifold Air Pressure Sensor
MATS Manifold Air Temperature Sensor
TOPS Tip-Over Protection System
Con. A Connector for Engine Wiring Harness
R1503motr212S Con. B Connector for MPEM Connection
SMR2002-077_07-02A.FM 07-02-1
COMPLETE ELECTRICAL SYSTEM OVERVIEW
- COMPASS
WH/RE INFORMATION - OUTSIDE AIR
WH/BK CENTER TEMPERATURE
SENSOR
COMMUNICATION LINK
COMMUNICATION
LINK
- TPS - POWER TO
WH/BK
- MAPS EMS ECU MPEM EMS ECU
WH/RE
- MATS - INFORMATION
- CTS CENTER
- EGT - SET AND MODE
- KS SWITCHES
- OPS - SPEED SENSOR
- OSPS - FUEL LEVEL
- CPS SENDER
- DESS - BEEPER
- IDLE
BYPASS
VALVE COMMUNICATION LINK
- START/STOP WH/BK VCK

SWITCH WH/RE (COMMUNICATION
- STARTING PORT)
SOLENOID
- FUEL PUMP
- FUEL INJECTORS
- IGNITION COILS
- TOPS VALVE
- TOPS SWITCH
- CAPS
EMS
COLOUR CODE
These components are shared between the MPEM and the WH = WHITE
EMS ECU. The MPEM supplies the power while the EMS ECU BK = BLACK
F18L2WS controls and completes the circuit by switching it to the ground. RE = RED
07-02-2 SMR2002-077_07-02A.FM
The complete electrical system is managed by OPERATING PRINCIPLE OF

micro-controllers working together. Overall, the
MPEM (multi-purpose electronic module) manag-
ENGINE MANAGEMENT
es the vehicle electrical system, the EMS (engine A highly advanced engine management system
management system) controls the engine man- (EMS) has been used to ensure a high power out-
agement and the information center is used to dis- put with cleanest combustion. The EMS calcu-
play information that comes both from MPEM and lates the proper air/fuel mixture and ignition timing
EMS. for each cylinder separately. The fuel is injected
A communication link is used between the elec- into the intake port of each cylinder.
tronic modules to communicate each other. It con- NOTE: On the 1503, PTO and magneto (MAG) are
sists of a twisted pair of wires (WHITE/RED and on the same engine side (rear). Each cylinder is
WHITE/BLACK). referenced as 1, 2 and 3 instead of PTO, CENTRE
For communication link troubleshooting, refer to and MAG. The numbers are stamped on the valve
INSTRUMENTS AND ACCESSORIES in ELECTRI- cover.
CAL section.
1 2 3
The communication link is also used to communi-
cate informative messages, monitoring and diag-
nostic codes to the information center and to the
VCK (vehicle communication kit) where B.U.D.S.
(Bombardier utility and diagnostic system) is used
for diagnosing and troubleshooting the system.
The fault code can be seen from either the infor-
mation center or B.U.D.S. Refer to DIAGNOSTIC
PROCEDURES section.
MAGNETO SYSTEM AND

POWER SUPPLY
The magneto is the primary source of electrical
R1503motr218A
energy. It transforms magnetic field into electric
current (AC). 1. Cylinder 1
2. Cylinder 2
The magneto has a 3 phases, delta wound stator 3. Cylinder 3
NOTE: “EMS” stands for engine management
It supplies DC current to battery after being trans- system. “EMS” includes an ECU (electronic control
formed by the voltage regulator/rectifier. Refer to unit), sensors, injectors, electromagnetic valves
CHARGING SYSTEM. and ignition system.
The battery then supplies all the electrical system
with regulated 12 Vdc.
SMR2002-077_07-02A.FM 07-02-3
AIR INDUCTION INTAKE MANIFOLD

Air for combustion is drawn directly at the front of
3 2
the engine through one 52 mm throttle body. The 5
air flow is controlled by a throttle plate and an idle
bypass valve respectively. The air continues
1
through the intake manifold, which contains the
flame arrester and goes into the cylinder head.
2
R1503motr214B
6 7 4
INTAKE MANIFOLD
1. Electronic Control Unit (EMS ECU)
2. Fuel rail
3. Injector
4. Throttle body
5. Ignition coil
R1503motr216A 1 6. Manifold air pressure sensor (MAPS)
52 mm THROTTLE BODY
1. Idle bypass valve The intake manifold is mounted on the engine block
2. Throttle position sensor (TPS) on the vehicle starboard side. It provides support
for the fuel injectors, the fuel rail, the EMS ECU, the
FUEL DELIVERY SYSTEM flame arrester and the throttle body. The air intake
manifold is a resonator between the throttle body
BASIC OPERATION and the air intake at the cylinder head with the
When the intake valve reaches the correct posi- flame arrester.
tion, the EMS ECU (Electronic Control Unit) opens
the fuel injector and fuel is discharged into the in- Fuel Rail
take port at the air intake manifold by the high fuel The fuel rail is a small tube on which the three
pressure inside the fuel rail. The air/fuel mixture injectors are mounted. It ensures all the time, that
enters then the combustion chamber through the enough fuel at the right pressure can be delivered
open intake valve. This mixture is then ignited by to the fuel injectors. The fuel rail is fed by the fuel
the spark plug. pump with a fuel pressure of approximately
303 kPa (44 PSI).
Fuel Injector
Three fuel injectors (one per cylinder) are used to
inject fuel into the intake port of the cylinder head.
Flame Arrester
The flame arrester is a tube inside the air intake
manifold. It prevents flames leaving through the
intake system if the engine backfires.
07-02-4 SMR2002-077_07-02A.FM
Throttle Body ELECTRONIC MANAGEMENT

It is a 52 mm throttle body mounted on intake
manifold. Fitted on the throttle body, there is the EMS
TPS and the idle bypass valve which allows the (engine management system)
EMS ECU to control the RPM while the throttle The engine management system is controlled by
plate is closed. the EMS ECU.
FUEL PUMP MODULE 1
R1503motr215A
1. EMS ECU
EMS ECU
The EMS ECU is mounted on the intake manifold.
It controls all engine management functions, by
R1503motr217A processing the information given by various sen-
sors.
The fuel pump module is located inside the fuel
tank. The module includes fuel pump, fuel pres-
sure regulator and fuel level sensor.
1
Fuel Pump
It provides fuel pressure and flow rate to the system.

A fuel pressure regulator controls the pressure in
the system and allows the excess of fuel to return
to the fuel tank. The fuel pressure regulator regu-
lates the fuel pressure at approximately 303 kPa
(44 PSI).
R1503motr214A
Fuel Filter
1. EMS ECU on intake manifold
pump module inside the fuel tank.
SMR2002-077_07-02A.FM 07-02-5
EMS — GENERAL FUNCTIONS

Safety Lanyard Reminder
If engine is not started within 5 seconds after in-
stalling the safety lanyard on its post, 2 very short
beeps every 3 second interval will sound for ap-
proximately 4 hours to remind you to start the en-
gine or to remove safety lanyard. Afterwards, the
beeps will stop. The same will occur when safety
lanyard is left on its post 5 seconds after engine is
stopped.
CAUTION: Leaving the safety lanyard on its
post when engine is not running will slowly dis-
charge battery.
Antistart Feature
R1503motr219A safety lanyard(s) that has been programmed to op-
The EMS ECU gets its power by the MPEM which DESS system. See below for details.
is directly powered by the battery. It is responsible
for the following engine management/electrical Digitally Encoded Security System
functions:
(DESS)
– interpreting information
– distributing information for this system: Multi-Purpose Electronic Module
– start/stop function (MPEM), EMS ECU, safety lanyard cap and safety
lanyard post.
– timer
The safety lanyard cap contains a magnet and a
ROM chip. The magnet actually closes the reed
– ignition timing control switch inside the post which is the equivalent of a
– injection control mechanical ON/OFF switch. The chip has a unique
digital code.
– The EMS ECU applies the proper map (injection
and ignition) for optimum engine operation in all The DESS circuitry in the EMS ECU is activated at
conditions. the factory. Therefore, a safety lanyard must be
programmed to start the engine.
NOTE: Actually, it is the memory of the EMS ECU
– etc.
which is programmed to recognize the digital code
The EMS ECU features a permanent memory that of the safety lanyard cap. This is achieved with the
will keep the programmed safety lanyard(s) active, VCK (Vehicle Communication Kit) P/N 529 035
fault codes and other engine information, even 844. Refer to B.U.D.S. help system to program a
when the battery is removed from the watercraft. safety lanyard.
The system is quite flexible. Up to 8 safety lan-
yards may be programmed in the memory of the
watercraft MPEM. They can also be erased indi-
vidually.
07-02-6 SMR2002-077_07-02A.FM
The EMS ECU also offers a special safety lanyard Engine RPM Limiter
— the Sea-Doo LK™ (learning key) — which can
The EMS ECU will limit the maximum engine
be programmed so that the vehicle can be run only
speed.
at a limited speed — approximately 55 km/h
(35 MPH). Such feature is ideal for first time riders
or renters.
Engine Stopping
There are 2 ways to stop the engine.
 WARNING Press and hold start/stop switch or remove the
When programming a Sea-Doo LK™ (learning safety lanyard cap from its post.
key), use only a lanyard that is identified for If the engine is stopped by removing the safety lan-
that purpose. Otherwise, a customer could yard, it is possible to restart the engine as explained
use a vehicle with a greater speed than he was in the engine starting section.
expecting.
If safety lanyard cap is reconnected within 6 sec-
NOTE: If desired, a safety lanyard can be used on onds, the current supply to gauges is cut for a brief
other watercraft equipped with the DESS. It only moment and comes back on with the audible sig-
needs to be programmed for that watercraft. nal of safety lanyard validation.
When connecting a safety lanyard cap on the post, Low-Oil Pressure Warning Device
the DESS is activated and will emit audible signals:
When the oil pressure falls under a certain level,
– 2 short beeps indicate a working safety lanyard. the EMS ECU sends out a signals for the beeper
Engine starting can take place. and to the information center gauge. Additionally
– 1 long beep indicates a wrong safety lanyard is the engine goes in limp home mode.
being used or that something is defective. En-
gine starting is not allowed. High Coolant Temperature and EGT
The memory of the EMS ECU features a self- Warning Device
diagnostic mode for the DESS operation. Refer to When the coolant temperature or the exhaust gas
DIAGNOSTIC PROCEDURES section for more in- temperature is getting to high, the EMS ECU
formation. sends out signals to the beeper.
The memory of the EMS ECU is permanent. If the
battery is disconnected, no information is lost.
When ordering a new EMS ECU from the regular
Engine Starting
If the EMS ECU recognizes a valid safety lanyard,
it allows engine to start when the start/stop switch
is pressed.
If start/stop button is held after engine has started,
the EMS ECU automatically stops the starter
when the engine speed reaches 1600 RPM.
is depressed more than 65%, the engine will not
be allowed to start.
SMR2002-077_07-02A.FM 07-02-7
EMS — ENGINE MANAGEMENT FUNCTIONS
R1503motr220S
07-02-8 SMR2002-077_07-02A.FM
This engine management system controls both All three ignition coils are located on the cylinder
the fuel injection and the ignition timing. head directly on the spark plugs.
As shown in the 1503 4-TEC CONTROL SYSTEM
1
illustration, the EMS ECU is the central point of the
fuel injection system. It reads the inputs, makes
computations, uses pre-determined parameters
and sends the proper signals to the outputs for
proper engine management.
The EMS ECU also stores the fault codes and gen-
eral information such as: operating conditions, ve-
hicle hours, serial numbers, customer and mainte-
nance information.
Electronic Fuel Injection

The EMS ECU reads the signals from different sen-
sors which indicate engine operating conditions at R1503motr213A
milli-second intervals.
1. Ignition coils
Signals from sensors are used by the EMS ECU to
determine the injection parameters (fuel maps) re- Ignition Timing
quired for optimum air-fuel ratio. The EMS ECU is programmed with data (it con-
The CPS, the MATS, the MAPS and the TPS are tains ignition mappings) for optimum ignition tim-
the primary sensors used to control the injection ing under all operating conditions. Using engine
and ignition timing. Other sensors (like tempera- operating conditions provided by the sensors, the
ture sensors, etc.) are used for secondary input. EMS ECU controls the ignition timing for optimum
NOTE: The EGT, OPS and OSPS sensors does not engine operation.There is no mechanical adjust-
provide control inputs to the EMS ECU. Their sole ment to perform.
purpose is to protect the engine components by
emitting a warning signal and/or a fault code in the Knock Sensor
event of overheating or low oil pressure or TOPS A knock sensor is mounted on the engine block
valve fault. behind the air intake manifold. It detects specific
vibration that would be typically generated by en-
Ignition System gine detonation. If detonation occurs, the knock
The ignition system is a digital inductive type. The sensor detects it and the EMS ECU retards the
EMS ECU control the ignition system parameters, ignition advance temporarily (it goes in a specific
such as spark timing, duration and firing in order mode) until detonation stops. The EMS ECU is
to achieve the proper engine requirements. able to evaluate the knocking cylinder and modi-
fies the ignition advance just on the detonating
Ignition Coils one.
Three separate ignition coils induce voltage to a Engine Modes of Operation
high level in the secondary windings to produce a
spark at the spark plug. The EMS ECU controls different operation modes
of the engine to allow proper operation for all pos-
The ignition coils receive input from the EMS ECU. sible conditions: Cranking, start-up, idle, warm up,
Each coil provides high voltage to its correspond- part load, full load, Sea-Doo LK™ (learning key, lim-
ing spark plug. ited vehicle speed), engine speed limiter, drowned
This ignition system allows spark plugs to spark engine and limp home (see below).
independently.
NOTE: Ignition coil cables are not interchangeable
due to different lengths.
SMR2002-077_07-02A.FM 07-02-9
Flooded Engine (drowned mode) The following components failure will trigger a
limp home mode: CTS, EGT, OPS, OSPS and
If engine is fuel-flooded and does not start, this
TOPS.
special mode can be activated to prevent fuel in-
jection and ignition while cranking. Proceed as fol- When minor fault occurs, the fault and message/
lows to activate it. beeper will disappear automatically, if the condi-
tion does not exist anymore.
With safety lanyard on its post while engine is
stopped, press and HOLD throttle lever. Releasing throttle and letting the engine returning
at idle speed may allow normal operation to come
Press the start/stop button. The mode is now on.
back. If it does not work, try removing and rein-
Releasing throttle lever will bring back to its nor- stalling the safety lanyard on its post.
mal mode.
Depending on the malfunction, the watercraft
If engine does not start, it may be necessary to speed may be reduced and not allowed to reach
remove spark plugs and crank engine with rags its usual top speed. The engine speed will be lim-
over spark plug holes. Refer to COMPONENT IN- ited to 2500 or 5000 RPM.
SPECTION AND ADJUSTMENT subsection.
These performance-reduced modes allow the rid-
 WARNING er to go back home which would not be possible
When disconnecting coil from spark plug, al- NOSTIC PROCEDURES for a complete chart.
ways disconnect coil from main harness first.
operation, the engine management system will re-
open coil and/or spark plug in the engine
duce engine RPM gradually to the proper level.
compartment as spark may cause fuel vapor
to ignite.
Diagnostic Mode
If engine is water-flooded, refer to WATER The malfunctions are recorded in the memory of
FLOODED ENGINE in MAINTENANCE section. the EMS ECU. The memory of the EMS ECU can
be checked using the VCK (Vehicle Communica-
Limp Home Modes tion Kit) (P/N 529 035 844) to see the fault codes.
Besides the signals as seen above, the EMS ECU The EMS ECU and the VCK are able to communi-
may automatically set default parameters to the cate through a connector on the vehicle. Refer to
engine management to ensure the adequate op- the D IA GN OSTIC PR OCE DUR ES section.
eration of the watercraft if a component of the fuel B.U.D.S. Version 1.1 and up must be used for this
injection system is not operating properly. system.
07-02-10 SMR2002-077_07-02A.FM
MPEM - MULTI-PURPOSE ELECTRONIC MODULE

Power Distribution
The MPEM distributes power from battery to all accessories and the EMS ECU. Accessories are protected
by fuses integrated in the MPEM. Fuse ratings is identified besides their holder.
T.O.P.S.
Bilge pump (optional)
Spare Beeper diagnostic,
10A 3A connector
Cylinder 3 2A 5A
ignition coil and injection 10A 10A Spare fuse
1A 2A Electric starter,
10A 7.5A fuel pump
Information center 10A 5A
MPEM
Cylinder 2
ignition coil and injection VTS (optional)
Cylinder 1 EMS
ignition coil and injection start/stop circuit
F18H07S
IMPORTANT: Some components are continu- Monitoring System

ously powered with the supply from the battery
The EMS ECU monitors the electronic compo-
through MPEM. The EMS ECU switches the
nents of the fuel injection system and also the en-
ground to complete the electrical circuits it con-
gine components of the electrical system.The
trols. Take this into account when troubleshooting
MPEM monitors the vehicle electrical system and
the electrical system. Refer to the illustration at
the accessories. When a fault occurs, it sends vi-
the beginning of this section.
sual messages through the information center
and/or audible signals through a beeper to inform
Gauges Current Supply you of a particular condition. Refer to the DIAG-
The purpose of this function is to allow reading of NOSTIC PROCEDURES section for the displayed
gauges without the engine running. It will give ac- messages and the beeper coded signals chart.
cess to functions of the information center gauge
without starting the engine. Addition of Accessories
Gauges are supplied with current whenever the Every time an accessory is added such as an elec-
safety lanyard cap is installed on its post. tric bilge pump or a VTS for instance, it must be
NOTE: The fuel pump will be activated for 2 sec- “registered” using B.U.D.S. to activate it in the
onds to build up pressure in the fuel injection sys- MPEM. Otherwise, the accessory will not work.
tem, only when connecting the safety lanyard cap Use the Options area in the Setting tab in B.U.D.S.
to the post.
Low-Fuel Level Warning Device

When the fuel level in the reservoir is low, the fuel
level sensor transmits a signal to the MPEM. The
MPEM sends out signals for the beeper and to the
information center gauge.
SMR2002-077_07-02A.FM 07-02-11

ADJUSTMENT 0
GENERAL  WARNING
Engine problems are not necessarily related to the Fuel lines remain under pressure at all times.
electronic fuel injection system. Always proceed with care and use appropriate
It is important to ensure that the mechanical integ- safety equipment when working on pressurized
rity of the engine/propulsion system is present: fuel system. Wear safety glasses and work in a
– fuel pump connection and fuel lines without leaks. fuel line connections. Use the VCK (Vehicle
Communication Kit) to release fuel pressure
Check the chart in TROUBLESHOOTING section prior to removing a hose. Cover the fuel line
to have an overview of problems and suggested connection with an absorbent shop rag. Slowly
solutions. disconnect the fuel hose to minimize spilling.
When replacing a component, always check its Wipe off any fuel spillage in the bilge. Fuel is
operation after installation. flammable and explosive under certain condi-
Whenever watercraft is out of water and engine is tions. Always work in a well ventilated area. Al-
running, ensure to supply water through the con- ways disconnect battery prior to working on the
nector on jet pump support to cool down exhaust fuel system. After performing a pressure test,
system. use the valve on the fuel pressure gauge to re-
lease the pressure (if so equipped).
water to the exhaust cooling system when wa- – Always disconnect battery properly prior to
tercraft is out of water. working on the fuel system. Refer to BATTERY
section.
FUEL SYSTEM When the job is done, ensure that hoses from fuel
rail going to fuel pump are properly secured in their
 WARNING supports. Then, pressurize the fuel system. Per-
The fuel system of a fuel injection system holds form the high pressure test as explained in this
much more pressure than on a carbureted wa- section and pressurize the fuel tank and fuel lines
tercraft. Prior to disconnecting a hose or to reas explained in FUEL SYSTEM section.
moving a component from the fuel system, fol- Properly reconnect the battery.
low the recommendation described here. Pay
attention that some hoses may have more than
 WARNING
same quantity of clamps at assembly.
age and that NO fuel line is disconnected prior
– Use the VCK (Vehicle Communication Kit) (P/N 529 to installing the safety lanyard on the DESS
035 844) to release the fuel pressure in the sys- post. Always perform the high pressure test if
tem. Look in the Activation section of the soft- any component has been removed. A pressure
ware B.U.D.S. test must be done before connecting the safety
lanyard. The fuel pump is started each time the
safety lanyard is installed and it builds pressure
very quickly.
SMR2002-078 _07_03A.FM 07-03-1

To check fuel rail for leaks, first pressurize the sys- Pay particular attention to ensure that pins are not
tem then spray soapy water on all hose connec- out of their connectors or out of shape. The trou-
tions, regulators and injectors. Air bubbles will bleshooting procedures cover problems not re-
show the leaking area. Check also for leaking fuel sulting from one of these causes.
or fuel odor.
 WARNING
 WARNING Ensure all terminals are properly crimped on
Never use a hose pincher on high pressure wires and connector housings are properly
hoses. fastened.
Before replacing a MPEM or EMS ECU, always

ELECTRICAL SYSTEM check electrical connections. Make sure that they are
It is important to check that the electrical system very tight and they make good contact and that they
is functioning properly: are corrosion-free. Particularly check MPEM and
EMS ECU ground connections. Ensure that con-
– battery tacts are good and clean. A “defective module”
– fuses could possibly be repaired simply by unplugging
– DESS and replugging the MPEM or EMS ECU. The volt-
age and current might be too weak to go through
– ignition (spark) dirty wire pins. Check carefully if pins show signs
– ground connections of moisture, corrosion or if they look dull. Clean
– wiring connectors. pins properly and then coat them prior to assem-
bling as follows:
It is possible that a component seems to operate
in static condition but in fact, it is defective. In this AMP connectors, EMS ECU connectors, OPS
case, the best way to solve this problem is to re- and OSPS connectors: Apply a thin coat of DEOX-
move the original part and replace it with one IT contact lubricant (P/N 293 550 015)
which is in good condition. Other connectors: Apply a silicon-based dielectric
Never use a battery charger to substitute tempo- grease or other appropriate lubricant. If the newly
rarily the battery, as it may cause the MPEM/EMS replaced MPEM or EMS ECU is working, try the
ECU to work erratically or not to work at all. Check old one and recheck if it works.
related-circuit fuse solidity and condition with an Ensure that all electronic components are genuine
ohmmeter. Visual inspection could lead to false re- — any modification on the wiring harness may
sults. lead to generate fault codes or bad operation.
NOTE: For diagnostics purposes, use Vehicle
 WARNING Communication Kit (VCK). See DIAGNOSTIC
All electrical actuators (idle bypass valve, PROCEDURES subsection.
TOPS valve, injectors, fuel pump, ignition coils After a problem has been solved, ensure to clear
and starter solenoid) are permanently sup- the fault(s) in the EMS ECU using the VCK. Refer
plied by the battery when the safety lanyard is to DIAGNOSTIC PROCEDURES subsection.
installed. Always disconnect the battery prior
to disconnecting any electric or electronic
parts.
To perform verifications, a good quality multimeter

such as Fluke 111 (P/N 529 035 868) should be
used.
07-03-2 SMR2002-078 _07_03A.FM

Resistance Measurement NOTE: In case of overheating, EGT and CTS do

not generate codes. No message will be displayed
on the information center. The beeper will be acti-
vated and the EMS will be set in limp home mode.
usual resistor or windings (such as injectors) in- ENGINE CONNECTOR PIN-OUT
our temperature sensors are NTC types (Negative Connector Position
Temperature Coefficient) and work the opposite
which means that the resistance value decreases
as the temperature increases. Take it into account
when measuring at temperatures different from
20°C (69°F). Use this table for resistance variation
relative to temperature for temperature sensors.
TEMPERATURE RESISTANCE (ohms)
°C °F NOMINAL LOW HIGH
- 30 - 22 12600 11800 13400
- 20 -4 11400 11000 11800
- 10 14 9500 8000 11,000
0 32 5900 4900 6900
R1503motr166A 1 2
10 50 3800 3100 4500
1. EMS ECU connector A
20 68 2500 2200 2800 2. Engine connector
30 86 1700 1500 1900 EMS ECU Connector

40 104 1200 1080 1320
50 122 840 750 930 EMS ECU connector A of the wiring harness when
60 140 630 510 750 performing tests.
70 158 440 370 510
13 1
80 176 325 280 370
90 194 245 210 280
28
100 212 195 160 210 14
110 230 145 125 160
120 248 115 100 125
41 29
R1503motr176A

EMS ECU CONNECTOR PIN-OUT (WIRING HARNESS SIDE)
defective at other temperatures. If in doubt, try a CAUTION: Probe on top of terminal only. Do
new sensor. not try to probe inside terminal or to use a pa-
Also remember this validates the operation of the per clip to probe inside terminal, it can damage
sensor at ambient temperature. It does not vali- the square-shaped terminal.
date the over temperature functionality. To test it, CAUTION: Do not disconnect the EMS ECU con-
the sensor could be removed from the engine/ nector needlessly. They are not designed to be
muffler and heated with a heat gun while it is still disconnected/reconnected repeatedly.
connected to the harness to see if the EMS ECU
will detect the high temperature condition and
generate a fault code.
SMR2002-078 _07_03A.FM 07-03-3

Engine Connector 3 2
Engine connector of the wiring harness when per-
forming tests.
1 4
2 3
R1503motr192A
ENGINE CONNECTOR PIN-OUT (WIRING HARNESS SIDE)

F18Z0KA 1
CONNECTORS ON ENGINE 1. Engine connector bracket
2. Deutsch connector
3. Flat screwdriver
Removal
To disconnect two connectors slide a flat screw-
To remove connectors from engine connector driver between each other to disengage, press the
bracket, slide a flat screwdriver between the con- release button and disconnect them.
nector bracket and the connectors and remove
connectors. 1
F18Z0LA 2
F18Z0JA 1 1. Flat screwdriver

2. Connectors
1. Engine connector bracket
2. Connectors
07-03-4 SMR2002-078 _07_03A.FM

2 AIR INDUCTION SYSTEM

THROTTLE BODY
6
5
F18Z0MA 1 2 2
1. Release button
2. Connectors R1503motr160A 1 3
1. Throttle body
3. Throttle plate
4. TPS
5. Idle bypass channel
6. Idle bypass valve
Mechanical Inspection
Check that the throttle plate moves freely and
smoothly when depressing throttle lever. Take this
opportunity to lubricate the throttle cable.
IMPORTANT: The throttle body is designed to be
tamper proof. Changing the idle stop or modifying it
in any way will not increase performance or change
the idle speed but may cause poor startability and
F18Z0NA 2 1 erratic idling.
1. Connectors Before replacing any part, check the following as
2. Press release button these could be causing the fault. Perform the test
while the engine is not running.
– Throttle cable adjustment too tight. Not return-
ing fully to idle stop.
– TPS is loose.
– Idle bypass valve is loose.
– Corroded or damaged wiring or connectors.
– Throttle body has been replaced and the Closed
Throttle and Idle Actuator reset has not been
performed.
– EMS ECU has been replaced and the Closed
Throttle and Idle Actuator reset has not been
performed.
SMR2002-078 _07_03A.FM 07-03-5

Electrical Inspection Adjustment

Refer to THROTTLE POSITION SENSOR (TPS) and
1
IDLE BYPASS VALVE in ELECTRONIC MANAGE-
MENT below.
Replacement
Removal
To remove the throttle body from engine, proceed
as follows:
– Disconnect air intake silencer from throttle body.
Move boot away.
– Remove retaining screws of throttle body.
R1503motr161A
THROTTLE BODY
2 1. Idle stop screw
CAUTION: It is not allowed to perform any

change on the idle stop screw.
The adjustment of the idle stop screw is optimized
by the throttle body manufacturer and locked to
prevent any modification.
CAUTION: Never attempt to adjust the idle
speed through the throttle body tamper proof
screw. If so, it would impair the idle speed sta-
R1503motr205A 1 2 bility. Besides, no adjustment could be per-
1. Throttle body formed by the dealer nor the factory to correct
2. Screws the idle speed. The throttle body would need to
– Slightly pull throttle body out. be replaced. Also take into account that might
change the engine emission level and the en-
– Disconnect connectors from idle bypass valve, gine might not meet the EPA/CARB require-
and TPS. ments.
– Disconnect throttle cable. CAUTION: Do not alter or tamper with throttle
Installation cable adjustment or routing. It may cause poor
Installation of the new throttle body is the reverse startability and erratic idling.
of the removal procedure. The only thing that has to be performed when the
For TPS and idle bypass valve replacement proce- throttle body has been replaced is the Closed
dures, refer to the respective paragraph in ELEC- Throttle and Idle Actuator reset. Refer to THROT-
TRONIC MANAGEMENT below. TLE POSITION SENSOR (TPS) in ELECTRONIC
MANAGEMENT below.
07-03-6 SMR2002-078 _07_03A.FM

Throttle Cable Adjustment To adjust, loosen jam nut then turn adjustment nut
Mechanically adjust the throttle cable. as necessary.
Lubricate cable with BOMBARDIER LUBE lubricant.
When throttle is released, cable must have a free
play of 0.5 - 4 mm (1/64 - 5/32 in).
Besides, throttle lever must reach handlebar grip
without causing strain to cable or brackets. Ensure
throttle lever fully closes on it’s stopper.
F18F07A 3 2 1
1
F01K08A 1. Adjustment nut
2. Jam nut
1. Must touch handlebar grip 3. Throttle lever stopper
Ensure throttle body is fully open at full throttle po- Tighten jam nut and recheck adjustment.
sition. At this position, throttle lever stopper is al-
most in contact with throttle body.
 WARNING
NOTE: Apply a light pressure on the throttle plate, a Make sure idle speed stopper contacts throt-
slight play should be obtained. tle cam when throttle lever is fully released at
CAUTION: If there is no free-play at idle posi- handlebar.
tion, it may cause poor idling and startability.
Improper cable adjustment will cause strain on Closed Throttle and Idle Actuator Reset
cable and/or damage cable bracket or throttle
lever at handlebar. Perform the Closed Throttle and Idle Actuator re-
set as described in THROTTLE POSITION SENSOR
(TPS) in ELECTRONIC MANAGEMENT below.
SMR2002-078 _07_03A.FM 07-03-7

FUEL DELIVERY
4-TEC FUEL DELIVERY SYSTEM DIAGNOSTIC FLOW CHART
Fuel pump does not run Connect safety lanyard Fuel pump runs
for 2 sec. then stops
Check fuses Install fuel pressure gauge

Check safety lanyard connection on fuel pressure line
Check fuel pump operation
Repair or replace if necessary Replace fuel
pump module
Fuel pump runs
Repair or Fuel pressure less Fuel pressure is Fuel pressure more

replace than 303 kPa (44 PSI) 303 kPa (44 PSI) than 303 kPa (44 PSI)
Fails
Check fuel line /
rail for leaks
OK
Fails Crank or start
Perform fuel pump test engine
OK
Fast Fuel pressure less Fuel pressure more Fuel pressure is

pressure drop than 303 kPa (44 PSI) than 303 kPa (44 PSI) 303 kPa (44 PSI)
No
Yes
Check
OK fuel line /
Verify fuel
pump check rail for leaks Repair or
valve Fails
replace FUEL SYSTEM OK
Fails OK
Fails
OK
Check fuel Perform fuel Replace fuel
injector pump test pump module Retest
OK
R1503motr209S
07-03-8 SMR2002-078 _07_03A.FM

FUEL PUMP
Before proceeding to the pressure test ensure the
battery is fully charged. Battery voltage must be
over 12 volts.
Release the fuel pressure in the system using
B.U.D.S. Look in the Activation tab.
 WARNING
The fuel hose may be under pressure. Cover
the fuel line connection with an absorbent
shop rag. Slowly disconnect the fuel hose to
release the pressure. Wipe off any fuel spill-
age inside bilge. F18R08A 2 1
1. Hose disconnected from fuel pump
The pressure test will show the available pressure 2. In-line installation of fuel pressure gauge
at the fuel pump outlet. It validates the pressure
regulator, the fuel pump and leaks in the system. Install safety lanyard and observe fuel pressure. Do
not crank engine. Repeat twice. Release pressure
Remove glove box to have access to fuel pump.
using B.U.D.S. between tests so that the gauge is
Refer to HULL/BODY section.
“reset” to zero (0).
Remove air vent tube from front storage area.
FUEL PRESSURE
Ensure there is no leak from hoses and fittings.
Repair any leak.
Ensure there is enough gas in fuel tank. 303 kPa (44 PSI)
Disconnect outlet hose from fuel pump.
Install fuel pressure gauge (P/N 529 035 591) be- The fuel pressure should be the same as above.
tween disconnected hose (inline installation).
If pressure is within limits, fuel pump and pressure
regulator are working adequately.
A rapid pressure drop indicates leakage either from
the fuel rail or from the fuel pump check valve.
Check fuel rail for leaks. If it is not leaking then re-
place fuel pump.
leaking then replace fuel pump module.
Release fuel pressure in the system using B.U.D.S.
Look in the Activation tab.
Remove pressure gauge and reinstall fuel hose.
 WARNING
F02B0BA Wipe off any fuel spillage in the bilge. Fuel is
Reinstall removed parts.
SMR2002-078 _07_03A.FM 07-03-9

Electrical Test
When connecting the safety lanyard to the DESS
post, the fuel pump should run for 2 seconds to
If the pump does not work, disconnect the plug
Install a temporary connector to the fuel pump
test harness.
If pump does not run, replace the fuel pump module.
Otherwise, probe terminals A and D of fuel pump
F18R09A
connector on vehicle harness side. When installing
safety lanyard, you should read battery voltage for Pull fuel pump out from glove box opening.
approximately 2 seconds (then voltage will drop to
approximately 11 V). If battery voltage is read, the Installation
problem can be in harness or in fuel pump connec- For installation, reverse the removal process but
tor. Repair or replace appropriate part. pay attention to the following.
If battery voltage is not read, probe pin A and bat- Align tab of gasket with tank neck and then align
tery ground. arrow of fuel pump with tab of gasket.
a. If battery voltage is read, check continuity of cir- Refer to following illustration for tightening se-
cuit B-29 going towards EMS ECU. If it is good, quence. Torque 1 to 4 at 1 N•m (9 lbf•in) and then
try a new EMS ECU. 5 to 13 at 2 N•m (18 lbf•in).
b. If battery voltage is not read, check continuity
of circuit 1-26 going towards MPEM. If it is 1
good, try a new MPEM. 6 3 7
Fuel Pump Replacement
1 5 8
Removal
Open front storage compartment cover.
Remove the storage basket (if so equipped).
13 2 9
Remove front access panel (see HULL/BODY sec-
tion).
Remove front vent tubes. 4 12 10
Remove glove box (see HULL/BODY section). 11
Disconnect electrical connector.
F18R0AA 2
Disconnect vent tube from fuel pump.
TIGHTENING SEQUENCE
Release the fuel pressure in the system using 1. Fuel tank neck
B.U.D.S. Look in the Activation tab. 2. Align
Disconnect inlet hose from fuel pump. Perform a pressure test on fuel tank. Refer to FUEL
From glove box opening, remove fuel pump retain- SYSTEM section.
ing nuts.
07-03-10 SMR2002-078 _07_03A.FM

FUEL RAIL Disconnect wiring harness from the three fuel in-
jectors.
Pressure at fuel rail is supplied and controlled by Cut tie raps and remove the wiring harness from
the fuel pump module. Refer to FUEL PUMP for the fuel rail.
pressure test.
Fuel Rail Replacement Gently pull rail up by hand, working each side slight-
Removal ly at a time.
Pull rail out with fuel injectors.
Remove fuel rail cover from the engine.
Release the fuel pressure in the system using If necessary remove fuel injectors as described be-
B.U.D.S. Look in the Activation tab. low.
Insert pointed tools each side. Installation
Disconnect fuel hose at the connector. For installation, reverse the removal process but
pay attention to the following.
1 A thin film of injection oil should be applied to
O-rings of fuel injectors to ease installation in in-
take manifold.
Apply Loctite 243 on rail retaining screws then torque
When installing fuel line connector to the fuel rail,
put some oil on the O-ring to ease installation.
 WARNING
Perform a fuel pressure test and ensure that
there is no leak. Refer to FUEL PUMP above.
Run engine and check for leaks.
R1503motr162A FUEL INJECTOR

1. Insert pointed tools each side
Leakage Test
Wrap a rag around the hose end to prevent rail drain- To perform a leakage test, the injectors and fuel
ing. rail have to be removed from the engine. Refer to
REMOVAL in FUEL RAIL REPLACEMENT for the
procedure.
NOTE: Do not detach injectors from the fuel rail.
Reconnect the fuel line and the wiring harness.
Place each injector in a clean bowl.
Install the safety lanyard cap on the DESS post to
activate the fuel pump.
Check for fuel leakage from the injector nozzle.
There should be less than 1 drop per minute. Per-
form the test for 2 minutes.
If not within specification, replace the fuel injector(s).
The leakage test is validated when performing the
R1503motr163A 1
1. Fuel injector connectors CHART elsewhere in this section.
SMR2002-078 _07_03A.FM 07-03-11

Electrical Test
Using the vehicle communication kit (VCK) with 1 4
the B.U.D.S. software, energize the fuel injector
If the injector does not work, disconnect the plug 2 3
R1503motr192A
wires long enough to make the connection out- ENGINE CONNECTOR
harness. 15 14
This will validate the injector mechanical and elec-
trical operation.
If it does not work, replace it.
Using B.U.D.S., activate injector while probing pin
2 (of injector on harness side) and battery ground.
a. If 12 V is read, check continuity of circuit as per
following table. If it is good, try a new EMS ECU.
CIRCUIT NUMBER
(EMS ECU INJECTOR NUMBER R1503motr193A
33
CONNECTOR “A“)
EMS ECU CONNECTOR
A-15 1
A-33 2 COMPONENT CONTACT LOCATION
A-14 3 1 (Engine Connector)
Fuel injector cylinder 1 and A-15 (EMS ECU
b. If it does not read 12 V, check continuity of cir- Connector)
cuit as per following table. If it is good, try a new
MPEM. 2 (Engine Connector)
Fuel injector cylinder 2 and A-33 (EMS ECU
CIRCUIT NUMBER Connector)
INJECTOR NUMBER
(AMP CONNECTOR # 2)
3 (Engine Connector)
2-16 1 Fuel injector cylinder 3 and A-14 (EMS ECU
2-17 2 Connector)
2-18 3 The resistance should be between 11.4 and 12.6 Ω.

Otherwise, check the resistance of the fuel injec- If resistance value is correct, try a new EMS ECU.
tor circuit. Refer to EMS ECU REPLACEMENT procedures
Reconnect the injector and disconnect the EMS
ECU connector A EMS ECU. If resistance value is incorrect, repair the wiring
harness/connectors or replace the wiring harness
Using a multimeter, check resistance value be- between EMS ECU plug connector and fuel injec-
tween terminals as follows. tor.
07-03-12 SMR2002-078 _07_03A.FM

Fuel Injector Replacement IMPORTANT: When the EMS ECU is replaced,

the safety lanyard(s) and the Closed Throttle and
Removal Idle Actuator must be reprogrammed/reset. Re-
Before removing the injectors, the fuel rail has to fer to their specific section for adjustment.
be removed from the engine. Refer to REMOVAL To allow transferring the previous recorded informa-
in FUEL RAIL REPLACEMENT for the procedure. tion from the old EMS ECU or MPEM to the new
3 2 one, use the vehicle communication kit (VCK) with
the B.U.D.S. software. Use Replace EMS or MPEM
in the ECU menu. Follows instructions in its help sys-
tem.
NOTE: If the old EMS ECU or MPEM is working, it
must be read inside B.U.D.S. prior to removing it
from the vehicle to carry vehicle information and his-
tory to the new EMS ECU or MPEM.
EMS ECU Replacement

R1503motr164A 1 Disconnect battery cables.
FUEL RAIL ASS’Y
1. Fuel injector
2. Injector clip
 WARNING
3. O-ring Battery BLACK negative cable must always
be disconnected first and connected last.
Then remove the injector clip. Now the fuel injec-
tor can be easily pulled out of the fuel rail. Disconnect both EMS ECU connectors from EMS
Installation ECU.
For the installation, reverse the removal proce- 2 1
Install new O-rings, if you reinstall a used injector
then insert the fuel injector in place with your hand.
Do not use any tool. Ensure clip and injector are
properly installed.
NOTE: A thin film of engine oil should be applied
to O-rings to ease insertion in rail.
Apply Loctite 243 on rail retaining screws then torque
 WARNING
Perform a fuel pressure test and ensure that
there is no leak. Refer to FUEL PUMP above.
Run engine and check for leaks.
R1503motr180A 2
ELECTRONIC MANAGEMENT 1. EMS ECU
2. Retaining screws
EMS ECU AND MPEM Unscrew all retaining screws and remove the en-
REPLACEMENT gine EMS ECU from intake manifold.
General Install the new EMS ECU to the engine.
Prior to replacing a suspected EMS ECU or MPEM, Reconnect EMS ECU connectors to EMS ECU then
ensure that all the recommendations in the general battery cables.
introduction of this section have been followed.
SMR2002-078 _07_03A.FM 07-03-13

Transfer the data from the previous EMS ECU to ENGINE WIRING HARNESS
the new one using B.U.D.S. then proceed with the
required resets and reprogram safety lanyard (s), 3 4 5 6 7 8 10 9 11 12
if you were unable to transfer the data.
NOTE: If data cannot be transferred, manually en-
ter information in Vehicle tab.
After performing the required resets, ensure to
clear all faults from the newly replaced EMS ECU.
Start the engine and increase engine speed above
5000 RPM to be sure no fault appears.
MPEM Replacement
Disconnect battery cables.
 WARNING
Battery BLACK negative cable must always
be disconnected first and connected last.
Disconnect AMP connectors from MPEM. Re-

move retaining nuts on top.
2 1 19 20 18 17 16 15 14 13
Pull MPEM out. R1503motr199A
Install the new MPEM in vehicle. Reconnect AMP 1.EMS ECU connector
2.CTS connector
connectors to MPEM. 3.EGT connector
4.CAPS connector
Transfer the data from the previous MPEM to the 5.Fuel injector connector (cylinder 1)
new one using B.U.D.S. 6.Ignition coil connector (cylinder 1)
7.Fuel injector connector (cylinder 2)
NOTE: If data cannot be transferred, manually ac- 8.Ignition coil connector (cylinder 2)
9.Fuel injector connector (cylinder 3)
tivate the options installed in vehicle under the 10. Ignition coil connector (cylinder 3)
Setting tab. If an option is installed but not 11. TOPS valve connector
12. OSPS connector
checked in B.U.D.S., the information center will 13. TPS connector
not display that option. If an option is checked in 14. Idle bypass valve connector
15. MATS connector
B.U.D.S. but not installed in vehicle, a fault code 16. Engine connector
will be generated. 17. MAPS connector
18. OPS connector
Ensure to clear all faults from the newly replaced 19. KS connector
20. CPS connector
MPEM.
Start engine and ensure no fault is active. Resistance Test
Check continuity of the circuits according to the
wiring diagram in the WIRING DIAGRAMS section
of this manual.
If wiring harness is good, check the respective
sensor/actuator as described in this section.
Otherwise, repair the connectors, replace the wir-
ing harness or the EMS ECU/MPEM as diagnosed.
07-03-14 SMR2002-078 _07_03A.FM

Removal Lead the cable bundle with the injector and igni-
tion coil connectors to the fuel rail and fix it also by
Remove fuel rail cover.
using 4 locking ties.
Disconnect the wiring harness from all sensors/
actuators. 1 1
Disconnect the EMS ECU connector from the EMS
ECU.
Cut all tie raps which are holding the wiring harness
in position.
R1503motr202A
1. Locking ties
Connect the fuel injectors, ignition coils, CAPS, CTS

and EGT to the wiring harness.
 WARNING
1 Pay attention not to mix injectors or ignition
R1503motr200A
coils wires between cylinders. The location of
the splice connectors indicate which cylinder
1. Wiring harness
wires belong to.
Remove complete wiring harness.
Install the engine connector on the appropriate
Installation bracket on the wiring support.
First connect the EMS ECU connector A to the Then fix the other bundle on the appropriate sup-
EMS ECU and fix the harness on the wiring supports on the wiring support and the EMS ECU brack-
port with a locking tie. et with locking ties.
1
R1503motr203A
R1503motr201A 1
1. Locking ties
1. Locking tie
SMR2002-078 _07_03A.FM 07-03-15

Connect the CPS, KS, OPS, and the MAPS to the IMPORTANT: Prior to testing the TPS, ensure that
wiring harness. mechanical components/adjustments are adequate
Also connect now the MATS, TPS, OSPS, idle by- according to THROTTLE BODY in AIR INDUCTION
pass and TOPS valve to the wiring harness. SYSTEM above.
Fix the wiring for the MATS with a locking tie to The EMS may generate several fault codes pertain-
support the cables. ing to the TPS. Refer to SYSTEM FAULT CODES in
DIAGNOSTIC PROCEDURES section for more in-
formation.
Wear Test
While engine is not running, activate throttle and
pay attention for smooth operation without physi-
cal stops of the cable.
the B.U.D.S. software, use the Throttle Opening
display under Monitoring.
Slowly and regularly depress the throttle. Observe
the needle movement. It must change gradually
and regularly as you move the throttle. If the nee-
dle “sticks”, bounces, suddenly drops or if any dis-
R1503motr204A 1 crepancy between the throttle movement and the
needle movement is noticed, it indicates a worn
1. Locking tie
TPS that needs to be replaced.
Install all remaining parts, which has been removed.
Voltage Test
THROTTLE POSITION SENSOR Check the voltage output from EMS ECU to the de-
(TPS) sired throttle position sensor.
General
The throttle position sensor (TPS) is a potentiom-
eter that sends a signal to the EMS ECU which is
proportional to the throttle shaft angle.
3
1
R1503motr167A
TPS
R1503motr165A
07-03-16 SMR2002-078 _07_03A.FM

Disconnect plug connector from throttle position Check the resistance between terminal A-24 and
sensor. To unlock connector, insert a small screw- A-25 with throttle plate in idle position.
driver between the folded tab. To see the connec- The resistance should be 1000 - 1100 Ω.
tor pin-out, temporarily remove the connector
shield joining the harness, to expose the pin num- Now check the resistance with the throttle plate
bers. Connect a voltmeter between pin 1 and 3 in wide open position.
and also between pin 1 and 2 in the wiring har- The resistance should be 2600 - 2700 Ω.
ness. NOTE: When measuring between pins A-24 and
Remove and reinstall the safety lanyard to activate A-39, resistance value decreases while depress-
the EMS ECU. ing throttle lever. when measuring between pins
Check the voltage readings as follows. A-24 and A-25, resistance value increases while
depressing throttle lever. The resistance value
CONNECTION VOLTAGE should change smoothly and proportionally to
Pin 1 with engine ground 0V throttle movement. Otherwise, replace TPS.
Pin 2 with engine ground 5V If resistance values are correct, try a new EMS ECU.
Refer to EMS ECU REPLACEMENT procedures
Pin 3 with engine ground 4.75 - 5 V elsewhere in this section.
If voltage test is good, replace the TPS. If resistance values are incorrect, repair connector
or replace the wiring harness between EMS ECU
If voltage test is not good, check the resistance of connector and the TPS.
the TPS circuit.
Replacement
Resistance Test
Remove the throttle body as described above.
Reconnect the TPS.
Loosen two screws retaining the TPS.
Disconnect the EMS ECU connector A on the EMS
ECU. Remove TPS.
25 24
R1503motr191A
39
R1503motr168A 2
tween terminal A-25 and A-39. THROTTLE BODY
The resistance should be 1600 - 2400 Ω. 2. Screws
Check the resistance between terminal A-24 and Apply Loctite 243 on screw threads, install the new
terminal A-39 with the throttle plate in idle posi- TPS.
tion.
The resistance should be approximately 2500 Ω.
Proceed with the Closed Throttle and Idle Actu-
Check the resistance between terminal A-24 and ator Reset. See below.
terminal A-39 with the throttle plate in wide open
position.
The resistance should be 1000 - 1100 Ω.
SMR2002-078 _07_03A.FM 07-03-17

Closed Throttle and Idle Actuator Reset IDLE BYPASS VALVE

NOTE: This operation performs a reset of the val- An idle bypass valve with good resistance mea-
ues in the EMS ECU. surement can still be faulty. It is also possible that
This reset is very important. The setting of the TPS a mechanical failure occurs which is not detect-
will determine the basic parameters for all fuel able without measuring the air flow. Replacing the
mapping and several EMS ECU calculations and idle bypass valve may be necessary as a test.
the setting of the idle bypass valve will determine
the basic parameters for the idle speed control of Resistance Test
the engine. Disconnect idle bypass valve from the wiring har-
NOTE: Reset must be done each time the throttle ness.
position sensor (TPS) or the idle bypass valve is Using a multimeter, check the resistance in both
loosened or removed or throttle body is replaced windings.
or EMS ECU is replaced.
Check the resistance between pin A and pin D and
CAUTION: An improperly set TPS or idle by- also between pin C ad pin B of the idle bypass
pass valve may lead to poor engine perfor- valve.
mance and emission compliance could possi-
bly be affected. The resistance in each winding should be approx-
imately 50 Ω at 23°C (73°F).
Use the vehicle communication kit (VCK) with the
B.U.D.S. software to perform this adjustment. If the resistance of one or both windings is not
good, replace the idle bypass valve.
Ensure the throttle body plate stop lever rest
against its stopper. Open throttle approximately If resistance test of valve windings is good, check
one quarter then quickly release. Repeat 2 - 3 times continuity of circuits A-35, A-36, A-37, A-38.
to settle throttle plate. If stopper does not rest Visual Inspection
against its stop lever, perform throttle cable ad-
justment. Refer to THROTTLE BODY in AIR IN- Remove idle bypass valve from throttle body.
DUCTION SYSTEM above. Check the piston and bypass channel for dirt/de-
Push the Reset button in the Setting section of posits which can cause a sticking piston.
B.U.D.S. CAUTION: Do not try to operate the piston of
NOTE: No message will be displayed if operation the idle bypass valve when it is dismounted.
is good. If operation is wrong, an error message Also do not move the piston by hand. The
will be displayed. screw drive is very sensitive and will be de-
stroyed.
NOTE: There is no idle speed adjustment to per-
form. The EMS ECU takes care of that. If TPS is Clean the parts and install the idle bypass valve on
not within the allowed range while resetting the the throttle body.
Closed Throttle and Idle Actuator, the EMS ECU Proceed with the Closed Throttle and Idle Actu-
will generate a fault code and will not accept the ator Reset. See above.
setting.
Start engine and make sure it operates normally
through its full engine RPM range. If fault codes ap-
pear, refer to SYSTEM FAULT CODES in DIAGNOS-
TIC PROCEDURES section for more information.
07-03-18 SMR2002-078 _07_03A.FM

CRANKSHAFT POSITION
5
SENSOR (CPS)
1
R1503motr182A
19

If resistance value is correct, try a new EMS ECU.
R1503motr169A
If resistance value is incorrect, repair the connec-
1. CPS connector tors or replace the wiring harness between EMS
Ensure that information center works. Needles ECU connector and the MATS.
will sweep, LED and LCD segments will turn on
when the safety lanyard is installed. Check for Replacement
RPM display at the information center while crank- Disconnect connectors and remove the PTO cov-
ing in engine drowned mode. Press and HOLD er. Refer to PTO HOUSING/MAGNETO in ENGINE
throttle lever then press start/stop button. 800- section.
1000 RPM should display. Otherwise perform the Remove CPS.
following tests.
NOTE: Take into account that a CPS fault can be 1
triggered by bent or missing encoder wheel teeth.
First check fault codes then check the teeth con-
dition if necessary. See below.
Disconnect CPS wiring harness connector. Probe
terminals coming from CPS while cranking en-
gine. Voltage should be within 1-2 Vac. Otherwise,
inspect wiring and replace CPS if wiring is good.
Resistance Test
Disconnect the CPS plug connector from the wir-
ing harness and check the resistance of the sensor
itself.
The resistance should be between 190 Ω and 290
R1503motr170A
Ω.
1. CPS inside PTO cover
Otherwise, replace the CPS.
If resistance tests good, reconnect the CPS and Apply Loctite 243 on screw threads then install the
disconnect the EMS ECU connector A on the EMS new CPS. Torque to 10 N•m (89 lbf•in).
ECU. Reinstall remaining removed parts.
SMR2002-078 _07_03A.FM 07-03-19

Encoder Wheel Inspection Voltage Test (harness)

To check the encoder wheel for bent teeth, pro- Disconnect the connector from the wiring harness.
ceed as follows. To see the connector pin-out, temporarily remove
Remove PTO cover. Refer to PTO HOUSING/ the connector shield joining the harness, to ex-
MAGNETO in ENGINE section. pose the pin numbers.
Install a dial indicator on crankcase casting. Posi- Remove and reinstall safety lanyard to activate the
tion the gauge on a tooth and set it to zero (0). system.
Rotate flywheel and check needle movement. The Probe pin 3 of CAPS connector (wiring harness
maximum allowed difference between teeth is side) and battery ground.
or replace the encoder wheel. a. If 12 V is read, check continuity of circuits A-20
and A-34. If they test good, perform the CAPS
2 voltage test as explained below. If CAPS tests
good, try a new EMS ECU.
20
R1503motr183A
34
EMS ECU CONNECTOR

R1503motr177A 1
b. If 12 V is not read, check continuity of circuit 2-19
1. Encoder wheel from MPEM to the CAPS. If it tests good, try a
2. Dial indicator
new MPEM. Otherwise, repair wiring harness.
Properly reinstall cover. Remove the CAPS from the cylinder head.
CAMSHAFT POSITION SENSOR
(CAPS)
R1503motr178A 1
1. CAPS
07-03-20 SMR2002-078 _07_03A.FM
Set up the following electric circuit to perform the

voltage test. 2 V
3 2 1
1 Pin 1 Pin 2 Pin 3

R1503motr207A 1200 W resistor
R1503motr184A
1. CAPS
2. Conductor
CAPS PIN-OUT
If the voltage is not good, replace the CAPS.
1200 W Voltmeter
V Replacement
Unscrew the retaining screw and replace the
CAPS. Ensure to reinstall O-ring.
+ Apply Loctite 243 (blue) on thread and torque to
3 2 1
6 N•m (53 lbf•in).
12 V CAPS MANIFOLD AIR TEMPERATURE
SENSOR (MATS)
-
R1503motr208A
Touch the CAPS with a conductor (ex.: screwdriv-

er) and look if the voltage at the multimeter
switches from 12 V to less than 1 V.
R1503motr171A 1
INTAKE MANIFOLD
SMR2002-078 _07_03A.FM 07-03-21

Resistance Test COOLANT TEMPERATURE

Disconnect the plug connector from the MATS SENSOR (CTS)
and check the resistance of the sensor itself.
The resistance should be between 2280 Ω and
2740 Ω at 20°C (68°F).
Otherwise, replace the MATS.
If resistance tests good, reconnect the MATS and
disconnect the EMS ECU connector A on the EMS
ECU.
R1503motr172A 1
1. Coolant temperature sensor (CTS)
Resistance Test
R1503motr186A
21 Disconnect the plug connector from the CTS and
tween terminals 7 and 21. The resistance should be between 2280 Ω and
2740 Ω at 20°C (68°F).
Refer to EMS ECU REPLACEMENT procedures Otherwise, replace the CTS.
elsewhere in this section. If resistance tests good, reconnect the CTS and
If resistance value is incorrect, repair the connec- disconnect the EMS ECU connector A on the EMS
tors or replace the wiring harness between EMS ECU.
ECU connector and the MATS.
11
Replacement
Screw MATS out and install the new one. Torque
to 18 N•m (159 lbf•in).
R1503motr187A
27

tors or replace the wiring harness between EMS
ECU connector and the CTS.
07-03-22 SMR2002-078 _07_03A.FM

Replacement Remove and reinstall the safety lanyard to activate

the EMS ECU. There should be 5 Vdc in each test.
Unlock expansion tank and temporarily move
away to gain access. If voltage test is good, replace the MAPS.
Remove the fuel rail cover. If voltage test is not good, check the continuity of
the MAPS circuit.
Disconnect CTS connector and remove CTS.
Install the new CTS and torque to 18 N•m (159 Resistance Test
lbf•in).
Disconnect the EMS ECU connector A on the EMS
Reinstall remaining removed parts. ECU.
MANIFOLD AIR PRESSURE 28 and 40.
SENSOR (MAPS) If wiring harness is good, try a new EMS ECU.
Otherwise, repair the connectors or replace the
wiring harness between EMS ECU connector and
the MAPS.
Replacement
Disconnect MAPS connector and remove the MAPS.
tab into the adaptor notch. Apply Loctite 243 (blue)
on screw then torque to 10 N•m (89 lbf•in).
EXHAUST GAS TEMPERATURE

R1503motr173A 1 SENSOR (EGT)
1 2
NOTE: This sensor is a dual function device. When
engine is started and it runs at idle speed, the sen-
the EMS ECU. Thereafter, it takes the manifold air
pressure at operating RPMs.
Ensure sensor is correctly installed on intake man-
ifold. Otherwise, the MAPS could generate a fault
code for an unexpected sensor range at idle when
it reads the atmospheric pressure. Remove sensor
and check for oil or dirt on its end and if problem
persists, check throttle plate condition/position
and the wiring harness. Perform the following
tests.
F18D2IA
Voltage Test 1. Muffler

Check the voltage output from EMS ECU to the man-
ifold air pressure sensor (MAPS).
Disconnect plug connector from maps and con-
nect a voltmeter between pin 1 and 3 and also
between pin 1 and 2 of wiring harness.
SMR2002-078 _07_03A.FM 07-03-23

Resistance Test Start the engine and bring engine RPM above
sor is good.
The resistance should be between 2280 Ω and
2740 Ω at 20°C (68°F). Ensure sensor and head contact surfaces are clean
and mounting bolt and washer are correct and prop-
erly torqued down.
If resistance tests good, reconnect the EGT and
NOTE: It is necessary to remove intake manifold
disconnect the EMS ECU connector A on the EMS
to inspect contact surfaces. Refer to INTAKE SYS-
ECU.
TEM section.
Disconnect the connector from knock sensor har-
ness.
Refer to EMS ECU replacement procedures else-
Static Resistance Test
tor or replace the wiring harness between EMS Using a multimeter, check the resistance between
ECU connector and the EGT. both terminals on the knock sensor harness side.
The resistance should be approximately 5 MΩ.
Replacement If resistance is not good, replace knock sensor.
Disconnect EGT connector and remove EGT. If resistance is good, reconnect the knock sensor
Apply Loctite 518 on threads of the EGT then in- connector and disconnect the EMS ECU connec-
stall. tor A from the EMS ECU.
Replug connector.
9
KNOCK SENSOR (KS)
R1503motr188A
23

If wiring harness is good, try a new EMS ECU. Re-
fer to EMS ECU REPLACEMENT procedures else-
R1503motr174A 1
Otherwise, repair the connector or replace the wir-
1. Knock sensor (KS) ing harness between EMS ECU connector and
knock sensor.
Dynamic Test
the B.U.D.S. software, monitor the knock sensor
using the Faults section.
07-03-24 SMR2002-078 _07_03A.FM

Replacement When engine is stopped the resistance is infinitely

high (normally open switch).
Remove the intake manifold. Refer to INTAKE
MANIFOLD REPLACEMENT in INTAKE section. When engine is running and the oil pressure reach-
es 180 - 220 kPa (26 - 32 PSI), the resistance of
the OPS is close to 0 Ω.
Clean contact surface, apply Loctite 243 in thread-
If resistance values are incorrect, replace OPS.
ed hole then install the new knock sensor.
If the values are correct, check the continuity of
Torque screw to 24 N•m (18 lbf•ft).
the wiring harness.
CAUTION: Improper torque might prevent sen-
Disconnect the EMS ECU connector A from the
sor to work properly and lead engine to severe
EMS ECU and check continuity of circuit 6.
damage of internal components.
Replug connector. 6
OIL PRESSURE SWITCH (OPS)
R1503motr195A
If wiring harness is good, try a new EMS ECU. Re-

fer to EMS ECU REPLACEMENT procedures else-
ing harness between EMS ECU connector and
OPS.
R1503motr194A 1
1. OPS
OIL SEPARATOR PRESSURE
SWITCH (OSPS)
Oil Pressure Test
To check the function of the oil pressure switch,
an oil pressure test has to be performed. Refer to
OIL PRESSURE TEST in LUBRICATION SYSTEM
section.
If the engine oil pressure is out of specifications,
check the points described in TROUBLESHOOT-
ING section.
If the engine oil pressure is good, check the resis-
tance of the OPS while engine is off and while
engine is running.
Resistance Test 1
Disconnect the plug connector from the OPS and

use a multimeter to check the resistance between
OPS pin and engine ground while engine is
stopped (without oil pressure) and while engine is R1503motr189A
running (with oil pressure). 1. OSPS
SMR2002-078 _07_03A.FM 07-03-25

TOPS Pressure Test When engine is stopped and the blow-by pressure
is released, the resistance of the OPS is close to
 WARNING 0 Ω (normally closed switch).
The TOPS system might be pressurized. When engine is running and the blow-by pressure
When the TOPS valve is disconnected from exceeds 40 kPa (6 PSI), the resistance is infinitely
the wiring harness, never open the oil filler high.
cap. Stop the engine and wait at least 30 sec- If resistance values are incorrect, replace OSPS.
onds before opening it, to release the pres-
If the values are correct, check the continuity of
sure.
the wiring harness.
To check the function of the oil separator pressure Disconnect the EMS ECU connector A from the
switch, disconnect the TOPS valve and perform a EMS ECU and check continuity of circuit 31.
TOPS pressure test. Refer to TOPS PRESSURE
TEST in LUBRICATION SYSTEM section.
If the engine blow-by pressure does not reach
40 kPa (6 PSI), check the points described in the
following illustration.
Otherwise, check the resistance of the OSPS
while engine is off and while engine is running.
Resistance Test
Disconnect the plug connector from the OSPS and R1503motr198A
31
use a multimeter to check the resistance between
OSPS pin and engine ground while engine is If wiring harness is good, try a new EMS ECU. Re-
stopped (without blow-by pressure) and while en- fer to EMS ECU REPLACEMENT procedures else-
gine is running (with blow-by pressure). where in this section.
ing harness between EMS ECU connector and OPS.
07-03-26 SMR2002-078 _07_03A.FM

TOPS VALVE (blow-by)
TOPS DIAGNOSTIC FLOW CHART

Connect safety
lanyard
Repair or
replace
TOPS valve opens No Check

(short knocking noise) TOPS switch Fails
Yes OK
Install oil pressure gauge Check Fails

on oil dipstick tube wiring harness
OK
Lower than 8 V
Check output voltage
Start engine on wiring harness
Greater than 8 V
No
Pressure drops Pressure stays below
down directly after 40 kPa (5.8 PSI) for 10 min. Replace
TOPS valve Try a new MPEM
reaching 40 kPa (5.8 PSI) (TOPS valve is open)
(TOPS valve opens again)
Yes Retest
No
Yes No
Working ?
Check OK
OSPS Yes Try a new
EMS ECU
Fails
Fails
Replace TOPS OK
Retest OK Retest
OSPS
R1503motr206S
The valve is turned on as soon as safety lanyard is The OSPS monitors the pressure to detect a mal-
installed on its post. The valve opening allows ven- function of this valve. If pressure rises above a pre-
tilation of crankcase. set threshold, the valve is re-energized again and
if it fails, a fault code is generated.
SMR2002-078 _07_03A.FM 07-03-27

The TOPS switch (mercury type), located besides

the MPEM (on MPEM bracket), monitors the wa-
tercraft position. If the watercraft rolls above a
present threshold (or tips over) the switch opens
and the EMS ECU closes the valve to prevent oil
in engine crankcase to flow towards intake mani-
fold. Besides, the engine RPM will be gradually
reduced then it will be stopped.
1
1
2
3
R1503motr181A 4
1. Solenoid valve
2. Spring
3. Valve disc
4. Retaining washer
 WARNING
The spring on the TOPS valve is tensioned and
can shoot away the valve disc. Hold the valve
disc with fingers while removing the washer.
Remove the valve disc and the spring on the bot-

tom of the TOPS valve after removing the retain-
R1503motr179A
ing washer.
1. TOPS valve
Unscrew and remove the TOPS valve.
Install the new valve with new gasket. Apply Loc-
Resistance Test tite 243 (blue) on threads and torque to 10 N•m
Disconnect the plug connector from the TOPS valve (89 lbf•in).
and check the resistance of the solenoid itself. Reinstall remaining removed parts.
The resistance should be between 1.27 Ω and TOPS Switch
2.47 Ω.
Disconnect TOPS switch and remove from MPEM
Otherwise, replace the TOPS valve. bracket.
Using and ohmmeter, measure resistance between
Dynamic Test
pins.
Activate the TOPS valve by installing the safety
Position switch as it is located in vehicle. Resistance
lanyard on the DESS post.
should be close to 0 Ω.
If you can hear the movement of the piston (knock-
Rotate switch as it would do in vehicle. Switch
ing), the valve works fine, otherwise follow the pro-
should remain closed up to approximately 120°
cedure shown in the following chart.
(from the vertical axis) in either direction. Other-
wise, replace switch.
TOPS Valve Replacement
NOTE: Since this is a mercury switch, dispose it
Disconnect the wiring harness from the TOPS properly according to the environmental regula-
valve. tions in your area.
Remove the oil separator cover. Refer to OIL SEP- Farther than 120° and when switch is upside
ARATOR REPLACEMENT in the LUBRICATION down, switch should be open and resistance will
SYSTEM section. be infinite.
07-03-28 SMR2002-078 _07_03A.FM

IGNITION COILS Disconnect the plug connector from the ignition

coil and check the voltage supplied by the MPEM.
1
1
2
R1503motr196A
Install safety lanyard on the DESS post.

R1503motr175A Check voltage between terminal 2 of ignition coil
1. Ignition coil
connector on the wiring harness and battery
ground.
NOTE: The MPEM energizes the primary side of The voltage should be 12 V.
and short circuit in the primary winding but it does If 12 V is NOT read, check continuity of appropri-
not check the secondary winding. ate circuit 2-16 (cylinder 1), 2-17 (cylinder 2) or 2-18
(cylinder 3). If it tests good, try a new MPEM.
the B.U.D.S. software, energize the ignition coil If 12 V is read, disconnect the EMS ECU connector
from the Activation section. A from the EMS ECU and check the continuity of
appropriate circuit 41 (cylinder 1), 1 (cylinder 2) or
You should hear the spark occurring. In doubt, use an 29 (cylinder 3).
inductive spark tester or a sealed tester – available
from after-market tool/equipment suppliers – to pre-
1
the following checks.
An ignition coil with good resistance measure-
ment can still be faulty. Voltage leak can occur at
high voltage level which is not detectable with an
ohmmeter. Replacing the ignition coil may be nec-
essary as a test.
 WARNING
Never make a spark test with spark plug re- 41 29
R1503motr190A
the bilge and ignited which could cause an ex- EMS ECU CONNECTOR
plosion.
If wiring harness is defective, repair the connector
or replace the wiring harness between EMS ECU
Voltage Test connector and the ignition coil.
 WARNING If wiring harness is good, test resistance of prima-

ry and secondary winding of ignition coil.
ways disconnect coil from main harness first. Resistance Test
open coil and/or spark plug in the engine CAUTION: Do not remove the ignition coil be-
compartment as spark may cause fuel vapor fore disconnecting the connector, or the wires
to ignite. will be damaged. Do not pry up ignition coil
with a screwdriver to avoid damage.
SMR2002-078 _07_03A.FM 07-03-29
Remove ignition coil from spark plug. ENGINE START/STOP SWITCH

VERIFICATION
1 1
A quick operation test can be done using the vehi-
cle communication kit (VCK) with the B.U.D.S. soft-
ware, using the Monitoring section. Press the
start button and look at the start button LED. It
should turn on, indicating the starting system is
working on the input side of the starting system
(start button, MPEM, EMS ECU and wiring). You
R1503motr197A
2 know now the problem is on the output side of the
starting system (MPEM output signal to starting so-
1. Spark plug terminal lenoid, wiring harness going to the solenoid and
Using a multimeter, check the resistance in both starter motor. Refer to STARTING SYSTEM for test-
primary and secondary windings. ing procedures). Otherwise, check the input side as
follows.
For primary winding check the resistance between
pin 1 and pin 2 of the ignition coil. Disconnect the start/stop switch connector. Using
an ohmmeter, connect test probes to YELLOW/RED
The resistance should be between 0.85 and and PURPLE wires.
1.15 Ω at 20°C (68°F).
Measure resistance, it must be an open circuit
For secondary winding check the resistance be- (switch is normally open). Depress and hold switch,
tween pin 1 and spark plug terminal. the ohmmeter should read lower than 200 ohms.
The resistance should be between 9.5 and 13.5 kΩ Otherwise, replace switch. Reconnect connector.
at 20°C (68°F). If the switch tests good, temporarily disconnect
If the resistance of one of both windings is not the inline DESS auxiliary module (see safety lan-
good, replace the defective ignition coil. yard switch verification below for more informa-
If the windings test good, try a new engine EMS tion). Connect the 6-pin connector to bypass the
ECU. auxiliary module. Try the start/stop switch.
NOTE: Prior to inserting the ignition coil to its lo- If it works, try a new auxiliary module. Otherwise,
cation, apply some silicone lubricant (P/N 293 600 continue testing procedure.
041) around the seal area that touches the spark Test continuity of circuit 2-23. If it is good, try a new
plug hole. After installation, ensure the seal seats MPEM. Otherwise, repair harness/connectors.
properly with engine top surface. Test continuity of circuit B-19. If it is good, try a new
EMS ECU. Otherwise, repair harness/connectors.
 WARNING
Always reconnect ignition coil cables at the SAFETY LANYARD SWITCH
same spark plugs where they come from.
Otherwise, severe backfire may occur with
VERIFICATION
possible damage to exhaust system compo- If 2 short beeps are not heard when installing the
nents. The genuine wiring harness is de- safety lanyard, refer to DIAGNOSTIC PROCEDURES.
signed to prevent a cable mixing by using dif-
The following continuity tests can also be per-
ferent cable lengths.
formed using an ohmmeter.
Disconnect switch wires.
TDC SETTING (Top Dead Center) Safety Lanyard Removed
The EMS is able to determine the exact position Connect test probes to switch BLACK and BLACK/
of camshaft and crankshaft. That means that no YELLOW wires. Measure resistance, there should
TDC setting has to be performed. It is used for be NO continuity (open circuit).
both injection and ignition timings.
07-03-30 SMR2002-078 _07_03A.FM

Connect one test probe to the WHITE/GRAY wire Disconnect the wiring harness from the ignition
and the other test probe to the switch top termi- coil.
nal. Measure resistance, it must be close to Remove the ignition coil.
0 ohm.
First unscrew the spark plug one turn.
Connect one test probe to the BLACK wire and the
other test probe to the switch ring. Measure resis- Clean the spark plug and cylinder head with pres-
tance, it must be close to 0 ohm. surize air then completely unscrew.
DESS Auxiliary Module Spark Plug Installation

This module enhances safety lanyard recognition Prior to installation make sure that contact surfac-
at the EMS ECU. It is located under steering sup- es of the cylinder head and spark plug are free of
port. It is an inline connection of the DESS post grime.
harness.
If a safety lanyard cannot be programmed or it fails cording to the following chart.
to be recognized, first refer to the basic self diagnos-
tic mode in DIAGNOSTIC PROCEDURES section. 2. Apply anti-seize lubricant over the spark plug
If it still does not work, disconnect the DESS aux-
iliary module and connect the regular 6-pin DESS 3. Hand screw spark plug into cylinder head. Then,
harness. tighten the spark plug clockwise an additional
1/4 turn with a proper socket.
a. If it is now working, check module harness/
connections. Ensure wires from MPEM and
EMS ECU are properly positioned in connector
and match those on auxiliary module side. Refer
to WIRING DIAGRAMS. If harness/connector
are correct, try a new module.
b. Try pushing down and turning the lanyard on its 1 2
post. If it is working now, check module harness/
connections and if they are in good condition, try
a new module.
Reconnect module.
If the above procedures did not work, refer to elec-
trical troubleshooting in TROUBLESHOOTING A00E0BA
and ENGINE MANAGEMENT sections. 1. Proper socket

2. Improper socket
Safety Lanyard on Switch
Connect test probes to switch BLACK and BLACK/ SPARK GAP
ENGINE TORQUE
YELLOW wires. Measure resistance, it must be PLUG mm (in)
close to 0 ohm. Hand tighten
1503 NGK 0.6
+ 1/4 turn with
4-TEC DCPR8-ES (.24)
SPARK PLUGS a socket
Disassembly CRANKING SYSTEM

 WARNING See above for start/stop switch and the DESS post
Never remove ignition coil from the spark other tests.
plug without disconnecting it from the wiring
harness. Flammable vapors may be present
in the bilge and ignited by a spark which
could cause an explosion.
SMR2002-078 _07_03A.FM 07-03-31

GENERAL
Here is the basic order suggested to diagnose a
suspected engine management or fuel injection
related problem:
– Check the chart in TROUBLESHOOTING sec-
tion to have an overview of problems and sug-
gested solutions.
– Check if there is a message displayed by the
vehicle information center. If so, use the VCK
(Vehicle Communication Kit) and look for fault
codes to diagnose the trouble.
NOTE: Fault codes, the letter P - followed by 4 digits
(P-1234), can be displayed in the information center
for troubleshooting. With safety lanyard on its post,
F18L09C 1
press 5 times the SET button to start the display of
P-codes (onboard diagnostic). Press MODE to scroll 1. Press to scroll if more than one P-code
codes if more than one is present. When “list” is
over, END will appear. When END appears, press
MODE to exit.
F18L09C 1
1. When END appears, press MODE to exit
F18L09D 1 – Check all fuses.

1. Press 5 times to activate display of P-codes (onboard diagnostic) – Check fuel rail pressure.
– Check all connections of the wiring harness.
– Refer to COMPONENT INSPECTION AND AD-
JUSTMENT section for procedures.
SMR2002-079 _07-04A.FM 07-04-1

Terminology
Some documents or softwares use technical terms
that may be different from the one used in this man-
ual. The following table will help to find the equiva-
lence.
TERMS USED IN
TERMS USED
OTHER DOCUMENTS/
IN THIS MANUAL
SOFTWARES
MAPS
APS
(manifold air pressure
(air pressure sensor)
sensor)
MATS
ATS
(manifold air
(air temperature sensor)
temperature sensor)
CTS WTS
(coolant temperature (water temperature
sensor) sensor)
EGT ETS
(exhaust gas (exhaust temperature
temperature) sensor)
TOPS valve
(tip-over protection Blow-by valve
system)
- DLA
(digital linear actuator)
Idle bypass valve
- Idle actuator
- Idle valve
OSPS OTPS
(oil separator pressure (oil tank pressure
switch) switch)
DESS auxiliary module DESS ECU
Safety lanyard Key

Information center Cluster
07-04-2 SMR2002-079 _07-04A.FM

SELF-DIAGNOSTIC MODE
Refer to the following chart. For other problems, refer to COMPONENT INSPECTION AND ADJUSTMENT
section.
CODED SIGNALS POSSIBLE CAUSE REMEDY
2 short beeps • Confirms safety lanyard signal operation. Engine can be started.
(while installing safety
lanyard on post). • Safety lanyard is recognized by the EMS ECU.
• Good contact between safety lanyard and DESS
post.
1 long beep • Bad DESS system connection. Reinstall safety lanyard cap correctly over post.
(while installing safety
lanyard on watercraft • Wrong safety lanyard. Use a safety lanyard that has been
post). programmed for the watercraft. If it does not
work, check safety lanyard condition with
BUDS. Replace safety lanyard if reported
defective.
• Defective safety lanyard. Use another programmed safety lanyard.
• Dried salt water or dirt in safety lanyard cap. Clean safety lanyard cap to remove salt water.
• Defective DESS post. Refer to ENGINE MANAGEMENT section.
• Improper operation of EMS ECU or defective wir- Refer to ENGINE MANAGEMENT section.
ing harness.
1 short beep followed • EMS ECU has been set to onboard diagnostic Remove and reinstall safety lanyard or press
by 1 long beep. mode. MODE button twice to exit that mode.
2 very short beeps • Safety lanyard has been left on its post without To prevent battery discharge, remove the
every 3 seconds starting engine or after engine was stopped. safety lanyard from its post.
interval for 4 hours.
A 2 seconds beep • High pressure in oil separator tank. Refer to LUBRICATION SYSTEM section.
every minute interval.
• Low fuel level. Refer to INSTRUMENTS AND ACCESSORIES
section.
• Fuel tank level sensor or circuit malfunction. Refer to INSTRUMENTS AND ACCESSORIES
section.
A 2 seconds beep • Watercraft is upside down. Turn watercraft upright. If it does not work,
every 15 minutes check the TOPS switch. Refer to ENGINE
interval. MANAGEMENT section.
• Engine coolant temperature sensor or circuit mal- Refer to ENGINE MANAGEMENT section.
function.
• Exhaust temperature sensor or circuit malfunction. Refer to ENGINE MANAGEMENT section.
• Engine oil pressure sensor or circuit malfunction. Refer to ENGINE MANAGEMENT section.
• Low pressure in oil separator tank (engine oil leak). Refer to ENGINE MANAGEMENT section.
• TOPS sensor or circuit malfunction. Refer to ENGINE MANAGEMENT section.
• TOPS valve solenoid or circuit malfunction. Refer to ENGINE MANAGEMENT section.
• EMS ECU failure. Refer to ENGINE MANAGEMENT section.
• Bilge pump circuit low or high voltage Refer to ENGINE MANAGEMENT section.
(if so equipped).
• Starter solenoid circuit malfunction. Refer to ENGINE MANAGEMENT section.
• Communication link fault detected by MPEM. Refer to ENGINE MANAGEMENT section.
• EMS ECU communication link message missing Refer to ENGINE MANAGEMENT section.
(detected by MPEM).
• Information center communication link message Refer to ENGINE MANAGEMENT section.
missing (detected by MPEM).
Continuously beeps. • High engine temperature coolant. Refer to COOLING SYSTEM.
• High exhaust temperature. Refer to COOLING SYSTEM.
SMR2002-079 _07-04A.FM 07-04-3

VCK
(vehicle communication kit)
Kw2000
The VCK (Vehicle Communication Kit) (P/N 529
035 844) is the primary tool to diagnose engine
management and fuel injection related problems. F18H0WA
NOTE: The MPEM programmer does not work on ONLY ONE “ECU” IS WORKING. THERE IS A PROBLEM
4-TEC models. If an “X” is shown, the safety lanyard is not in-
The 4-TEC requires B.U.D.S. version 1.1 or above. stalled on its post or there is a problem with both
B.U.D.S. diskettes are available under P/N 529 035 “ECUs“. Ensure VCK is working properly and
845 and CD-ROM under P/N 529 035 886. check connections on VCK and watercraft.
B.U.D.S. (Bombardier utility and diagnostic soft-
ware) is designed to allow actuators, sensors and VCK supply
electronic equipments inspection, diagnostic op- The VCK (MPI box) can use the watercraft power
tions and reset such as the closed throttle and idle for its supply.
actuator. The safety lanyard must be connected in order to
For more information pertaining to the use of the use the watercraft as a power source.
software B.U.D.S., use its help which contains de- If watercraft power is used, every time the safety
tailed information on its functions. lanyard is taken off the DESS post, the KW2000
protocol will have to be re-activated.
 WARNING
If the computer you are using is connected to Changes in EMS ECU
the 110 Vac power outlet, there is a potential
Anytime a change is brought in EMS ECU through
risk of electrocution when working in contact
B.U.D.S., there will be an “EMS Tracking” mes-
with water. Be careful not to touch water
sage that will say “Remove key from vehicle“.
When this occurs, remove the safety lanyard from
IMPORTANT: When using the software B.U.D.S., its post and wait until the message disappears (it
with the 4-TEC engines, ensure that the protocol lasts approximately 15 seconds after lanyard re-
“KW2000” is properly selected in “MPI” under moval).
“Choose protocol”.
When B.U.D.S. is connected with MPEM and
4-TEC SYSTEM FAULT CODES
EMS ECU, the status bar shows the protocol
(KW2000) and a number 1 or 2 to the right. To work
General
with the watercraft, number 2 must be displayed. The faults registered in the MPEM/EMS ECU are
Number 2 means that 2 “ECUs” are connected kept when the battery is disconnected.
(MPEM and EMS ECU). IMPORTANT: After a problem has been solved,
ensure to clear the fault(s) in the MPEM/EMS ECU
using the VCK. This will properly reset the appro-
priate counter(s). This will also records that the
Kw2000 problem has been fixed in the MPEM/EMS ECU
memory.
F18H0XA Many fault codes at the same time is likely to be
MPEM AND EMS ECU ARE CONNECTED burnt fuse(s).
Number 1 means that 1 “ECU” is connected (ei- For more information pertaining to the code faults
ther MPEM or EMS ECU). Therefore, there is a (state, count, first, etc.) and report, refer to B.U.D.S.
problem. Check fuses and connections. online help.
07-04-4 SMR2002-079 _07-04A.FM


Specific Faults
Communication link fault code 1681: Sometimes
the information center does not synchronize fast
enough for the MPEM. That brings this fault code.
Simply clear the fault and try again.
EMS ECU fault codes P0601, P0602, P0604 and
P605: These codes may occur in the following sit-
uations:
– Electrical noise is picked up by the EMS ECU.
Ensure that all connections are in good condi-
tion, also grounds (battery, EMS ECU, engine
and ignition system), they are clean and well
tightened and that all electronic components
are genuine — particularly in the ignition sys-
tem. Installing resistive caps, non-resistive
spark plugs or knock sensor wiring/routing may
lead to generate this fault code.
– Electrical noise might also lead engine to occa-
when engine is restarted. When looking at the
the software B.U.D.S. A value between 1 and 9
confirms an electrical noise problem. A value of
10 and above will generate a fault code.
– When installing a new EMS ECU. It is not proper-
ly programmed from the factory. The EMS ECU
must be returned to be properly “activated”.
– If everything is in good condition, try a new EMS
ECU.
When using the service action suggested in the
Fault section of B.U.D.S., the system circuits are
referred as 4-23 for instance. It means Amp con-
nector no. 4 and the circuit wire no. 23 as found in
the wiring diagram.
When they are referred as A-41, it means connec-
tor “A” on the EMS ECU and the circuit 41.
TPS (Throttle Position Sensor) Faults

Faults which are reported in B.U.D.S. fall into two
groups TPS faults and adaption faults. These are
displayed on the B.U.D.S. system as TPS OUT OF
RANGE and TPS ADAPTION FAILURE.
SMR2002-079 _07-04A.FM 07-04-5



Check if connector is disconnected from TPS Yes • Fix.
• Fix and reset Closed Throttle and

Check if sensor is loose Yes Idle Actuator.
• Replace and reset Closed Throttle and

Inspect sensor for damage or corrosion Yes
Idle Actuator.
Inspect wiring (voltage test) Failed • Repair.

Inspect wiring and sensor (resistance test) • If bad TPS, replace and
Failed reset Closed Throttle and Idle Actuator.
• Replace and reset Closed Throttle and

Test sensor operation (wear test) Idle Actuator.

Following failures can be effected by a TPS “Adaption Failure“:
– Idle speed is out of range.
– Engine stops, when throttle is released quickly.
– Engine runs inconsistent in low partload or low RPM.

Yes • Reset Closed Throttle and Idle Actuator.
position not reset

closed position not reset
EMS ECU has been replaced and TPS closed
position not reset
Throttle cable too tight Yes • Fix and reset Closed Throttle and
Idle Actuator.
Sensor is loose Yes • Fix and reset Closed Throttle and

Idle Actuator.
Throttle bracket is loose Yes • Fix and reset Closed Throttle and
Idle Actuator.
Adjustment screw worn or loose Yes • Change throttle body.
• Reset Closed Throttle and Idle Actuator

Idle bypass valve replaced but not reset Yes
using B.U.D.S.
07-04-6 SMR2002-079 _07-04A.FM

TABLE OF CONTENTS 0
CIRCUIT, COMPONENTS AND CARE................................................................................... 08-02-1
CIRCUIT .............................................................................................................................. 08-02-6
COMPONENTS .................................................................................................................. 08-02-8
CARE .................................................................................................................................. 08-02-12
CIRCUIT .............................................................................................................................. 08-02-13
COOLING SYSTEM LEAK TEST........................................................................................ 08-02-13
INSPECTION ...................................................................................................................... 08-02-15
DRAINING THE SYSTEM .................................................................................................. 08-02-15
COOLANT REPLACEMENT ............................................................................................... 08-02-15
COOLANT PUMP HOUSING............................................................................................. 08-02-17
THERMOSTAT ................................................................................................................... 08-02-18
COOLANT PUMP IMPELLER ............................................................................................ 08-02-18
ROTARY SEAL ................................................................................................................... 08-02-19
CARE .................................................................................................................................. 08-02-21
SMR2002-095_08-01ATOC.FM 08-01-1
CIRCUIT, COMPONENTS AND CARE 0

DI engines
Pipe
Pipe sealant
sealant
Pipe
sealant
Pipe
sealant
Pipe
sealant
Pipe
sealant
Loctite
243
3 Body
Silicone
sealant
2
4
Pipe
7 sealant
0.11 Nm
(1 lbfin)
8
0.6 Nm Loctite

(5 lbfin) 6 243
5 Nm
(44 lbfin) 5
F18E1NS
SMR2002-080_08_02A.FM 08-02-1
4-TEC Engines - Closed loop system
4
6
7
2 5
14
8 15
13
11
10
9
12
F18E0ZS
08-02-2 SMR2002-080_08_02A.FM
4-TEC Engines - Open loop system
F18E1DS
SMR2002-080_08_02A.FM 08-02-3
Water injected in Water flows through water jackets Water flows through
F12E09S
the tuned pipe to cool the magneto area and the crankcase water jackets to cool the
08-02-4
Water injected
controlled by the Temperature air compressor into muffler to
water flow sensor cool exhaust
DI Engines
regulator valve for activates Crankcase components
noise reduction monitoring
and performance beeper when Temperature
improvement temperature Magneto cover Air sensor activate
exceeds compressor monitoring
Water flows out 80°C (176°F) beeper when
of tuned pipe temperature
water jacket exceeds
100°C (212°F)
Quick
connect
hose fitting
for easy
engine
draining
Drain hose
Engine water (lowest point
supply hose of circuit)
from jet
pump
Cooling
System
GTX DI Indicator
routing (CSI)
GTX DI
RX DI
routing
Engine water
Water flows out of exhaust return hose
manifold water jacket and through from tuned Bleed hose Air
Side of hull pipe water (upper point compressor
tuned pipe water jacket before Cooling System
exiting the tuned pipe jacket of circuit) silencer
Indicator RX DI
SMR2002-080_08_02A.FM
(CSI)
4-TEC engines
Coolant temperature sensor (CTS)

activates when temperature exceeds
100°c (212°f)
Expansion
coolant tank
Bleed hose from

cylinder head to
expansion coolant tank
Coolant housing
including thermostat
opens at 87°c/(188°f)
and coolant pump
impeller
Ride plate Coolant flows

(operates as heat to ride plate
exhanger)
Coolant flows
to oil cooler
Oil cooler
Coolant returns Coolant returns
from ride plate from oil cooler
F18E0WS
SMR2002-080_08_02A.FM 08-02-5
DI engines Water circulates through the one piece cylinder

head which features improved combustion cham-
CIRCUIT ber and better spark plug cooling.
CAUTION: All hoses and fittings of the cooling

system have calibrated inside diameters to as-
sure proper cooling of the engine. Always replace
using appropriate Bombardier part number.
The water supply is provided by a pressurized area
The water flow is controlled by a reducer located
between the jet pump support and the jet pump
on the inlet side. The reducer is blue on the DI mod-
els.
The water is entering the engine by the water inlet
fitting at the cylinder head. F06D21A
1 Water enters cylinder block water jackets and is

directed to the water jackets of the exhaust man-
ifold and tuned pipe head through passages locat-
ed above and below exhaust ports.
F08E05A
Water from inlet hose also supplies the water reg-

F06D20A 1
ulator on muffler and magneto cover and crankcase
cover. 1. Water passages
Water then is expulsed through the pump support

drain.
08-02-6 SMR2002-080_08_02A.FM
Water exits tuned pipe water jackets through an Bleeding of the cooling system is accomplished by
outlet fitting. the bleed hose located at the uppermost point of
the circuit at the tuned pipe. The bleed hose also
serves as the Cooling System Indicator (CSI).
F06E08A 1
1. Engine water outlet F06E0BA 1
Water circulates in the water outlet hose and is 1. Bleed hose
expelled out of the cooling system through a fit- The water supply of the water flow regulator is pro-
ting located in the jet pump support on the tran- vided by the water supply hose coming from the
som of the watercraft. pump.
Water flows out of tuned pipe water jacket from
upper fitting of tuned pipe and is directed to the
air compressor, then to the air silencer at the tran-
som.
Water continues to flow in the crankcase water
jacket to cool the crankcase area to then be ex-
pulsed to the transom area.
the drain hose connected to a fitting at the bottom
of the cylinder-block, on tuned pipe side.
F06E09A 1
1. Water flow going to CSI
F06E0IA 1
1. Drain hose
SMR2002-080_08_02A.FM 08-02-7
The lower hose of the valve is the water supply COMPONENTS

and the upper hose is the regulated injection water
for the tuned pipe. Clamp
cooling system hoses, use pliers (P/N 295 000 070).
1
3
F06E0CA
1. Water from engine water supply hose

2. Regulated injection water to the tuned pipe
3. Muffler 2
F01B2KA
Regulated water is injected in the tuned pipe by a
calibrated fitting. 1. Cutting clamp
2. Securing clamp
Elbow Fitting
Water injection used on exhaust system cools the
exhaust gases to obtain maximum performance
from the tuned pipe. The elbow fitting no. 1 has a
calibrated inside diameter to optimize water flow
in tuned pipe.
The water injection also helps in reducing noise
level and cools components of the exhaust sys-
tem.
CAUTION: The elbow fittings are calibrated and
can not be interchanged with one of a different
size as severe engine damage could result.
F06E0AA 1
1. Injection fitting
08-02-8 SMR2002-080_08_02A.FM
The elbow fitting can be identified by using the The water flow regulator valve no. 2 is mounted
number stamped onto the fitting or by measuring directly onto the muffler.
its inside diameter. Refer to the following illustra-
tion and chart.
16
A
F01E1FA 3 1 2
F00E04A
B
TYPICAL
1. Stamped number 1. Water supply hose of regulator valve
A. Outlet diameter = 4.6 mm (.181 in) 2. Regulated water to injection fitting
B. Inlet diameter = 5.5 mm (.219 in) 3. Water injected into the muffler
STAMPED
NOTE: The water injected into the muffler is not
NUMBER FITTING INLET OUTLET regulated by the valve. A calibrated water injection
ON P/N DIAMETER DIAMETER fitting of 4.0 mm (.156 in) inside diameter limits
FITTING water flow into the muffler.
The water flow regulator valve has a calibrated
5.5 mm 4.6 mm
16 293 700 016
(.219 in) (.181 in)
spring and a tapered needle which regulate the
injected water in the tuned pipe.
CAUTION: Do not change anything on the wa-
Water Flow Regulator Valve ter flow regulator valve, otherwise serious en-
A water flow regulator valve is mounted so that gine damage can occur. In many countries it is
they can produce the maximum horsepower out- illegal to tamper with this valve as this will af-
put and yet maintain the necessary diameter of fect the EPA certification.
the injection fitting at the tuned pipe head for un- At low speed, water pressure in the supply hose
obstructed water flow. 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.
SMR2002-080_08_02A.FM 08-02-9
Adjustment
The water flow regulator valve has been calibrated
at the factory and should not be modified.
NOTE: Water flow regulator valves ordered from
the parts channel are also calibrated. The valve cap
on the is sealed and it is not adjustable.
If the maximum engine speed cannot be attained
or if the engine has poor performance, the water
flow regulator valve should be considered in the
2 troubleshooting of the problem.
Disassembly
1 Remove the cover no. 4 of the valve by releasing
the spring no. 3.
 WARNING
Firmly hold cover to valve base. The spring
3 inside the valve is applying a pressure against
F01E2BA
the cover.
LOW SPEED OPERATION
2. Water exiting regulator valve (less restriction)
At higher speed, water pressure increases in the

supply hose of the regulator valve and gradually
overcomes the return spring of the regulator valve. 1
Less water is being delivered to the injection fitting
at the tuned pipe.
F01E1RA
1. Spring
2. Cover
F01E2CA
3
HIGH SPEED OPERATION

2. Water exiting regulator valve (more restriction)
08-02-10 SMR2002-080_08_02A.FM
Remove fitting no. 5 from valve housing. Remove the tapered needle from valve housing.
1
1
F01E1SA F01E20A
1. Fitting 1. Remove tapered needle
Unscrew the tapered needle no. 6. Pull the valve slightly. Using pliers, release the clamp
NOTE: Hold the valve to prevent it from turning. which retains the bellows no. 8.
Remove valve no. 7 and bellows no. 8.
F01E1TA
F01E21A
1. Tapered needle
Loosen clamp to separate valve from bellows.
F01E24A 1
1. Clamp
SMR2002-080_08_02A.FM 08-02-11
Inspection When towing your watercraft in water, pinch the

Inspect parts for damage. Verify especially bellows water supply hose from the jet pump housing to the
for cracks. engine with a large Hose Pincher (P/N 529 032 500).
Assembly
Assembly is essentially the reverse of disassembly
procedures.
CARE
For flushing purposes, the cooling system is equipped
with hose adapter.
A garden hose is used to flush the whole system by
backwash. For flushing procedure, refer to FLUSH-
ING AND LUBRICATION.
F01B23A
For winterization of cooling system, refer to STOR-
AGE.
This will prevent the cooling system from filling
When servicing the hull, always rotate watercraft which may lead to water being injected into and
clockwise (seen from the rear). Rotating water- filling the exhaust system. Without the engine run-
craft on the opposite side could allow residual wa- ning there isn’t any exhaust pressure to carry the
ter in tuned pipe to enter the engine and cause water out the exhaust outlet.
damage.
max. 90° tercraft in water and do not have a hose pincher
speed of 24 km/h (15 MPH).
F06L0GA
Towing the Watercraft in Water F18E01A 1

Special precautions should be taken when towing 1. Hose pincher on water supply hose on this side of the T-fitting
Maximum recommended towing speed is 24 km/h the hose pincher must be removed before oper-
(15 MPH). ating it.
08-02-12 SMR2002-080_08_02A.FM
1503 engines CAUTION: Never modify cooling system arrange-

ment, otherwise serious engine damage could
CIRCUIT occur.
Closed Loop System
Pressure Cap
A closed loop cooling system is utilized on the
1503 4-TEC engines, which offers an efficient en- Check if cap pressurize the system. if not, install
gine cooling while keeping dirt and salt water out a new 90 kPa (13 PSI) cap (do not exceed this pres-
of the cooling system. This system keeps the tem- sure).
perature constant and prevents internal engine
corrosion. COOLING SYSTEM LEAK TEST
A separate coolant expansion tank ensures that
enough engine coolant is in the circuit during any  WARNING
operating condition. To prevent burning yourself, do not remove
The coolant flow comes from the coolant pump the expansion tank cap or loosen the ride-
impeller into the engine block. It goes around the plate drain plug if the engine is hot.
cylinders and straight up to the cylinder head. A
Install test radiator cap (P/N 529 021 400) and hose
smaller quantity of engine coolant enters the en-
pincher (P/N 295 000 076) on overflow hose. Pres-
gine block on the exhaust side for a better cooling.
surize all system through coolant expansion tank
In the cylinder head the water channels flow
to 90 kPa (13 PSI).
around the exhaust and then the intake valves and
leave the engine through a large hose. From there
the coolant goes back to the water pump housing
and depending on the engine temperature, it
flows through the thermostat directly back to the 2
water pump impeller, or it takes its way through
the ride plate which operates as a heat exchanger.
A smaller quantity of engine coolant is also direct-
ed towards the oil cooler, which is located under
the air intake manifold, to increase cooling effi-
ciency.
Coolant temperature sensor and bleed nipple are
located on the cylinder head.
1 F18E1IA 1
1. Hose pincher
2. Pressure pump (P/N 529 021 800)
2
Check all hoses, ride plate, engine and oil cooler for
coolant leaks. Spray a soap/water solution and look
for air bubbles.
Remove hose pincher and test pressure cap.
Open Loop system

The water supply is provided by a pressurized area
F18E0XA The water flow is controlled by a reducer located
1. Bleed nipple between the jet pump support and the jet pump
2. Coolant temperature sensor (CTS) on the inlet side. The reducer is black on the 4-TEC
models.
SMR2002-080_08_02A.FM 08-02-13
Water is directed to the exhaust manifold fitting Water enters exhaust pipe and flows in the water
located at front of manifold. jacket of pipe.
3 1
F18E1FA 2
1. Exhaust manifold
2. Water inlet
3. Water outlet
Water enters the manifold end and is directed to

water jackets of exhaust manifold.
Water exits exhaust manifold through 2 hoses at 2
rear manifold.
3 2 1
F18E1GA
1. Exhaust pipe
2. Outlet holes of exhaust pipe
3. Muffler
Bleeding of the exhaust system is accomplished

by the bleed hose located at the upper most point
of the circuit of the exhaust pipe.
Water exits exhaust pipe through holes at the end
of the water packet and mixes with exhaust gas
in the muffler.
F18E1EA
Water is expulsed from mufflers then through the
1. Water coming from exhaust manifold exhaust outlet in transom area.
2. Exhaust pipe
3. Bleed hose
08-02-14 SMR2002-080_08_02A.FM
Clamp DRAINING THE SYSTEM

cooling system hoses, use pliers (P/N 295 000 070).  WARNING
Never drain or refill cooling system when en-
gine is hot.
Remove expansion tank cap.

To drain cooling system, unscrew cooling system
drain plug at the rear of ride plate.
2
F01B2KA
1. Cutting clamp
2. Securing clamp
INSPECTION F18E1JA 1
Check general condition of hoses and clamp tight- 1. Cooling drain plug
ness.
Use an appropriate container to collect coolant.
Check the weep hole if there is oil or coolant. Dispose coolant as per local regulations.
Do not reinstall drain plug at this time.
COOLANT REPLACEMENT
Recommended Coolant
Use a blend of 50% antifreeze with 50% water.
Premixed antifreeze/water is available (P/N 293 600
038).
To prevent antifreeze deterioration, always use the
same brand. Never mix different brands unless cool-
ing system is completely flushed and refilled.
Do not reinstall pressure cap.
F18E1CA 1 CAUTION: To prevent rust formation or freez-
1. Weep hole ing condition in cold areas, always replenish the
system with 50% antifreeze and 50% water.
NOTE: Flowing coolant indicates a damaged rota- Pure antifreeze will freeze at a higher tempera-
ry seal. Oil out of the weep hole indicates a non ture than the optimal water/antifreeze mix. Al-
working oil seal. ways use ethylene glycol antifreeze containing
corrosion inhibitors specifically recommended
for aluminum engines.
System Capacity
Refer to TECHNICAL DATA.
SMR2002-080_08_02A.FM 08-02-15
Coolant Replacement Procedure Continue to pour and fill expansion tank between
marks.
 WARNING
To prevent burning yourself do not remove
the expansion tank cap or loosen the ride
plate drain plug if the engine is hot.
Drain the system completely as described above.

Watercraft should be level, engine cold and drain
plug removed for refilling.
Place a container under drain plug to collect anti- 1
freeze.
Ask someone to pour antifreeze in expansion tank
while watching antifreeze and air bubble flowing out
through drain hole. When no air bubbles escape, re-
install drain plug. Torque to 8.3 N•m (73 lbf•in).
F18E0NA
1. Level between marks when engine is cold

1
Do not install pressure cap at this time.
Properly cool exhaust system by installing a gar-
den hose. Refer to flushing in MAINTENANCE
Section.
Start engine and let run for 2 minutes. Stop engine
and wait 15 minutes to cool down. Refill tank as
necessary.
Repeat this run-stop cycle 2-3 times until thermo-
F18E1LA
stat opens and stop engine.
1. Pour antifreeze/water mix in expansion tank
Last, refill expansion tank and install cap.
When engine has completely cooled down, re-
check coolant level in radiator and coolant tank and
top up if necessary.
Test the density of the coolant using an antifreeze
hydrometer.
1 NOTE: Follow hydrometer manufacturer instruc-
tions for proper use.
The reading should be some degrees below the
coldest temperature you expect in the area where
the watercraft is to be used. Add water or anti-
freeze accordingly. Refill to the proper level.
F18E1KA
CAUTION: Pure antifreeze will freeze at a high-
er temperature than the optimal water/anti-
1. Watch air bubbles flowing here freeze mix.
08-02-16 SMR2002-080_08_02A.FM
COOLANT PUMP HOUSING Check if thermostat is in good condition. Refer to

THERMOSTAT elsewhere in this section.
Installation
cedure. Install screws as per the following illustra-
tion.
2 2 1
1
1 1
F18E0YA
1. Coolant pump housing
Removal 1
Drain cooling system and engine oil, refer to LU-
BRICATION SYSTEM.
F18E10A 1 1
Remove from housing:
1. Screw M6 x 25
– ride plate inlet and outlet hoses 2. Screw M6 x 105
– cylinder head outlet hose no. 1 CAUTION: To prevent leaking, take care that
– oil cooler inlet hose no. 2 the gaskets are exactly in groove when you re-
install the coolant pump housing.
– oil cooler outlet hose no. 3
Apply Loctite 243 on screw threads and torque to
– screws no. 4 and no. 5 retaining coolant pump 10 N•m (88 lbf•in).
housing no. 6
Tightening sequence for screws on coolant pump
– coolant pump housing no. 6. housing is as per following illustration.
Inspection 7 8 1
Check if gasket no. 7 is brittle, hard or damaged
and replace as necessary.
1 6
5
F18E10B 2 3
F18E11A
1. Weep hole pump housing gasket
SMR2002-080_08_02A.FM 08-02-17
THERMOSTAT Dynamic Test

The thermostat is a single action type. To check the operation of the thermostat, put it in
water and heat water. Look inside the cylinder
Removal head return hose connection to see the move-
ment of the thermostat. Thermostat should open
Remove the coolant pump housing from the PTO when water temperature reaches 87°C (188°F).
cover. Refer to COOLANT PUMP HOUSING RE-
MOVAL elsewhere in this section. If there is no operation, replace coolant pump
housing and thermostat.
NOTE: The thermostat is located inside the cool-
ant pump housing. Installation
Leak Test For installation, reverse the removal procedure,
paying attention to the following details.
Plug the connections of the oil cooler return hose,
coolant tank hose, ride plate return hose and cyl- Refer to COOLANT PUMP HOUSING REPLACE-
inder head return hose with a rag. MENT in this section.
COOLANT PUMP IMPELLER

Removal
Remove:
– coolant pump housing no. 6
– unscrew the impeller no. 8 clockwise.
4 1
F18E12A 1 3
1. Oil cooler return connection
2. Coolant tank hose connection
3. Ride plate return hose connection
4. Cylinder head return hose connection
F18E13A
Fill the coolant pump housing with water.
1. Impeller
If a bigger quantity of coolant leaks out at the ride
plate outlet connection, replace the coolant pump CAUTION: Coolant/Oil pump shaft no. 9 and
housing. Refer to COOLANT PUMP HOUSING in impeller no. 8 have left-hand threads. Remove
this section. by turning clockwise and install by turning
If there is no leak, check the operation of the ther- counterclockwise.
mostat.
Inspection
Check impeller for cracks or other damage. Replace
impeller if damaged.
08-02-18 SMR2002-080_08_02A.FM
Installation 2
cedure. Pay attention to the following details.
CAUTION: Be careful not to damage impeller
wings during installation.
Torque impeller to 3 N•m (26 lbf•in).
ROTARY SEAL 1
Inspection
Check weep hole for oil or coolant leak.
F18E14A
1. Retaining screws
2. Oil pump cover
– remove oil pump cover no. 12

– remove outer oil pump rotor no. 13
1
F18E1CA 1
1. Weep hole
Coolant leaking out of the hole indicates a defective

rotary seal. Leaking oil indicates a faulty oil seal.
However, if seal is disassembled both parts have
to be replaced together.
F18E15A
Removal 1. Outer oil pump rotor

Remove:
– coolant pump housing no. 6
CAUTION: Always unscrew the impeller clock-
wise otherwise you can damage the compo-
nents.
– unscrew the impeller no. 8 clockwise
– remove PTO cover no. 10. Refer to PTO HOUS-
ING/MAGNETO Section
– remove screws no. 11 retaining oil pump cover
SMR2002-080_08_02A.FM 08-02-19
– extract the coolant/oil pump shaft no. 9 from Installation

outside PTO housing cover with a pusher
cedure. Pay attention to the following details.
1
2 NOTE: Never use oil in the press fit area of the oil
seal and rotary seal.
Push water pump shaft oil seal in place by using
thumb.
Install the new rotary seal using the rotary seal in-
staller P/N 529 035 823.
CAUTION: Never use a hammer for the rotary
seal or water/oil pump shaft installation. Only
use a press to avoid damaging the ceramic
component.
F18E16A
2 1
1. Pusher
– remove Rotary Seal no. 14 with a screwdriver
F18E19A
1. Rotary seal
2. Rotary seal installer
F18E17A
Install the coolant/oil pump shaft using the rotary
CAUTION: Be careful not to damage the surface of seal installer P/N 529 035 823 on the opposite side
the rotary seal bore in magneto housing cover. to the rotary seal and the oil seal protector P/N 529
035 822 with a press.
– always replace also the oil seal no. 15 behind
the rotary seal. 2 1
F18E1AA
1. Oil seal protector

F18E18A
1. Oil seal
08-02-20 SMR2002-080_08_02A.FM
This will prevent the exhaust cooling system from

1 filling which may lead to water being injected into
and filling the exhaust system and the engine.
Without the engine running there isn’t any ex-
haust pressure to carry the water out the exhaust
outlet.
tercraft in water and do not have a hose pincher
2 speed of 24 km/h (15 MPH).
F18E1BA
1. Coolant/oil pump shaft with oil seal protector
2. Rotary seal installer
CARE
For flushing purposes, the exhaust cooling system is
equipped with a hose adapter.
To connect to the fitting spigot. A garden hose is
used to flush the whole system by backwash. For
flushing procedure, refer to FLUSHING AND LU-
BRICATION.
For winterization of cooling system, refer to STOR-
AGE.
When servicing the hull, rotate watercraft either
way (seen from the rear) maximum to 90°.
Towing the Watercraft in Water

Special precautions should be taken when towing
Maximum recommended towing speed is 24 km/h
(15 MPH).
When towing your watercraft in water, pinch the
water supply hose from the jet pump housing to the
engine with a large Hose Pincher (P/N 529 032 500).
1
F18E0RA
1. Hose pincher

the hose pincher must be removed before oper-
ating it.
F01B23A
SMR2002-080_08_02A.FM 08-02-21
TECHNICAL DATA
TYPE:
Closed and open loop cooling system.
COOLANT FLOW:
Pressure build-up at coolant pump.
TEMPERATURE CONTROL:
Thermostat.
SYSTEM BLEEDING:
Self-bleed type through expansion tank
(hose at uppermost point of circuit).
SYSTEM DRAINING:
Self-drain type on the exhaust cooling system
(hose at lowest point of circuit).
SYSTEM FLUSHING:
Required only for exhaust cooling system
(open loop system).
MONITORING BEEPER:
Turns on at 100°C (212°F).
COOLANT LIFE CYCLE
2 years
08-02-22 SMR2002-080_08_02A.FM
TABLE OF CONTENTS 0
FUEL CIRCUIT........................................................................................................................ 09-02-1
GENERAL ........................................................................................................................... 09-02-3
REMOVAL........................................................................................................................... 09-02-3
INSPECTION ...................................................................................................................... 09-02-5
ASSEMBLY......................................................................................................................... 09-02-6
FUEL SYSTEM PRESSURIZATION ................................................................................... 09-02-6
AIR INTAKE ............................................................................................................................ 09-03-1

REMOVAL........................................................................................................................... 09-03-3
ASSEMBLY ........................................................................................................................ 09-03-4
SMR2002-095_09-01ATOC.FM 09-01-1
FUEL CIRCUIT 0
947 DI Engines
6
7
16
4 Nm
(35 lbfin)
4
22 Nm 2.5 Nm
(16 lbfft) (22.12 lbfin)
8
5
13
4 Nm
4 (35 lbfin)
14
F12F0ZT
SMR2002-081_09_02A.FM 09-02-1
4-TEC Engines
22 Nm
(16 lbfft)
8
2.5 Nm
(22.12 lbfin)
4
4 Nm 5
(35 lbfin)
13
4 Nm
(35 lbfin)
4
14
F18F08S
09-02-2 SMR2002-081_09_02A.FM
GENERAL
 WARNING
The fuel system of a fuel injection system
hold much more pressure than on a carburet-
ed watercraft. Prior to disconnecting a hose
or to removing a component from the fuel
system, follow the recommendations de-
scribed in ENGINE MANAGEMENT under F01B04A 1
Fuel System.
1. Securing clamp
 WARNING
Whenever repairing the fuel system, always
verify for water infiltration in reservoir. Re-
place any damaged, leaking or deteriorated
fuel lines.
When working with fuel, pay attention to the fol-

lowing warning.
 WARNING
Fuel is flammable and explosive under cer-
tain conditions. Always work in a well venti- 1
F01B05A
lated area. Always wipe off any fuel spillage
from the watercraft. 1. Securing clamp in limited access
When replacing fuel lines on SEA-DOO water-

To secure or cut Oetiker clamps on fuel lines, use
craft, be sure to use “B1” hoses as available from
pliers (P/N 295 000 070).
Bombardier parts department. Use hoses ass’y
available as parts replacement only. This will en-
sure continued proper and safe operation.
 WARNING
Use of improper fuel lines could compromise
fuel system integrity.
REMOVAL
1 Fuel Filter
F01B03A
DI Models
1. Cutting clamp A replaceable inline filter is located near the fuel
tank. Another filter is located at the electric fuel
pump inlet. The pump has to be removed from the
fuel tank to have access to its filter. Refer to EN-
GINE MANAGEMENT (DI) section.
SMR2002-081_09_02A.FM 09-02-3
Disconnect MPEM connectors.

 WARNING Detach MPEM assembly and support from bilge.
The inline filter needs to be replaced only with
4 Oetiker clamps (2 on each side). Remove TOPS switch from electrical harness or
MPEM bracket.
CAUTION: A pressure test needs to be complete Remove air box. (Refer to AIR INTAKE SYSTEM
after replacement. sub-section.
Electric Fuel Pump From storage compartment disconnect fuel pump
connections.
Refer to appropriate ENGINE MANAGEMENT
Remove fuel pump from fuel tank. Refer to EN-
section.
GINE MANAGEMENT section.
Fuel Tank Detach reverse system support.
947 DI Engines
Remove electric fuel pump. Refer to the above sec-
tion.
Detach all fuel tank straps.
Pull out fuel tank.
4-TEC Engines
NOTE: It is necessary to remove the engine. Refer
to REMOVAL AND INSTALLATION sub-section.
Siphon fuel tank. 1
Use pliers to pull out darts and remove front ac-
cess panel.
F18F0BA
1. Screw
Remove battery. Refer to CHARGING SYSTEM

sub-section.
Disconnect fuel tank connections.
Cut locking ties as required to release wiring har-
ness.
Detach straps with hook tool (P/N 529 035 559).
Remove fuel tank from the vehicle.
 WARNING
Check that fiberglass is not exposed.
F18F0AA
1. Dart
09-02-4 SMR2002-081_09_02A.FM
INSPECTION Pressure Relief Valve

This valve will eliminate fuel spillage when the wa-
Fuel Filter Bowl tercraft is upside down. If pressure is built up in fuel
Check filter bowl for water contamination. system the valve should open at 3.5 kPa (0.5 PSI)
for DI.
Gasket
Inspect gasket condition. Make sure gasket no. 3  WARNING
is well positioned into the filter bowl no. 2. If pressure relief valve is stuck, the pressure
in fuel system will build up and it may cause
fuel leakage in engine compartment.
1
NOTE: It is a one-way valve with an arrow to indi-
cate the air flow.
Check Valve
Fuel Tank
Visually inspect the inside and outside of the fuel
tank necks for crack(s). If crack(s) are existing, re-
place fuel tank no. 14.
F01F02A
Check with your finger to feel the inside and out-
1. Gasket in bowl side surfaces of fuel tank. Flex fuel tank necks to
Inspect inline filter condition. Carefully use low ensure there are no hidden cracks.
pressure compressed air to clean. Replace if per- 4 2
manently clogged or damaged.
DI Models
NOTE: The fuel filter needs to be replaced after
250 hours. 1
All Models
The filter at fuel pump inlet is not replaceable indi-
vidually. The complete fuel pump unit has to be
3 A 5
replaced. F07F06A
1. Tank upper surface

Fuel Filler Hose 2. Inspect outside, above upper surface
3. Normal molding seam
Verify fuel filler hose no. 5 for damage. Always en- 4. Inspect inside, above upper surface
5. Base of the neck
sure that clamps no. 4 are well positioned and A. Approx. 4 mm (5/32 in)
tightened. Torque clamps to 4 N•m (35 lbf•in).
NOTE: A fuel tank is comprised of 3 components:
the tank, the fuel pick up neck and the filler neck.
The necks are injection molded and the tank is
then blow molded over the necks. During the
molding process, a small molding seam may ap-
pear on the inner side of the necks at approximate-
ly 4 mm (5/32 in) from the base of the neck. It is a
normal situation to have a molding seam and it
should not be confused with a crack.
Inspect rubber carpet under tank for damage.
SMR2002-081_09_02A.FM 09-02-5
ASSEMBLY FUEL SYSTEM PRESSURIZATION

bly procedures.  WARNING
947 DI Engines craft or if any components of the fuel system
Install fuel pump on fuel tank and torque nuts to are disconnected, a pressure test must be
2.5 N•m (1.8 lbf•in). done before starting engine. Ensure to verify
fuel line ends for damage. Always cut dam-
2 aged end before reinstallation.
9
8
10 Pressure Test (supply and vent circuits)
Proceed as follows:
– Fill up fuel tank.
3
7 – Disconnect air inlet hose of fuel tank from body.
– Install a hose pincher (P/N 295 000 076) on fuel
11 tank vent hose.
RE
S
OU
T
12 1
1 2
F18F09A 5
TORQUE AS PER SEQUENCE
4-TEC Engines
Ensure rubber carpet is in place.
Insert tank, air box and straps. F01F0KA
Place straps in clips (bottom) and in guides of air-

TYPICAL
box. 1. Disconnect air inlet hose
Insert strap ends in hoops. Use tape to hold in 2. Install a hose pincher to vent hose
place. – Connect pump gauge tester (P/N 529 021 800)
Properly secure harnesses. to air inlet hose.
Reinstall fuel pump. Refer to ENGINE MANAGE- NOTE: This pump is included in the ENGINE LEAK
MENT section. TESTER KIT (P/N 295 500 352).
09-02-6 SMR2002-081_09_02A.FM
– Pressurize fuel system to 34 kPa (5 PSI).

– If no leaks are found, turn fuel valve to ON po-
sition and pressurize once more.
– If pressure is not maintained locate leak and
repair/replace component leaking. To ease leak
search spray a solution of soapy water on com-
ponents, bubbles will indicate leak location.
34 kPa (5 PSI) during 10 minutes. Never pressurize
over 34 kPa (5 PSI).
Reconnect air inlet hose of fuel tank to body.
 WARNING
If any leak is found, do not start the engine
and wipe off any fuel leakage. Do not use
electric powered tools on watercraft unless
system has passed pressure test.
NOTE: Before removing the hose pincher, block

with your finger the outlet fitting to feel if air is
coming out when removing hose pincher. This will
indicate that pressure relief valve and the outlet
fitting are not blocked.
Remove hose pincher from fuel tank vent hose.
High Pressure Test (fuel pump circuit)

Refer to the appropriate ENGINE MANAGEMENT
section.
 WARNING
Prior to installing the safety lanyard, refer to
the appropriate ENGINE MANAGEMENT sec-
tion for safety precautions to take.
SMR2002-081_09_02A.FM 09-02-7
AIR INTAKE 0
947 DI Engines
Loctite 243
2
1112
Loctite 243
14 4
13
Super
Lube Loctite
243
3
F12F0KT
SMR2002-082_09_03A.FM 09-03-1
4-TEC Engines
1
14
4 Nm
(35 lbfin)
13
5
7
6
4
2
8 2
3
12
9
10
11
10
11
F18F0FS
09-03-2 SMR2002-082_09_03A.FM
REMOVAL Pull air ducts out.
947 DI Engines
Air Intake Silencer
Pull hair pin out to allow removal of clip no. 2.
1
F08F09A
1. Air duct
4-TEC Engines
F00F0FA
Disconnect connectors no. 1, no. 2 and no. 3.

2. Clip Detach straps no. 4 using hook tool (P/N 529 035
3. Hair pin
559).
Unlock the clip no. 2 on top of air intake silencer.
1 2 3
Remove bolts retaining both air ducts to engine (both
sides).
F18F0GA 4
1. Magneto connector
F08F08A 1 1 2.
3.
Voltage regulator connector
Fuse connector
4. Straps
1. Remove bolts
Loosen spring clamp no. 2 and remove formed
hose no. 3 from engine.
Loosen clamp no. 5 and remove intake hose no. 6
from engine.
SMR2002-082_09_03A.FM 09-03-3
ASSEMBLY Ensure the elbow adaptor is well inserted and that

it has not pushed the gasket inside the air box.
NOTE: Make sure the air intake silencer is retained
by the lower bracket no. 4.
the following.
Place protector pads on duct supports. Use slot in
rubber to insert pad on bracket eyelet. Side tongue
of protector pad should be toward outside of vehi-
947 DI Engines cle and bent downward toward the exhaust flange.
Air Intake Silencer Put air ducts in intake adapters and secure them
on duct supports with hexagonal screws no. 13,
Ensure that support plate edges no. 14 are prop- wide washers, narrow washers and elastic stop
erly crimped to air intake silencer. Use pliers as nuts. A slight lift will be required to make the bolts
necessary. line up with brackets.
Make sure that gaskets no. 11 are installed into
4-TEC Engines
carburetor holes of air intake silencer or throttle
bodies. Air Intake Silencer
Check O-rings no. 12 on carburetor intake adap- Put air intake silencer in place over fuel tank.
tors or throttle bodies and change them if neces-
Fasten air intake silencer with straps no. 4, using
sary.
hook tool (P/N 529 035 559).
NOTE: Apply Super Lube grease (P/N 293 550
Attach intake hose no. 6 to engine and tighten
014) to mating surface of air intake silencer no. 1.
clamp no. 5 to 4 N•m (35 lbf•in).
Install air intake silencer on carburetor intake adap-
Attach formed hose no. 3 to engine and fasten
tor or throttle bodies and latch in place.
with spring clamp no. 2.
Clip air intake silencer back in place.
Attach connectors no. 1, no. 2 and no. 3.
Properly reinstall hair pin to secure clip no. 2.
09-03-4 SMR2002-082_09_03A.FM
Section 10 LUBRICATION SYSTEM (DI)
TABLE OF CONTENTS 0
OIL INJECTION SYSTEM ...................................................................................................... 10-02-1
GENERAL ........................................................................................................................... 10-02-2
OIL SYSTEM PRESSURIZATION ...................................................................................... 10-02-2
OIL INJECTION PUMP .......................................................................................................... 10-03-1

OIL PUMP IDENTIFICATION ............................................................................................. 10-03-2
REMOVAL........................................................................................................................... 10-03-2
DISASSEMBLY .................................................................................................................. 10-03-2
CLEANING ......................................................................................................................... 10-03-2
ASSEMBLY ........................................................................................................................ 10-03-2
ADJUSTMENT ................................................................................................................... 10-03-3
CHECKING OPERATION.................................................................................................... 10-03-4
SMR2002-095_10-01ATOC.FM 10-01-1
OIL INJECTION SYSTEM 0
Under Air
Compressor
27 Nm
(20 lbfft)
3.5 Nm 1
(31 lbfin)
3
2
3.5 Nm 1
(31 lbfin)
Dielectric
grease
4
F12G07S
SMR2002-083_10_02A.FM 10-02-1
GENERAL Disconnect oil tank vent line on PTO side throttle

body.
Whenever repairing the oil injection system, al-
Connect pump gauge tester (P/N 529 021 800) to
ways verify for water infiltration in reservoir.
disconnected tube at throttle body.
Perform also a pressure test of the oil injection
NOTE: Use the same pump included in the EN-
system.
GINE LEAK TESTER KIT (P/N 295 500 352).
Clamp and Hose 1
Verify oil filler neck hose no. 2 for damage. Always
ensure that clamps no. 1 are well positioned and
tightened. Torque clamps to 3.5 N•m (31 lbf•in).
Check Valve
Oil Filter
Oil filter no. 4 should be replaced annually. F01G0IA
TYPICAL
OIL SYSTEM PRESSURIZATION 1. Connect pump to check valve
 WARNING – Pressurize oil system to 21 kPa (3 PSI).

Whenever oil system components are dis- – If pressure is not maintained, locate leak and
connected or replaced, a pressure test must repair/replace component leaking. To ease leak
be done before starting engine. Ensure to ver- search spray a solution of soapy water on compo-
ify oil line ends for damage. Always cut dam- nents, bubbles will indicate leak location.
aged end before reinstallation. Verify check valve inside filler neck if pressure
does not hold. Also ensure air can enter through
check valve in the opposite direction.
Pressure Test
Proceed as follows: 21 kPa (3 PSI) for at least 10 minutes. Never pres-
– Fill up oil reservoir. surize over 21 kPa (3 PSI).
– Install a hose pincher to oil injection pump sup- CAUTION: If any leak is found, do not start the
ply hose. engine and wipe off any oil leakage.
Install a hose pincher to return line of air compres- – Disconnect pump gauge tester and remove
sor. hose pinchers. Reconnect line at throttle body.
10-02-2 SMR2002-083_10_02A.FM
OIL INJECTION PUMP 0
To air compressor
(supply line)
Loctite 1 To crankcase
243
6 Nm
(53 lbfin) 6
4.5 Nm
(40 lbfin)
Molykote 111
7 4.5 Nm
(40 lbfin)
Throttle body
F12G01S
SMR2002-084_10_03A.FM 10-03-1
OIL PUMP IDENTIFICATION

Pump Lever
Different engines need different pumps. See identifi-
cation on lever.
CAUTION: Always mount proper pump on en-
gine.
OIL PUMP
ENGINE
IDENTIFICATION
947 09
NOTE: The following procedures can be done with-

out removing the engine from hull.
F12G02A
REMOVAL
Oil Injection Pump
The cable end has a slight press fit in the lever.
Using a small screwdriver, pry cable end out.
Disconnect oil injection pump cable no. 7.
Remove 2 Allen screws no. 6 with flat washers
retaining oil injection pump to magneto housing
cover.
Pull pump.
Disconnect oil hoses from fittings of oil injection
pump.
DISASSEMBLY
F12G03A
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 compo-
nents in a solvent.
ASSEMBLY
Oil Injection Pump and Shaft
Make sure shaft no. 8 is installed in crankshaft
end.
Install pump. Secure with flat washers and screws
F12G04A 2 1
no. 6. Torque to 6 N•m (53 lbf•in).
1. Cable end completely inserted
Install oil injection pump cable. 2. Cable end NOT seated on the steps
10-03-2 SMR2002-084_10_03A.FM
CAUTION: Ensure cable end is completely en-

tered in its housing. Ensure it is NOT seated on
the steps. 1
ADJUSTMENT
CAUTION: As oil injection pump adjustment is
dependent on throttle cable position, make
sure to perform throttle cable adjustment first
except if otherwise specified.
Preliminary Synchronization
NOTE: To check synchronization of pump as a rou-
tine maintenance, see FINAL SYNCHRONIZATION.
Turn oil pump cable adjustment nut to align refer-
ence marks on pump.
NOTE: A mirror may be used to facilitate this ver-
ification.
Loosen jam nut and turn cable adjustment nut to
obtain pump mark alignment. Refer to following
photos.
The adjustment is located under the throttle body
bracket.
F16G03B
1 2
1. Mark on pump must be facing longest mark on lever
Start and bring engine to normal operating temper-

ature.
must be cooled using the flush kit. If air bubbles
are present in the oil injection system, bleed
system before operating engine.
There is no idle speed adjustment to perform.
Stop engine.
Final Synchronization
F16F01A
Eliminate throttle cable free-play by depressing
throttle lever until a slight resistance is felt. In this
1. Oil pump cable adjustment
2. Throttle cable position, marks on pump body and lever must
align.
Adjust the cable to the rich position. Use the long-
est mark. If necessary, turn cable adjustment nut to obtain
pump mark alignment. Refer to above illustrations.
Tighten jam nut and recheck alignment marks.
CAUTION: Proper oil injection pump adjustment
is very important. Any delay in the opening of
pump can result in serious engine damage.
SMR2002-084_10_03A.FM 10-03-3
Bleeding 1
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.
1
F07G06A 2
1. Lines must be full of oil
2. Oil pump
If not, proceed as follows.

– Use the VCK (Vehicle Communication Kit) P/N
529 035 676. Look in the Monitoring section of
the software B.U.D.S.
– Use the “Oil lines bleeding” function that al-
lows to “lock” the engine RPM in idle speed
while the throttle is fully depressed to ease the
bleeding operation.
F16G02A
– Since oil cannot be seen through the small oil
1. Bleed screw lines, press and hold the vehicle throttle to wide
Keep bleeding until all air has escaped from line. open position for 45 seconds.
Make sure no air bubbles remain in oil supply line. CAUTION: If watercraft is out of water, engine
Tighten bleed screw. must be cooled using the flush kit.
Wipe any oil spillage.
CHECKING OPERATION
Check small oil lines of pump. They must be full
of oil. 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.
If not, remove pump assembly and check the shaft
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.
10-03-4 SMR2002-084_10_03A.FM
Bench Test
Connect a hose filled with injection oil to main line
fitting. Insert other hose end in an injection oil con-
tainer. Using a counterclockwise (reverse position)
rotating drill rotate pump shaft. Oil must drip from
fittings in parts of rotary valve cover while holding
lever in a fully open position.
2
3
F01G02A
TYPICAL
1. Supply oil line to an oil container
2. Hold lever in fully open position
3. Counterclockwise (reverse) rotating drill
4. Oil must drip here
For an accurate test, each port should be checked

separately to ensure equal delivery on both ports.
To obtain a precise result of the oil pump delivery
rate, rotate it counterclockwise at 1500 RPM for a
total time of 5 minutes.
NOTE: To ensure accuracy of test, oil lines should
be completely filled before starting test.
Compare the results with the chart below. If oil
pump is out of specification, replace it.
OIL PUMP FLOW RATE AT

ENGINE
1500 RPM (5 minutes)
947 DI 7.5 - 9.1 mL (each port)
SMR2002-084_10_03A.FM 10-03-5
TABLE OF CONTENTS 0
CHARGING SYSTEM............................................................................................................. 11-02-1
GENERAL ........................................................................................................................... 11-02-1
BATTERY ............................................................................................................................ 11-02-3
STARTING SYSTEM .............................................................................................................. 11-03-1

GENERAL ........................................................................................................................... 11-03-2
STARTING SYSTEM TROUBLESHOOTING ..................................................................... 11-03-3
STARTER REMOVAL.......................................................................................................... 11-03-4
STARTER DISASSEMBLY.................................................................................................. 11-03-4
CLEANING ......................................................................................................................... 11-03-7
STARTER ASSEMBLY........................................................................................................ 11-03-9
STARTER INSTALLATION ................................................................................................. 11-03-9
STARTER SPECIFICATION ................................................................................................ 11-03-11
INSTRUMENTS AND ACCESSORIES .................................................................................. 11-04-1

GENERAL ........................................................................................................................... 11-04-1
ADDITION OF ACCESSORIES .......................................................................................... 11-04-6
INSPECTION ...................................................................................................................... 11-04-6
SMR2002-095_11-01ATOC.FM 11-01-1
CHARGING SYSTEM 0
GENERAL DI
A 25 A fuse is mounted on the MPEM and a 30 A
Magneto fuse is located in the rear electrical box.
The purpose of the charging system is to keep the 4-TEC Engines
battery at a full state of charge.
The charging system is protected by 1 fuse (30 A)
The magneto is the primary source of electrical in starter relay.
energy. It transforms magnetic field into electric
current (AC).
TESTING PROCEDURE
DI Engines
NOTE: First, ensure that battery is in good condi-
The magneto has a 3 phase, delta wound stator tion prior to performing the following tests.
4-TEC Engines
Rectifier/Regulator
The magneto has a 3 phase, delta wound stator STATIC TEST: CONTINUITY
on 18 poles. Capacity is 380 watts. Due to internal circuitry, there is no static test avail-
able.
Rectifier/Regulator DYNAMIC TEST
All Current Test
The rectifier receives AC current from the magne- Proceed as follows:
to and transforms it into direct current (DC).
– Start engine.
The regulator, included in the same unit, limits
voltage at a maximum level (14.5 to 14.8 volts) to – Lay an inductive ammeter on positive cable of
prevent any damage to components. battery.
The unit is using a 3 phase in series rectifier/regulator – Bring engine to approximately 6000 RPM.
which transforms (AC) from the magneto into (DC) to Current reading should be approximately 5 amperes,
allow battery charging. depending on battery state. If not, check magneto
output prior to concluding that rectifier is faulty.
Battery Voltage Test
The battery is the DC source for the electric start-
er, the Multi-Purpose Electronic Module and all ac- All Models
cessories. Proceed as follows:
– Start engine.
Fuse
– Connect a multimeter to battery posts. Set mul-
If the battery is regularly discharged, check fuse timeter to Vdc scale.
condition.
The rectifier/regulator could be the culprit of a blown
fuse. To check, simply disconnect the rectifier/ If multimeter reads over 15 volts, regulator is defec-
regulator from the circuit. tive. Replace it.
The charging system is protected by 2 fuses. NOTE: If it is continually necessary to add distilled
water to the battery, this indicates an over voltage
If the fuse still burns, check for a defective wire. situation, requiring replacement of the rectifier/
CAUTION: Do not use a higher rated fuse as this regulator. If, on the other hand, the battery will not
could cause severe damage. stay charged, the problem can be any of the charg-
ing circuit components. If these all check good,
you would be accurate in assuming the problem
to be in the rectifier/regulator.
SMR2002-085_11_02A.FM 11-02-1
Stator 4 3 1
tor.
2. Install the 6-pin magneto harness adapter (P/N
295 000 136).
NOTE: On 4-TEC engines disconnect the stator
wiring harness connector and probe the three con-
nectors.
3. Check resistance between two of the YELLOW
wires. The resistance should be between 0.1 to
1.0 ohm.
3 1 F01H60A 2
1. Multimeter
3. Positive (+) probe to YELLOW wire
4. Negative (-) probe to ground
5. Repeat test with the other two YELLOW wires of

the 6-pin magneto harness adapter.
NOTE: There should be no continuity (infinity) be-
there is a reading, the stator coils and/or the wiring
from the coils is grounded and needs to be re-
placed or repaired.
DYNAMIC TEST
F01H5ZA 3 2 1. Disconnect the magneto wiring harness connec-
tor.
1. Multimeter
2. Magneto harness adapter 2. Install the 6-pin magneto harness adapter (P/N
3. YELLOW wires 295 000 136). Leave wiring harness side discon-
4. Place either meter lead into the remaining YEL- nected.
LOW wire and note the resistance (same as NOTE: On 4-TEC engines disconnect the stator
step no. 3). If the readings are out of specifica- wiring harness connector and probe the three con-
tion, the stator will need to be replaced. nectors.
STATIC TEST: INSULATION 3. Connect test probes of the multimeter to two
1. Disconnect the magneto wiring harness connec- of the YELLOW wires of the 6-pin magneto har-
tor. ness adapter.
2. Install the 6-pin magneto harness adapter (P/N 4. Set multimeter to Vac scale.
295 000 136). 5. Start and rev engine to 3500 RPM. The obtained
NOTE: On 4-TEC engines disconnect the stator value should be between 45 and 70 Vac on DI
wiring harness connector and probe the three con- engines, and 25 Vac on 4-TEC engines.
nectors. 6. If the stator is out of specification, replace it.
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 read-
ing.
11-02-2 SMR2002-085_11_02A.FM
BATTERY CAUTION: Should any electrolyte spillage oc-

cur, immediately wash off with a solution of
Troubleshooting baking soda and water.
SYMPTOM: DISCHARGED OR WEAK BATTERY Cleaning

CAUSE REMEDY Clean the battery casing, caps, cables and battery
posts using a solution of baking soda and water.
1. Battery posts and/or Clean and coat with CAUTION: Do not allow cleaning solution to en-
cable terminal dielectric grease.
oxidized. ter battery.
Remove corrosion from battery cable terminals
2. Loose or bad Check wiring and
connections. connector cleanliness,
and battery posts using a firm wire brush. Rinse
damaged or short circuit. with clear water and dry well.
3. Faulty battery Replace. Inspection

(sulfated, doesn’t
keep a full charge, Visually inspect battery casing for cracks or other
damaged casing, possible damage. If casing is damaged, replace
loose post). battery and thoroughly clean battery tray and close
4. 15 amp fuse(s) burnt First check fuse.
area with water and baking soda.
or faulty rectifier. If it is in good condition, Inspect battery posts for security of mounting.
check rectifier/regulator. Inspect for cracked or damaged battery caps, re-
5. Faulty battery charging Replace. place defective caps.
coil (or stator).
4-TEC Models
NOTE: Hand tighten caps then tighten an addi-
Removal tional 1/4 turn using a 20 mm (3/4 in) socket. Using
other tool could damage the plastic battery caps.
 WARNING
Battery BLACK negative cable must always  WARNING
be disconnected first and connected last. Battery electrolyte is caustic. To prevent spill-
Never charge or boost battery while installed age, battery cell cap should be sufficiently tight
in watercraft. to properly seal.
All Models All Models

Proceed as follows:
1. Disconnect the BLACK negative cable first.  WARNING
2. Disconnect the RED positive cable last. Battery caps do not have vent holes. Make sure
that vent line is not obstructed.
3. Remove the vent line from the battery.
4. Remove the holding strap(s).
Electrolyte Level
5. Withdraw battery from watercraft being careful
not lean it so that electrolyte flows out of vent Check electrolyte level in each cell, add distilled wa-
elbow. ter up to upper level line.
CAUTION: Add only distilled water in an activat-
 WARNING ed battery.
Electrolyte is poisonous and dangerous. Avoid
contact with eyes, skin and clothing. Wear a
suitable pair of non-absorbent gloves when re-
moving the battery by hand.
SMR2002-085_11_02A.FM 11-02-3
Battery Testing
ELECTROLYTE
There are 2 types of battery tests: electrolyte read- TEMPERATURE OPERATION TO
ing and load test. An electrolyte reading is made PERFORM
on a battery without discharging current. It is the °C °F
simplest and commonly used. A loaded test gives
more accuracy of the battery condition. 38 100 .012 Add
32 90 .008 to the
Electrolyte Reading 27 80 .004 reading
Check charge condition using either a hydrometer
or multimeter. 21 70 CORRECT READING
With a multimeter, voltage readings appear in- 16 60 .004
stantly to show the state of charge. Always re- Subtract
10 50 .008
spect polarity. A fully charge battery will have a from the
4 40 .012
reading of 12.6 Vdc. reading
-1 30 .016
A hydrometer measures the charge of a battery in
terms of specific gravity of the electrolyte. A fully EXAMPLE NO. 1 EXAMPLE NO. 2
charge battery will have a specific gravity between TEMPERATURE ABOVE 21°C (70°F): TEMPERATURE ABOVE 21°C (70°F):
Hydrometer reading: 1.250 Hydrometer reading: 1.235
1.265 to 1.280. Electrolyte temperature: - 1°C (30°F) Electrolyte temperature: 38°C (100°F)
Most hydrometers give a true reading at 21°C (70°F). Subtract .016 Sp. Gr. Add .012 Sp. Gr.
Corrected Sp. Gr. is 1.234 Corrected Sp. Gr. is 1.247
SPECIFIC GRAVITY READING

1 USING A HYDROMETER
ELECTROLYTE
STATE OF TEMPERATURE
CHARGE
27°C (80°F) 4°C (40°F)
100% 1.26/1.27 1.27/1.28
75% 1.21/1.22 1.22/1.23
A17E0JA
50% 1.16/1.17 1.17/1.18
25% 1.12/1.13 1.13/1.14
In order to obtain correct readings, adjust the initial
0% 1.10 or less 1.11 or less
reading by adding .004 points to the hydrometer
readings for each 5.5°C (10°F) above 21°C (70°F)
and by subtracting .004 point for every 5.5°C Load Test
(10°F) below 21°C (70°F). This is the best test of battery condition under a
This chart will be useful to find the correct reading. starting load. Use a load testing device that has an
adjustable load.
Apply a load of 3 times the ampere-hour rating of
the battery. At 14 seconds into the test, check bat-
tery voltage; if battery is in good condition, it will
have at least 10.5 Vdc.
11-02-4 SMR2002-085_11_02A.FM
Battery Storage Activation of a New Battery

CAUTION: Battery storage is critical for battery
life. Regularly charging the battery during stor-  WARNING
age will prevent cell sulfation. Keeping the bat- Never charge or boost battery while installed in
tery in vehicle for storage may lead to contacts watercraft.
degradation/corrosion and case damage if freez-
ing occurs. A discharged battery will freeze and A new battery is factory fresh dry charged.
break in area where freezing point is experi- CAUTION: Do not loosen battery caps unless
enced. Electrolyte leakage will damage sur- activation is desired.
rounding parts. Always remove battery from ve-
NOTE: In case of accidental premature removal
hicle for storage and regularly charge to keep
of caps, battery should be given a full charge.
an optimal condition.
Perform the following operations anytime a new
Disconnect and remove battery from watercraft
battery is to be installed.
as explained in REMOVAL.
1. Remove caps and fill battery to UPPER LEVEL
Check electrolyte level in each cell, add distilled
line with electrolyte (specific gravity: 1.265 at
water up to upper level line.
21°C (70°F)).
CAUTION: Do not overfill.
NOTE: This battery may fill slower than others
The battery must always be stored in fully charged due to the anti-spill check ball design.
condition. If required, charge until specific gravity
2. Allow the battery to stand for 30 minutes MIN-
of 1.265 is obtained.
IMUM so that electrolyte soak through battery
CAUTION: Battery electrolyte temperature must cells.
not exceed 50°C (122°F). The casing should not
feel hot.
Clean battery terminals and cable connections using
a wire brush. Apply a light coat of dielectric grease
on terminals.
Clean battery casing and caps using a solution of
baking soda and water.
CAUTION: Do not allow cleaning solution to en- 1
ter battery.
A17E0GA
Rinse battery with clear water and dry well using
a clean cloth. 1. 30 minutes
Store battery in a cool dry place. Such conditions 3. Readjust the electrolyte level to the UPPER LEVEL
reduce self-discharging and keep fluid evaporation line.
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. 1
If necessary, keep the battery at its upper level line
and near full charge as possible (trickle charge).
A17E0RB
2. Upper level line
SMR2002-085_11_02A.FM 11-02-5
4. Connect a 2 A battery charger for 3 to 5 hours. 6. Test battery state of charge. Use a hydrometer.
3
1
2 - + 1
A17E0IA
Step 1 : Connect + lead to battery + post

Step 2 : Connect - lead to battery - post A17E0JA
Step 3 : Plug battery charger

 WARNING 7. If electrolyte level has dropped after charging,

Gases given off by a battery being charged fill with distilled water to UPPER LEVEL line. Af-
are highly explosive. Always charge in a well ter water is added, continue charging for 1 to 2
ventilated area. Keep battery away from cig- hours to mix water with electrolyte.
arettes or open flames. Always turn battery 8. Reinstall caps and clean any electrolyte spillage
charger off prior to disconnecting cables. Oth- using a solution of baking soda and water.
erwise a spark will occur and battery might ex-
plode. 4-TEC Models
NOTE: Hand tighten caps then tighten a additional
CAUTION: If charging rate raises higher than 1/4 turn using a 20 mm (3/4 in) socket. Using other
2.4 A reduce it immediately. If cell temperature tool could damage the plastic battery caps.
rises higher than 50°C (122°F) or if the casing
feels hot, discontinue charging temporarily or  WARNING
reduce the charging rate. Battery electrolyte is caustic. To prevent spill-
5. Disconnect battery charger. age, battery cell cap should be sufficiently tight
to properly seal.
1 All Models
Charging a Used Battery
2 - + 3
 WARNING
Never charge battery while installed in water-
craft.
A17E0IB
For best results, battery should be charged when
Step 1 : Unplug battery charger the electrolyte and the plates are at room temper-
Step 2 : Disconnect - lead ature. A battery that is cold may not accept current
Step 3 : Disconnect + lead for several hours after charging begun.
Do not charge a frozen battery. If the battery charge
is very low, the battery may freeze. If it is suspected
to be frozen, keep it in a heated area for about 2 hours
before charging.
11-02-6 SMR2002-085_11_02A.FM
NOTE: Some chargers have a polarity protection

 WARNING feature which prevents charging unless the charg-
Always charge battery in a well ventilated area. er leads are connected to the correct battery ter-
minals. A completely discharged battery may not
The time required to charge a battery will vary de- have enough voltage to activate this circuitry, even
pending on some factors such as: though the leads are connected properly. This will
– Battery temperature: The charging time is in- make it appear that the battery will not accept a
creased as the temperature goes down. The charge. Follow the charger manufacturer’s instruc-
current accepted by a cold battery will remain tion on how to bypass or override this circuitry
low. As the battery warms up, it will accept a so that the charger will turn on and charge a low-
higher rate of charge. voltage battery.
– State of charge: Because the electrolyte is near- – Since the battery chargers vary in the amount
ly pure water in a completely discharged battery, of voltage and current they provide, the time
it cannot accept current as well as electrolyte. required for the battery to accept measurable
This is the reason the battery will not accept charger current might be up to approximately
current when the charging cycle first begins. As 10 hours or more.
the battery remains on the charger, the current – If the charging current is not up to a measurable
from the charger causes the electrolytic acid amount at the end of about 10 hours, the bat-
content to rise which makes the electrolyte a tery should be replaced.
better conductor and then, the battery will ac-
cept a higher charging rate. – If the charging current is measurable before the
end or at the end of about 10 hours, the battery
– Type of charger: Battery chargers vary in the is good and charging should be completed in
amount of voltage and current that they can the normal manner as specified in ACTIVATION
supply. Therefore, the time required for the bat- OF A NEW BATTERY.
tery to begin accepting measurable current will
also vary. – It is recommended that any battery recharged
by this procedure be load tested prior to return-
Charging a Very Flat or Completely Discharged ing it to service.
Battery
The battery charger should have an adjustable Battery Installation
charging rate. Variable adjustment is preferred,
but a unit which can be adjusted in small incre-  WARNING
ments is acceptable. Always connect battery cables exactly in the
The battery charger must be equipped with an am- specified order, RED positive cable first BLACK
meter capable of accurately measuring current of negative cable last.
less than 1 ampere.
Proceed as follows:
Unless this procedure is properly followed, a good
battery may be needlessly replaced. 1. Install battery in its emplacement.
– Measure the voltage at the battery posts with 2. Secure vent line to the battery and support. En-
an accurate voltmeter. If it is below 10 volts, the sure vent line is not kinked or obstructed.
battery will accept current at very low rate, in
term of milliamperes, because electrolyte is  WARNING
nearly pure water as explained above. It could Vent line must be free and open. Avoid skin con-
be some time before the charging rate increas- tact with electrolyte.
es. Such low current flow may not be detect-
able on some charger ammeters and the bat- 3. First connect RED positive cable.
tery will seem not to accept any charge. 4. Connect BLACK negative cable last.
– Exceptionally for this particular case, set the 5. Apply dielectric grease on battery posts.
charger to a high rate.
6. Verify cable routing and attachment.
Reinstall seat support.
SMR2002-085_11_02A.FM 11-02-7
STARTING SYSTEM 0
DI Engines
Dielectric
grease
Loctite 2
243
1
10 Nm Ground
(89 lbfin) cable
Synthetic
grease
Synthetic
grease
8
12
10
11
9
7
F07H0TT
SMR2002-086_11_03A.FM 11-03-1
4 -TEC Engines Battery

To check battery condition, refer to CHARGING
Grease Klueber Isoflex
Topas NB 52 SYSTEM.
4 3 2 MPEM/ECU
If 2 short beeps are not heard when installing the
5
1 safety lanyard, refer to ENGINE MANAGEMENT
section.
Engine Start/Stop Switch and Safety

Lanyard Switch
Refer to ENGINE MANAGEMENT section.
Solenoid
NOTE: Solenoid is located in the electrical box for
the DI engines and besides the MPEM for 4-TEC
engines.
Inspect connections and clean as necessary.
Static Test: Continuity
With a multimeter, check primary winding resis-
F18H0MA
tance. It should be approximately 5 Ω (ohms) for
the DI engines and 7.2 Ω (ohms) for 4-TEC en-
GENERAL gines. Measure the resistance value through pins
1 and 2 for 4-TEC engines.
Causes of troubles are not necessarily related to
starter but may be due to a burnt fuse, faulty bat-
tery, start/stop switch, safety lanyard switch,
MPEM, or ECU, DESS auxiliary module on 4-TEC
engines, solenoid, electrical cables or connec-
tions.
Check these components before removing start-
er. Consult also the starting system troubleshoot-
ing table on next page for a general view of possi-
ble problems.
 WARNING
Short circuiting electric starter is always a dan-
ger, therefore disconnect the battery ground 1
cable before carrying out any kind of mainte-
nance on starting system. Do not place tools
on battery.
Fuse F18H0SA
Make sure the starting system fuse on MPEM is 1. Pins 1 and 2

in good condition.
There should be no continuity between the posi-
The solenoid may be the cause of a burnt fuse. If tive posts of the solenoid.
the solenoid checks good, one of the accessory
may be defective.
11-03-2 SMR2002-086_11_03A.FM
Dynamic Test Electrical Cables or Connections

Depress start/stop button and measure the volt- Check all connections, cables and wires. Tighten
age on the solenoid positive posts with a multim- any loose cables. Replace any chafed wires.
eter.
If there is no voltage and battery is in good condi-
tion, replace the solenoid.
STARTING SYSTEM TROUBLESHOOTING

NOTE: Other causes of the problem may not be related to the starting system. Refer to TROUBLESHOOT-
ING section.
SYMPTOM CAUSE REMEDY
STARTER DOES NOT TURN. Burnt fuse on MPEM. Check wiring condition and replace fuse.
Poor contact of battery terminal(s). Clean and tighten terminal(s).
Poor battery ground cable connection. Clean and tighten.
Poor contact of start/stop switch, Check connectors and clean contacts.
safety lanyard switch or solenoid. Check and replace defective parts.
Open circuit: start/stop switch or
Check and replace.
solenoid.
Safety lanyard or MPEM or ECU. Refer to ENGINE MANAGEMENT.
DESS auxiliary module. Refer to engine management.
STARTER ENGAGES; Poor battery cable connections. Clean battery cable connections.
BUT DOES NOT CRANK Poor contact of brush. Straighten commutator and brush.
THE ENGINE.
Burnt commutator. Turn commutator on a lathe.
Worn commutator segments. Undercut mica.
Shorted armature. Repair or replace armature.
Weak brush spring tension. Replace brush holder or spring.
Weak magnet. Replace yoke assembly.
Worn bushings. Replace clutch.
STARTER TURNS, BUT Worn clutch pinion gear. Replace clutch.
OVERRUNNING CLUTCH Defective clutch. Replace clutch.
PINION DOES NOT MESH
WITH RING GEAR. Poor movement of clutch on splines. Clean and correct.
Worn clutch bushing. Replace clutch.
Worn ring gear. Replace ring gear.
STARTER MOTOR KEEPS Shorted solenoid winding. Replace solenoid.
RUNNING.
Melted solenoid contacts. Replace solenoid.
Sticking or defective starter clutch. Lubricate or replace.
SMR2002-086_11_03A.FM 11-03-3
STARTER REMOVAL 4-TEC Engines

Remove retaining screws no. 1 from starter.
Disconnect BLACK cable ground connection from
battery. Pull starter no. 3 out. Lift starter enough to reach
starter cable then disconnect from starter (nut
 WARNING no. 2).
Always disconnect ground cable first and re-
connect last.
Disconnect RED cable connection from battery.

4 2
DI Engines
1
Disconnect starter cables and loosen Allen screws
no. 1 retaining starter bracket to engine.
3 2
F18H0UA
1. Exhaust manifold
2. Starter
3. Retaining screws
4. Nut
STARTER DISASSEMBLY
F06H35B 1 3 DI Engines
Locate index marks on yoke no. 6 and end covers
2. Negative starter cable no. 7 and no. 8.
3. Allen screw
1
Remove bracket and starter.
NOTE: To remove the starter drive assembly, mag-
neto flywheel has to be removed. Refer to MAG-
NETO SYSTEM and BOTTOM END.
To check and replace the starter end bearing, refer
to BOTTOM END section.
F06H1FA
1. Index marks
11-03-4 SMR2002-086_11_03A.FM
Loosen through bolts no. 9.

1
1
F06H1IA
1. Washers
F06H1GA
Remove armature no. 12.
1. Through bolts
Remove end cover no. 7 and gasket on armature

shaft side.
Remove thrust washers no. 10 from armature shaft.
F06H1JA 1
TYPICAL
Release brush wires of yoke from brush holder

no. 11.
Remove brush holder no. 11.
F06H1HA 1
TYPICAL
1. Thrust washers
Remove the other end cover no. 11 and gasket.

Remove the three washers no. 10 from armature
shaft.
F06H1KA
1. Remove brush holder
SMR2002-086_11_03A.FM 11-03-5
To remove brushes from yoke no. 6, loosen nut 4-TEC Engines

and remove washers. Remove bendix retaining circlip no. 4 and starter
bendix no. 5.
F06H1LA
1. Loosen nut and remove washers
Remove brushes.
To remove bearing and seal in end cover, release
tabs of retainer.
F18H0NA 1 2
1. Retaining circlip
2. Starter bendix
Locate index marks on yoke and end covers.
F06H1MA 1
1. Retainer
F18H0OA 1
1. Index marks
11-03-6 SMR2002-086_11_03A.FM
Loosen through bolts.
F06H1JA 1
1 TYPICAL
Remove brushes from brush holder by loosening

retaining screws.
1 2 3
F18H0PA
1. Through bolts
Remove end cover.

Remove thrust washer from armature shaft.
F18H0QA
1. Brushes
2. Retaining screw
3. Brush holder
Remove springs.
F06H1HA 1
TYPICAL CLEANING
1. Thrust washers
All Models
Remove the other end cover with brushes and brush
holder assembly. CAUTION: Yoke ass’y and drive unit assembly
must not be immersed in cleaning solvent.
Remove armature.
Discard all O-rings.
Clean brushes and holders with a clean cloth
soaked in solvent. Brushes must be dried thorough-
ly with a clean cloth.
SMR2002-086_11_03A.FM 11-03-7
Blow brush holders clean using compressed air. Check commutator outer diameter. If less than
27 mm (1.063 in), replace.
 WARNING
Always wear safety glasses when using com-
pressed air.
Remove dirt, oil or grease from commutator using

a clean cloth soaked in suitable solvent. Dry well
using a clean, dry cloth.
Clean engine ring gear teeth and drive unit (clutch).
NOTE: Bushings or bearings must not be cleaned
with grease dissolving agents.
Immerse all metal components in cleaning solution. A03E06A
Dry using a clean, dry cloth.
4-TEC Engines
PARTS INSPECTION
Check commutator condition with an indicator. If
Armature out of specification, replace the starter.
NOTE: An ohmmeter may be used for the follow-
ing testing procedures, except for the one con-
cerning shorted windings in armature.
1
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.
DI Engines F18H0RA
1. Commutator undercut 0.20 mm (.008 in)
Brush Holder
1 All Engines
Check brush holder for insulation using an ohm-
meter. Place one test probe on insulated brush
F01H0RA
holder and the other test probe on brush holder
1. Commutator undercut 0.20 mm (.008 in) plate. If continuity is found, brush holder has to be
repaired or replaced.
Check commutator out of round condition with V-
shaped blocks and an indicator. If commutator out
of round is more than 0.40 mm (.016 in), commu-
tator should be turned on a lathe.
11-03-8 SMR2002-086_11_03A.FM
Brush
Measure brush length. If less than 8.5 mm (.335 in),
replace them.
NOTE: New brush length is 12 mm (.472 in).
1 2
F06H1HA 1
1. Thrust washers
DI Engines
A03E05A
Install the three washers no. 10 onto armature shaft.
TYPICAL All Engines
1. New
2. Wear limit, 8.5 mm (.335 in) When installing end covers no. 7 and no. 8 to yoke,
align index marks.
Overrunning Clutch Apply Loctite 271 (red) on through bolts no. 9 and
DI Engines
Pinion of overrunning clutch should turn smoothly STARTER INSTALLATION
in clockwise direction, and should not slip in a
counterclockwise direction. If defective, replace. Installation is essentially the reverse of removal
Check pinion teeth for wear and damage. If defec-
the following.
tive, replace.
Make sure that starter and engine mating surfaces
NOTE: Always check engine ring gear teeth for
are free of debris. Serious trouble may arise if
wear and damage. If defective replace ring gear.
starter is not properly aligned.
Refer to MAGNETO.
DI Engines
STARTER ASSEMBLY Screw
All Engines Apply Loctite 243 (blue) to Allen screws no. 4 of
Reverse the order of disassembly to reassemble starter bracket and torque to 10 N•m (89 lbf•in).
starter. However, attention should be paid to the
following operations.
Install new O-rings on 4-TEC engines and gaskets
on DI engines.
Insert thrust washers no. 19 onto armature shaft.
SMR2002-086_11_03A.FM 11-03-9
Nut Nut
Connect the RED positive cable to the starter and CAUTION: The cable nut features 1/4-20UNC
torque nut no. 2 to 7 N•m (62 lbf•in). Apply dielec- SAE threads. If for some reason you replace it,
tric grease on terminal and nut. DO NOT use a metric one.
3 2 Connect the RED positive cable to the starter and
torque nut to 7 N•m (62 lbf•in). Apply dielectric
grease on terminal and nut.
Ensure to slide protector over nut to hide metallic
parts.
F06H35B 1 3
1. Torque nut to 7 N•m (62 lbf•in), apply dielectric grease and install
protection cover 2 3 1
2. Negative BLACK cable
3. Apply Loctite 243 to threads and torque screw to 10 N•m
(89 lbf•in)
 WARNING F18H0UB
Always connect RED positive cable first then 1. Grease on O-rings.

BLACK negative cable last. Whenever con- 2. Torque nut to 7 N•m (62 lbf•in) and apply dielectric grease and
necting the RED positive cable to the starter install protection cover
3. Apply Loctite 243 to threads and torque screws to 10 N•m
motor make sure the battery cables are dis- (89 lbf•in)
 WARNING
4-TEC Engines Always connect RED positive cable first then
Apply grease Isoflex Topas NB52 (P/N 293 550 021) BLACK negative cable last. Whenever con-
on O-rings of starter. necting the RED positive cable to the starter
Install Starter. connected to prevent electric shock.
NOTE: If starter does not mesh properly, try to pull
it out and slightly rotate the starter gear; then rein-
stall starter. One could also temporarily remove both
O-rings, properly mesh gears then remove starter
to reinstall O-rings, being careful not to rotate gear
to keep its position, to finally reinstall starter.
Apply Loctite 243 (blue) on retaining screws no. 1
and torque to 10 N•m (89 lb•in).
11-03-10 SMR2002-086_11_03A.FM
STARTER SPECIFICATION
DI Engines
Voltage 12 V
Performance specification at 20°C (68°F) Load 9V 120 A max. 5350 RPM
Battery 12 V, 19 Ah
4-TEC Engines
Voltage 12 V
Performance specification at 20°C (68°F) Load 8.5 V 140 A max. 5200 RPM
Battery 12 V, 30 Ah
SMR2002-086_11_03A.FM 11-03-11
INSTRUMENTS AND ACCESSORIES 0

GENERAL
It is possible to activate the instruments when the
engine is not running.
Make sure the safety lanyard is removed, then de-
press the start/stop button.
The timer of the MPEM will maintain the gauge(s)
activated during a period of approximately 33 sec-
onds.
Information Center Gauge/Buttons

This is a multifunction gauge that supplies several
real time useful information to the driver.
Components Description
F18L09A 1
1 2 1. Function buttons
Display Area
The display area comprises the following.
F18H08A 3
1. Speedometer
2. Tachometer
3. Display area
F18H08C 1 3 2
1. Fuel level indicator
2. Numerical section
3. Units and messages section
Fuel Level Display

Bar gauge continuously indicates the amount of
fuel in the fuel tank while riding. A low-fuel condi-
tion is also indicated when in the information cen-
ter when only one bar is displayed. See MESSAGE
DISPLAY below.
F18H08B 1 Numerical Section
1. Text and numerical area This section shows the digits of the function dis-
played such as the clock, trip hour meter etc. Time
is displayed in 12 hour format (from 1 to 12) with-
out am and pm indication.
SMR2002-087_11_04A.FM 11-04-1
Units and Messages Section

This section shows the units related to the num-
bers displayed. Units such as KMH (MPH), HOUR
etc. are displayed.
This section also display navigational and system
fault informations.
See the gauge functions and message lists below
for more details.
Gauge Functions
Clock: Indicates the actual time in hours and min-
utes (hh:mm).
Compass: Displays the cardinal points to indicate
the orientation of the watercraft.
1 2
 WARNING
F18L09B
1. To change display mode

Use the compass as a guide only. Not to be 2. To set or reset a function
used for navigation purposes.
Resetting a Function
Average Speed: The information center approxi- To reset a function (such as the trip hour meter, dis-
mately calculates and displays the average speed tance, etc.) press and hold the SET button for 2 sec-
(AV KM/H or AV MPH) of the watercraft since the onds while in the appropriate mode.
last engine start.
Display Selection
Distance (KM or MILES). The information center
The default display is the clock/compass unless
approximately calculates the distance based on the
another mode has been selected. See DISPLAY
operation time and the watercraft speed and dis-
PRIORITIES below.
plays the result in kilometers (KM) or miles (MILES).
Repeatedly pressing the MODE button scrolls the
Hourmeter: Displays the time in hours of the water-
following displays: average speed, distance, hour-
craft usage (HOUR).
meter, water temperature, exterior temperature
Water Temperature: Displays the water tempera- and trip hour meter.
ture (L TEMP) in degrees Celsius (°C) or Fahrenheit
(°F).
Exterior Temperature: Displays the exterior air
temperature (E TEMP) in degrees Celsius (°C) or
Fahrenheit (°F).
Trip Hour Meter: (TRIPMTR) Allows to measure an
interval of time in hours and minutes (hh:mm).
Function Buttons
Different displays and functions can be activated
using 2 buttons — MODE and SET — following
specific sequences as described below.
F18L09C 1
1. Press to change display mode
When you are satisfied with your choice, stop press-

ing the button and it will become active.
11-04-2 SMR2002-087_11_04A.FM
Display Priorities
As a self test at start-up, the needles of the speed-
ometer and tachometer will sweep to their maxi-
mum position, all LCD segments and the LED will
turn on for 3 seconds each time the information cen-
ter is activated. This allows the driver to validate
they are all working properly.
The clock/compass is the default display mode.
The default display is the one that appears when
the information center is first activated or dis-
played back after an alternate display was chosen.
The trip hour meter is the only mode that may be
chosen to replace the default display. When dis-
playing the trip hour meter, it becomes active
when you do not touch any button for 10 seconds. F18L09C 1
When active, it becomes the default display until
1. Repeatedly press
it is changed again.
When another display mode is chosen, the default
display will be displayed back after 10 seconds.
In the event of a warning message, the message
will blink and override the units display unless
MODE button is pressed. The display will then dis-
play the clock/compass after 10 seconds.
If more than one warning message occurs, the
blinking messages will scroll every 4 seconds.
Other Functions
The following describes how to select other avail-
able functions.
Language Option
F18L09D 1
1. Press to end
English/Metric System
Allows to display the units in the metric system or
in the SAE english system.
NOTE: This function is not available when infor-
mation center displays the clock/compass, hour-
meter or trip hour meter.
F18L09D 1
1. Press and hold for 2 seconds
SMR2002-087_11_04A.FM 11-04-3
F18L09A 1 F18L09C 1
1. Press TOGETHER and hold for 2 seconds 1. Repeatedly press to adjust HOURS
Clock Adjustment
F18L09D 1
1. Repeatedly press to adjust MINUTES
F18L09A 1
1. Press TOGETHER and hold for 2 seconds
F18L09A 1
1. Press TOGETHER to end
11-04-4 SMR2002-087_11_04A.FM
NOTE: If MODE and SET buttons are not pressed • high battery voltage (12 V HI).
at the end, the default display will come back after • low fuel level (FUEL-LO)
10 seconds and the time entered will remain.
• maintenance reminder (MAINT)
Trip Hour Meter
• check engine (CHK ENG)
While in the trip hour meter mode:
• sensor failure
(vehicle electronic equipment) (SENSOR)
• invalid safety lanyard (KEY)
• safety lanyard, learning key active (L KEY)
• end of faults (END).
A beeper will sound depending on the fault occur-
ring to catch the driver attention when necessary.
Except for low liquid levels, which can be corrected
by refilling.
NOTE: If a fault occurs, this system generates num-
bered fault codes (P-XXXX) that can be displayed
through the information center using a special pro-
cedure. In case of a failure, refer to DIAGNOSTIC
PROCEDURES in ENGINE MANAGEMENT.
F18L09D 1 Warning Light
1. Press to start or stop trip hour meter The red warning LED (Light-Emitting Diode) blinks
along with the beeper to catch your attention.
Maintenance Information
When the watercraft is due for a maintenance in-
spection, the message MAINT will blink. Afterwards,
it will blink at every start-up for 10 seconds.
GTX 4-TEC Models

Information Center Not Working
When there is no display at the information center,
perform the following:
– Check fuses.
– Check supply wire (1-23) and ground wire (1-8)
from MPEM.
F18L09D 1 – Check communication link wires (WHITE/RED
1. Press and hold for 2 seconds to reset and WHITE/BLACK):
Trip hour meter is reset every time engine is – To quickly check if the communication link is
turned off. working, temporarily disconnect a sensor on the
engine to create a fault code. The information
Message Display should display a fault code when in onboard di-
The information center features a display area that agnostic mode.
blinks a message whenever one of the following cir- – Check if wires are swapped, unconnected or
cumstances occurs. The abbreviations between pa- short circuit.
renthesis here are the code displayed:
– One faulty wire will cause a longer delay to
• low oil pressure (OIL) perform the self-test when safety lanyard is
• low battery voltage (12 V LOW). installed.
SMR2002-087_11_04A.FM 11-04-5
– If everything tests good, try a new information To check if the water temperature sensor is oper-
center. ational, activate the Info Center and select the lake
temperature mode.
ADDITION OF ACCESSORIES With a garden hose, spray the speed sensor with
water. The temperature reading on the Info Center
Every time an accessory is added such as an elec-
should adjust to the water temperature.
tric bilge pump or a VTS for instance, it must be
registered using BUDS to activate it in the MPEM. If not, replace the speed sensor.
If an option is installed but not checked in BUDS,
the information center will not display that option.
Compass
If an option is checked in BUDS but not installed The compass is located in the storage cover.
in vehicle, a fault code will be generated. Remove the back panel of the storage cover to ac-
Use the OPTIONS area in the Setting tab in cess the compass.
BUDS.
INSPECTION
All Models
Air Temperature Sensor
The temperature sensor is located in the storage
cover.
Remove the back panel of the storage cover to
access the temperature sensor.
F07H02A 1
1. Compass
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
F07H01A 1 same direction. Compare the given directions,
they should be the same.
To check if the temperature sensor is operational, Speed Sensor

activate the Info Center and select the exterior The speedometer gives a reading through a speed
temperature mode. sensor. Speed sensor is installed on riding plate. It
Use a heat gun to warm up the sensor. The tem- works with the water flow which turns a magnetic
perature should raise rapidly on the gauge. paddle wheel that triggers an electronic pick-up
that in turn sends a speed signal to the MPEM.
If not, replace the temperature sensor.
The paddle wheel is protected by the pick-up hous-
Water Temperature Sensor ing.
The water temperature sensor is integrated with
the speed sensor located on the ride plate.
11-04-6 SMR2002-087_11_04A.FM
Remove the BLACK wire from the receptacle hous-

ing.
Connect potentiometer test probes to the PINK
and BLACK wires.
1 NOTE: The gauge must be activated to obtain a
reading.
GTX 4-TEC
F01H3VA
2
RESISTANCE WET HEIGHT FROM
1. Pick-up housing (Ω) BOTTOM (mm)
2. Paddle wheel
4.8 ± 2.2 247 ± 5.0
To check if the speed sensor is operational, dis-
17.8 ± 2.2 207 ± 5.0
connect the speed sensor connector housing
from inside bilge. 27.8 ± 2.2 183 ± 5.0
Using an appropriate terminal remover (Snap-on 37.8 ± 2.2 158 ± 5.0
TT600-4), remove the PURPLE/YELLOW and 47.8 ± 2.2 133 ± 5.0
BLACK/ORANGE wires from the tab housing of 57.8 ± 2.4 105 ± 5.0
the speed sensor.
67.8 ± 2.8 76 ± 5.0
Reconnect the PURPLE/YELLOW and BLACK/
ORANGE wires in the receptacle housing. 77.8 ± 3.6 55 ± 5.0
Connect the positive probe of a multimeter to 89.8 ± 3.6 35.3 ± 5.0

speed sensor PURPLE/YELLOW wire and the
negative probe to speed sensor BLACK/ORANGE GTX DI
wire.
RESISTANCE WET HEIGHT FROM
Install safety lanyard to acticvate MPEM. (Ω) BOTTOM (mm)
Slowly rotate the paddle wheel. Every 1/8 turn, the 4.8 ± 2.2 228 ± 5.0
observed voltage should fluctuate between 5.5
17.8 ± 2.2 188 ± 5.0
and 8.5 Vdc.
27.8 ± 2.2 164 ± 5.0
Information Center Verification 37.8 ± 2.2 139 ± 5.0
The BLACK wire is the ground. 47.8 ± 2.2 114 ± 5.0
The RED/PURPLE wire is the 12 Vdc from the bat- 57.8 ± 2.4 88 ± 5.0
tery. It is protected by a fuse on the MPEM; the 67.8 ± 2.8 57 ± 5.0
fuse “MPEM” and the fuse “ACC” on DI models.
77.8 ± 3.6 38 ± 5.0
The accuracy of some features of the Information
89.8 ± 3.6 16 ± 5.0
Center can be checked with a potentiometer.
Fuel Level Water Temperature (L temp) (if so equipped)
Disconnect the 4-circuit connector housing of the Disconnect the 2-circuit connector housing of the
Info Center. Info Center which contains a BLACK/ORANGE
Using an appropriate terminal remover, remove and TAN/ORANGE wires.
the PINK wire from the tab housing. Connect potentiometer test probes to the BLACK/
Reconnect the connector housing. ORANGE and TAN/ORANGE wires.
Disconnect the 2-circuit connector housing which Adjust potentiometer to the resistance values as
contains a PURPLE and BLACK wires. per following chart to test the accuracy of the gauge.
SMR2002-087_11_04A.FM 11-04-7
NOTE: The gauge must be activated to obtain a GTX DI

reading.
RESISTANCE DISPLAY
GTX 4-TEC (Ω) TEMPERATURE (°F)
22919.8 45 ± 4
RESISTANCE DISPLAY
(Ω) TEMPERATURE (°C) 17491.7 55 ± 4
25407.3 5±2 13487.5 65 ± 4
19911.1 10 ± 2 10501.5 75 ± 4
15718.0 15 ± 2 8252.0 85 ± 4
12495.0 20 ± 2 6518.7 95 ± 4
10000.0 25 ± 2
8054.9 30 ± 2 Fuel Baffle Pick Up Sender
6528.3 35 ± 2 The fuel pick up system is part of the fuel pump
module mounted inside the fuel reservoir.
GTX DI
The fuel level gauge sender is also mounted on this
RESISTANCE DISPLAY module.
(Ω) TEMPERATURE (°F)
22799.0 45 ± 4
17262.0 55 ± 4
13470.0 65 ± 4
10496.3 75 ± 4
8264.4 85 ± 4
6528.3 95 ± 4
Exterior Temperature (if so equipped)

Info Center which contains a TAN/WHITE and
BLACK/WHITE wires.
Connect potentiometer test probes to the TAN/
WHITE and BLACK/WHITE wires. F07F09A
Adjust potentiometer to the resistance values as TYPICAL — FUEL LEVEL GAUGE SENDER MOUNTED ON FUEL
per following chart to test the accuracy of the PUMP MODULE
gauge.
Refer to ENGINE MANAGEMENT.
reading.
GTX 4-TEC
RESISTANCE DISPLAY
(Ω) TEMPERATURE (°C)
4712 5±2
3792 10 ± 2
3069 15 ± 2
2500 20 ± 2
2057 25 ± 2
1707 30 ± 2
1412 35 ± 2
11-04-8 SMR2002-087_11_04A.FM
DI Model Only NOTE: Wait about 15 - 20 seconds before taking

any reading to give the oil enough time to flow out
Oil Sensor or inside sensor reservoir.
The sensor sends the signal to the low-oil level Soak sensor in oil so that its reservoir fills up. Max-
light in the fuel gauge or the LED in the Info Center. imum resistance should be approximately 2 Ω
(closed circuit).
TEST CONDITION READING (Ω)

Sensor OUT of oil ∞ (open circuit)
Sensor soaked IN oil 2 Ω max. (closed circuit)
F00H0LA 1
1. Oil sensor
The bottom of the sensor has a small reservoir

with two small holes underneath to let the oil en- 2
ter inside and one at the top to let the air enter F03H0BA
allowing the oil to flow out.

1. Measure resistance here
When there is enough oil inside the oil tank (and 2. Sensor reservoir
therefore in the sensor reservoir), the sensor de-
tects the liquid and the light DOES NOT turn on. To Reinstall Sensor:
When the oil level goes at critical LOW level inside – Remove rubber seal from sensor.
the oil tank (and therefore in sensor reservoir), the – Install seal in oil tank hole.
sensor detects the absence of liquid and the light
TURNS ON. – Push sensor in seal.
To check the oil sensor, unplug its connector and – Plug connector.
pull sensor out of oil tank. NOTE: This sensor turns the LED to ON if the con-
Using a multimeter, check the continuity between nector has been forgotten unconnected even when
the BLUE and BLUE/BLACK terminals. there is enough oil in tank.
When sensor is out of oil tank and its reservoir is
empty, resistance must be infinite (open circuit).
SMR2002-087_11_04A.FM 11-04-9
TABLE OF CONTENTS 0
JET PUMP .............................................................................................................................. 12-02-1
GENERAL ........................................................................................................................... 12-02-2
REMOVAL........................................................................................................................... 12-02-4
DISASSEMBLY................................................................................................................... 12-02-6
CLEANING ......................................................................................................................... 12-02-9
ASSEMBLY......................................................................................................................... 12-02-11
INSTALLATION .................................................................................................................. 12-02-20
GENERAL ........................................................................................................................... 12-02-23
REMOVAL........................................................................................................................... 12-02-24
DISASSEMBLY................................................................................................................... 12-02-27
CLEANING ......................................................................................................................... 12-02-30
ASSEMBLY......................................................................................................................... 12-02-31
INSTALLATION .................................................................................................................. 12-02-36
DRIVE SYSTEM ..................................................................................................................... 12-03-1

GENERAL ........................................................................................................................... 12-03-3
REMOVAL........................................................................................................................... 12-03-3
INSPECTION ...................................................................................................................... 12-03-7
INSTALLATION .................................................................................................................. 12-03-9
LUBRICATION.................................................................................................................... 12-03-14
REVERSE SYSTEM................................................................................................................ 12-04-1

DISASSEMBLY................................................................................................................... 12-04-2
INSPECTION ...................................................................................................................... 12-04-3
ASSEMBLY......................................................................................................................... 12-04-3
ADJUSTMENT ................................................................................................................... 12-04-4
SMR2002-095_12-01ATOC.FM 12-01-1
JET PUMP 0
GTX DI Models
Loctite 518
3 1
2
31
38 Loctite
454 Loctite 518
6 Nm
(53 lbfin) 40 29
41 30
25
44
30 3 Nm
32
33 (27 lbfin) Primer N and
28 Pipe sealant 567
24 Nm
Primer N 36 Primer N 21 (18 lbfft)
and 35 and Pipe
37 45 sealant 23
Loctite 243
13 592 22
Synthetic
grease 26
34
Loctite
243 24
7.5 Nm 42
(66 lbfin)
Loctite 43
243 39 20
21 Nm
16 (16 lbfft)
14
15
2.5 Nm
(22 lbfin)
6
19
7 13
13
5
2.5 Nm
20 Nm 18 (22 lbfin)
(15 lbfft)
17 4
20 Nm
(15 lbfft) 8
F18J0CS
SMR2002-088_12_02A.FM 12-02-1
GENERAL JET PUMP INSPECTION ON

WATERCRAFT
4
3 Thus, if access is needed to water inlet area, it will
be easy to slide underneath watercraft.
A lift kit can be used to install watercraft on a stand.
2
5
1
F00J0SA
TYPICAL
1
1. Nozzle
2. Venturi
3. Housing
4. Wear ring
5. Impeller 2
F01J42A
6. Stator
TYPICAL
Impeller Identification 1. Lift kit
2. Work stand
To identify the impeller refer to the following illus-
tration and chart. Impeller Condition
F02J0VA

F01J0DA
WATERCRAFT IMPELLER
MATERIAL PITCH TYPICAL
MODEL P/N
Progressive
Stainless
GTX DI 271 000 920 pitch
steel
15° - 21°
12-02-2 SMR2002-088_12_02A.FM

This clearance is critical for jet pump performance.
Clearance can be checked from water inlet open-
ing or from venturi side. However, the last method
requires more work.
inlet grate.
To check clearance from venturi side, remove
venturi/nozzle assembly as described in Oil In-
spection in this subsection.
wear ring. Measure each blade at its center. Clear- F01J0FA 1
ance should not exceed 1.0 mm (.040 in). If clear-
TYPICAL — MEASURING FROM VENTURI SIDE
ance is greater, disassemble jet pump and inspect
1. Feeler gauge
impeller and wear ring. Renew worn parts.
Oil Inspection
1
Remove:
– reverse gate cable
– steering cable
– screws no. 10 retaining venturi to the housing.
Pull venturi.
F01J0EA

1. Feeler gauge
F01J5IA 1
TYPICAL
1. Remove plug
Check oil level, it should be at bottom of hole threads.

If oil level is low, check impeller shaft housing for
leaks. A pressure test must be performed. See
PUMP PRESSURIZATION in this subsection.
To check oil condition, insert a wire through oil lev-
el hole then withdraw. A whitish oil indicates wa-
ter contamination.
SMR2002-088_12_02A.FM 12-02-3
This may involve defective impeller shaft seal and/or CAUTION: This is a synthetic oil. Do not mix with
O-ring of housing cover. Jet pump unit should be mineral based oil. Do not mix oil brands.
overhauled to replace seal. Apply Loctite pipe sealant (P/N 293 800 018) on
If everything is correct, apply Loctite pipe sealant plug threads and reinstall it on cover.
(P/N 293 800 018) on plug threads and reinstall it NOTE: The plug threads are perpendicular to the
on cover. Properly reinstall removed parts. impeller shaft.
NOTE: The plug threads are perpendicular to the Properly reinstall removed parts.
impeller shaft.
Oil Replacement REMOVAL

Remove venturi as described in OIL INSPECTION. Reverse Gate
Remove 3 screws retaining cover. To remove reverse gate no. 4, put shift lever in
reverse position.
Unscrew pivot bolt no. 5.
1
F02J0TB 1
TYPICAL
1. Screws

it from housing cover.
F16J04A 2
Thoroughly clean reservoir and inside of cover
1. Pivot bolt no. 5
with a solvent. Check O-ring condition. Replace as 2. Screw no. 8
necessary.
Remove both reverse gate screws no. 8.
Apply a thin layer of Loctite 518 on mating surface
of cover and reinstall it with its O-ring.
Apply Loctite 243 on threads and torque screws
Pour oil through hole until oil reaches the bottom
of hole threads. Use SEA-DOO JET PUMP SYN-
THETIC OIL (P/N 293 600 011) only. Oil will drain
slowly into center area of housing, wait a few min-
utes and readjust oil level.
12-02-4 SMR2002-088_12_02A.FM
Pivot Support – pivot arm bolts no. 18. Take note of bushing size
for reinstallation.
Withdraw pivot arm no. 19.
Unscrew pivot support bolts no. 13.
1 2
F16J06A 2 3 1
F18J0JA 4 3 2. Spring
3. Pivot arm
1. Pivot bolt
2. Pivot support
3. Reverse gate Nozzle
4. Pivot support bolt no. 13
Withdraw pivot support.
Connecting Rod Remove OPAS “U” lever screw, washer and bush-
ings from nozzle.
Remove:
– reverse gate
– pivot bolt no. 14.
Withdraw connecting rod.
Pivot Triangle
Remove:
– reverse gate
– connecting rod
Pivot Arm F18J0DA 1

Position shift lever in forward. 1. “U” lever screw
Remove: Remove 2 retaining screws no. 21, 2 sleeves no. 22,

– reverse gate 2 washers no. 23.
– connecting rod Remove nozzle.
– spring no. 17
– reverse cable
SMR2002-088_12_02A.FM 12-02-5
Venturi
1
Remove:
– reverse gate
– nozzle.
Unfasten reverse cable from pivot arm.
Unplug OPAS hose from plastic elbow.
venturi no. 24.
It’s possible to remove the venturi without remov-
lowing instructions.
Disconnect:
– steering cable
F02J0TA 1
1
TYPICAL
1. Remove screws
Jet Pump Housing

Remove:
– nozzle
– venturi.
Loosen 4 hexagonal nuts no. 24 and remove flat
washers and lock washers from jet pump housing.
Remove jet pump with a wiggle movement.
CAUTION: When removing pump unit, a shim
F18J0KA
1. Steering cable engine and jet pump alignment will be altered.
– OPAS hose NOTE: After jet pump removal, if drive shaft re-
– reverse cable. mains in the PTO flywheel, simply pull it out. If
drive shaft is seized in the PTO flywheel, refer to
Remove 4 retaining screws no. 39 and withdraw DRIVE SYSTEM.
venturi no. 24.
DISASSEMBLY
NOTE: Whenever removing a part, visually check
for damage such as: corrosion, crack, split, break,
porosity, cavitation, deformation, distortion, heat-
missing or broken needles in needle bearing, wa-
ter damage diagnosed by black-colored spots on
metal parts, etc. Renew any damaged part. As a
quick check, manually feel clearance and end play,
12-02-6 SMR2002-088_12_02A.FM
Cover
With pump assembly in horizontal position, remove
3 retaining screws no. 26.
Place container under cover no. 27 to catch oil.
it from jet pump housing.
Impeller 1
Insert impeller shaft holder (P/N 295 000 082) on
impeller shaft flat end.
secure shaft holder to housing.
F00J0HA
1. Shaft holder
Impeller is loosened using impeller remover tool

(P/N 295 000 001).
F01J0TA
F00J07A 1
1. Shaft holder
Insert special tool in impeller splines.
Heat impeller shaft end with a propane torch to 1

approximately 150°C (300°F) to break the Loctite
bond before to remove impeller. Do not heat im-
peller directly.
Install shaft holder in a vice.
F00J08A
1. Impeller remover tool
SMR2002-088_12_02A.FM 12-02-7
Rotate impeller remover tool counterclockwise After cutting ring, insert a screwdriver blade be-
and unscrew completely impeller. tween jet pump housing and ring outside diameter.
CAUTION: Never use any impact wrench to loos- Push ring so that it can collapse internally.
en impeller. Pull ring out.
To remove impeller, apply a rotating movement
and pull at same time. Slide impeller out of hous- Impeller Shaft
ing. Remove tool from impeller. Remove shaft holder tool.
Wear Ring Remove impeller shaft no. 28 with thrust washer
and thrust bearing.
Remove the screws retaining wear ring in the jet
pump housing. Seal and Needle Bearing
Place jet pump housing in a vise with soft jaws. It Remove seal no. 29 and bearings no. 30 at the
is best to clamp housing using a lower ear. same time using bearing/seal remover tool (P/N 295
Cut wear ring at two places. 000 144).
F01J11A
Insert bearing remover then press tool using a ar-

bor press until seal and bearings are out. However,
care should be taken not to damage bearing jour-
nals.
F01J0VA
TYPICAL 1
F00J0MA
1. Bearing/seal remover tool
NOTE: It is always recommended to renew both

F01J0WA
bearings, even if only one bearing needs to be re-
TYPICAL placed.
1. Snap-on HS3
12-02-8 SMR2002-088_12_02A.FM

Thoroughly clean jet pump housing by applying Loc- Impeller
tite Stripper (P/N 293 110 004). Allow it some time
to dissolve the old dried Loctite (10 to 15 minutes). Visually inspect impeller splines. Check for wear or
deformation. Renew parts if damaged.
 WARNING NOTE: Check also PTO flywheel and drive shaft
Technician should wear gloves when using this condition. Refer to BOTTOM END and DRIVE SYS-
cleaning product. TEM.
Examine impeller in wear ring for distortion.
CAUTION: DO NOT use Loctite Stripper on wear
ring since it will cause irreparable damage to it. Check if blade tips are blunted round, chipped or
broken. Such impeller is unbalanced and will vi-
Wipe Loctite Stripper with a clean cloth. brate and damage wear ring, impeller shaft, shaft
Make sure surface is cleaned and dried of Loctite seal or bearings. Renew if damaged.
Stripper.
1
scraper.
Carefully check water passages and oil passages.
Blow low pressure compressed air through them
and make sure they are clear.
F02J0VB
1

F01J13A
2
TYPICAL
1. Water passages
2. Oil passages

and drive shaft splines with Pulley flange cleaner
splines from any residue.
CAUTION: Be careful not to damage impeller F02J0UA
shaft diameter. 1. Check for cavitation, deep scratches or other damage
SMR2002-088_12_02A.FM 12-02-9
Wear Ring To check both bearings, proceed the same way

with other shaft end. Position gauge tip on diam-
eter, close to flats on shaft.
peller is in good shape, renew wear ring. 1
Needle Bearing and Impeller Shaft

WEAR
Inspect needle bearings no. 30 and their contact
surface. Check for scoring, pitting, chipping or oth-
er evidence of wear.
With your finger nail, feel contact surface of seal.
If any irregular surface is found, renew impeller
shaft no. 28.
Install bearings, then install impeller shaft and ro-
tate it. Make sure it turns smoothly. F01J19A 2
RADIAL PLAY TYPICAL — MEASURING IMPELLER SHAFT RADIAL PLAY
1. Dial gauge
Radial play is critical for jet pump unit life span. 2. Measure close to flats at shaft end
Radial play of impeller shaft is checked with shaft Excessive play can come either from worn bear-
in housing, without impeller. ings or impeller shaft or damaged jet pump hous-
Retain housing in a soft jaw vise making sure not ing bearing surfaces.
to damage housing lug. Measuring shaft diameter will determine the de-
Set a dial gauge and position its tip onto shaft end, fective parts.
close to end of threads. Using a micrometer, measure diameter on bearing
Move shaft end up and down. Difference between contact surfaces. Minimum shaft diameter should
highest and lowest dial gauge reading is radial be 22.24 mm (.876 in).
play.
1
F01J1AA
1. Inspect for wear at the bearing pilot

2. Radial bearing raceway
F01J18A 2 NOTE: If shaft is to be replaced, it is recommend-

ed to replace both bearings at the same time. In
TYPICAL — MEASURING IMPELLER SHAFT RADIAL PLAY addition, it is suggested to replace thrust bearing
1. Dial gauge and thrust washer.
12-02-10 SMR2002-088_12_02A.FM
Thrust Washer and Thrust Bearing Seal

Visually inspect thrust washer no. 32, thrust bear- Carefully inspect seal lips. Make sure that lips are
ing no. 33 and their contact surface. Check for not worn, distorted, cracked or show signs of any
scoring, pitting, flaking, discoloration or other evi- other damage. Replace after 150 hours even if it
dence of wear. For best inspection, use a 7X mag- seems good.
nifying glass to check wear pattern.
OPAS Filter
1 2
OPAS filter is part of plastic elbow no. 45. Check
3 for cleanness. Replace or clean it as necessary.
ASSEMBLY
Plastic Elbow
Install plastic elbow no. 45 at 20° angle to the right.
It may exceed inside housing by 1.0 mm (.039 in).
It may be positioned up to 2.0 mm (.078 in) from
housing edge.
F01J52A
TYPICAL
1. Worn roller (trunnion worn on end roller)
2. Good roller (cylindrical shape)
3. Look for scoring on retainer
NOTE: When replacing either washer or bearing,

it is recommended to renew both.
Anti-Rattle Pusher
B
Check for melted plastic around metal pad. If so,
replace it.
F18J0EA C
A. 20°
B. 2.0 mm (.078 in)
C. 1.0 mm (.039 in)
F08J05A
Check for excessive wear of pad.
SMR2002-088_12_02A.FM 12-02-11
Wear Ring
This model is equipped with large pump. It is im-
portant that the screws retaining wear ring to hous-
ing are installed on this model.
F01J5DA
1. Seal lip
2. Press wear ring
F08J06A
If a press is not readily available, a piece of wood
such as a 2 x 4 in x 12 in long, can be used.
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.
F08J07A
To install ring in housing, use a square steel plate of 3

approximately 180 x 180 mm x 6 mm thick (7 x 7 in
x 1/4 in) and a press.
equally inserted all around. Press ring until it seats 2
into bottom of housing. 1
F01J5EA
1. Piece of wood
3. Wear ring
Install retaining screws.
12-02-12 SMR2002-088_12_02A.FM
Seal and Needle Bearing

Bearings no. 30 and seal no. 29 will be properly
installed in housing using bearing/seal installer
tool (P/N 295 000 107).
1
F01J4KA 2
F01J1HA
1. Seal side
2. Bearing side
1. Stamped end this side
For the bearing on venturi side use inner bearing
CAUTION: Never hammer the bearing into its
installer tool (P/N 529 035 609).
housing.
1
F08B01A
CAUTION: Failure to use this tool will cause ma-

jor damage to the pump.
Impeller Side 2
Stamped end of bearings (showing identification
markings) must be located toward outside of hous-
ing.
Properly insert bearing on tool. Using an arbor press F00J0ZA
only, push tool until tool flange contacts housing.
2. Bearing

properly position bearings and seal, thus pro-
viding space for lubrication purposes. The tool
flanges allow this. If a different pusher type is
being used, components must be properly po-
sitioned as follows.
SMR2002-088_12_02A.FM 12-02-13
Bearing on impeller side must be 1.5 to 2.5 mm CAUTION: Prevent sealant from contacting any
(.060 - .100 in) inside reservoir measured from seal needles of bearing.
seat. Refer to following illustration. Push on tool end with a press until tool flange con-
tacts housing.
F01J5YA
1. Seal seat
A. 1.5 - 2.5 mm (.060 - .100 in) F00J0CA 1
Apply Loctite 518 (P/N 293 800 038) to seal hous- 1. Press on tool until it stops
ing, all around outer diameter and on seal seat. Apply synthetic grease (P/N 293 550 010) between
Properly insert seal on tool. seal lips.
NOTE: Apply synthetic grease on tool to ease seal
insertion. 1
Install seal with the spring toward the outside.
F01J1MA
F01J1KA 1 1. Loctite 518 all around and behind

2. Spring of seal lip this side
1. Spring of seal this side
12-02-14 SMR2002-088_12_02A.FM
Venturi Side Bearing on venturi side must be 2 to 3 mm (.078 -

Stamped end of bearings (showing identification .118 in) inside reservoir measured from thrust wash-
markings) must be located toward outside of hous- er seat. Refer to following illustration.
ing.
Properly insert bearing on tool. Using an arbor press
only, push tool until tool flange contacts housing.
F01J5YB
1. Thrust washer seat

1 2. Stamped end of bearing
A. 2 - 3 mm (.078 - .118 in)
F01J1HA
Thrust Washer
1. Stamped end this side Position jet pump housing with the stator vanes on
top.
CAUTION: Never hammer the bearing into its
Insert thrust washer no. 32 in the stator seat.
housing.
F00J0DA 1
1. Thrust washer properly installed in stator seat
F16J09A

properly position bearing, 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 fol-
lows.
SMR2002-088_12_02A.FM 12-02-15
Thrust Bearing
Apply SEA-DOO JET PUMP SYNTHETIC OIL (P/N
293 600 011) on both sides of thrust bearing.
Position thrust bearing no. 33 on thrust washer
no. 32.
F00J0FA 1 2
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.
F00J0EA 1
Remove shaft guide.
1. Thrust bearing on top of thrust washer
Impeller Shaft Impeller

To prevent seal lip damage when inserting impeller Apply Loctite primer N (P/N 293 600 012) on threads
shaft, use impeller shaft guide (P/N 295 000 002). of impeller shaft no. 28. Allow to dry for 2 minutes.
NOTE: Loctite primer is used to reduce Loctite
243 curing time and to activate stainless steel and
aluminum surfaces for better bonding action. If ap-
plied, complete curing time is 6 hours, if primer is
not used, allow 24 hours for curing time.
Apply Loctite 243 (blue) to shaft threads.
F01J1OA
Insert tool onto shaft end then carefully install

shaft in jet pump housing.
F00J0GA 1
1. Apply Loctite 243 (blue) on threads
12-02-16 SMR2002-088_12_02A.FM
Using 2 screws previously removed from venturi, Torque impeller to 115 N•m (85 lbf•ft) then remove
secure impeller shaft holder tool (P/N 295 000 082) tools.
to housing. CAUTION: Never use any impact wrench to tight-
Install shaft holder tool in a vise. en impeller.
Apply synthetic grease (P/N 293 550 010) on im-
peller splines.
Insert a new boot no. 2 and ring no. 3 to impeller.
F00J0HA
1. Impeller shaft holder secured in a vise
To ease impeller installation, apply BOMBARDIER

LUBE lubricant on wear ring. F00J10A 1
Insert impeller into wear ring. Manually rotate im- 1. Boot and ring
peller and push so that it slides on impeller shaft
threads. Carefully engage threads making sure Anti-Rattle System
they are well aligned. Install spring no. 34 on slider no. 35.
Install impeller remover/installer tool into impeller
splines and tighten.
F00J0VA 2 1
F00J08A
1. Spring
1. Impeller remover/installer tool 2. Slider
CAUTION: Make sure thrust washer and bear-

ing are not wedged in shaft groove. To check,
manually pull and push jet pump housing, some
axial play must be felt.
SMR2002-088_12_02A.FM 12-02-17
Insert slider and spring into cover. Hold tab and torque screws.
NOTE: Align the longer slider tab with hole. Remove pencil or tool to release locking mecha-
nism.
Check if the mechanism worked properly. Push
tab with the pencil or tool; if there is a small play
the installation is correct. If not, redo the proce-
dure.
Verify if the impeller is rotating freely.
Add oil.
Oil Fill
NOTE: It is highly recommended to perform a
leakage test prior adding the oil. See PUMP PRES-
SURIZATION in this subsection.
F00J0WA
Place housing horizontally as in its operating posi-
tion so that filler plug is located on top. Remove
Apply synthetic grease in the center hole of the filler plug from cover. Pour SEA-DOO JET PUMP
cover. SYNTHETIC OIL (P/N 293 600 011) in reservoir un-
Install pusher no. 36 into cover. Place the flat side til oil comes level with bottom of hole. Let oil drain
in front of slider tab. 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.
Apply Loctite pipe sealant (P/N 293 800 018) on
plug threads and reinstall it on cover.
impeller shaft.
F00J0XA
Install O-ring no. 37 to cover. Apply Loctite 518 on

O-ring.
Install cover to jet pump housing making sure to
properly position filler plug on top side. Do not
torque yet, keep a small gap. F00J0JA 1
Insert a pencil or any other plastic tool in the hole TYPICAL
and push on the slider tab. 1. Pour oil slowly until it is level with bottom of filler hole
CAUTION: Do not use a metal tool to push the
tab. It is possible to damage the inner threads.
12-02-18 SMR2002-088_12_02A.FM
Venturi O-Rings
If needed, install new O-rings no. 38 around bailer Install O-rings no. 38 around bailer passages or
passages. make sure they are in place if they were not re-
moved.
PUMP PRESSURIZATION
Whenever doing any type of repair on jet pump, a
pressure test should be done to check for leakage.
Proceed as follows:
– Remove drain plug from cover.
– Apply Loctite Pipe sealant on threads of fitting
tool (P/N 295 000 086) then secure on cover.
to fitting.
– Pressurize pump to a maximum of 70 kPa (10 PSI).
F00J0KA 1
1. O-rings
Apply Primer N on mating surface. Allow to dry for

2 minutes.
Apply Loctite 518 (Gasket Eliminator) on mating
surface.
Position venturi no. 24 with bailer passages on
top.
Apply Loctite 243 (blue) on threads of screws no. 39.
Install screws no. 39, lock washers and flat wash-
1 F00J0LA
– Pump must maintain this pressure for at least

10 minutes.
CAUTION: Repair any leak, failure to correct a
leak will lead to premature wear of pump com-
ponents.
NOTE: If there is a pressure drop spray soapy wa-
ter around cover. If there are no bubbles, impeller
shaft, impeller shaft seal, or jet pump housing is
leaking through porosity and has to be replaced.
Jet pump unit has to be disassembled. If jet pump
has been overhauled, the impeller shaft seal
no. 22 may be leaking; Add a small quantity of
1 SEA-DOO JET PUMP SYNTHETIC OIL to wet the
F02J0TA
oil seal. Let soak and recheck.
SMR2002-088_12_02A.FM 12-02-19
– Disconnect pump gauge tester and remove fit- Nozzle

ting.
Insert bushing no. 42 in nozzle no. 20.
– Check oil level. Refill as necessary.
Insert bushing no. 43 in nozzle no. 20 with its off-
– Apply Loctite Pipe sealant (P/N 293 800 018) to set pointing rearward.
threads of filler plug then secure it in cover.
1
impeller shaft.
INSTALLATION
Jet Pump Housing
Make sure that blue rubber covered reducer no. 44
is installed as shown.
1
F18J0GA
1. Bushing offset
Position their flanges from inside of nozzle.

Insert sleeves no. 22 in bushings no. 42 and no. 43.
Install nozzle on venturi no. 24; position its steer-
ing arm on RH side. Apply Loctite 243 (blue) on
F18J0FA
screw threads (or use new self-locking screws).
Install screws no. 21 and washer no. 23 then
1. Blue rubber covered reducer
Generously apply synthetic grease on drive shaft
splines.  WARNING
Make sure rubber damper is on drive shaft end. Screws must be torqued as specified.
Install jet pump. If necessary, wiggle jet pump to
engage drive shaft splines in impeller. OPAS
CAUTION: Some watercraft require a shim be- Reconnect OPAS hose. Torque clamp screw to 1.7
tween hull and pump; if shim has been re- N•m (15 lbf•in).
moved at pump removal, be sure to reinstall it,
otherwise engine alignment will be altered. Fasten OPAS “U” lever to nozzle. Apply Loctite 243
(blue) on screw threads (or use new self-locking
Apply Loctite 243 (blue) on stud threads of jet screws). Torque screw to 20 N•m (15 lbf•ft).
pump housing.
Install flat washers no. 40, lock washers no. 41 Pivot Triangle
and nuts no. 25. Tighten nuts of jet pump housing Install head bolts toward inside.
in a criss-cross sequence and torque to 31 N•m
(23 lbf•ft). NOTE: Make sure the pivot triangle turn freely.
NOTE: Slightly lubricate wear ring with BOMBARDIER
LUBE lubricant to minimize friction during initial
start.
12-02-20 SMR2002-088_12_02A.FM
Reverse Gate
Install reverse gate with spacer and washer. Torque
NOTE: When installing the reverse gate, pay atten-
tion to position its lever behind the reverse gate
support stopper.
F07J07A
1. Stopper
Steering Cable
Refer to section, STEERING SYSTEM.
Reverse Cable
Refer to REVERSE SYSTEM.
SMR2002-088_12_02A.FM 12-02-21
GTX 4-TEC Models
Loctite 454
3
2 1
31
Loctite
518
6 Nm
(53 lbfin) 38
44
40
41
34 25 31 Nm
35 (23 lbfft)
36
30 Alsaco
46 grease
32 33 Pipe sealant
592 24 Nm
(18 lbfft)
Primer N 28 45
and 21
37 23
Loctite 243 24
13 22
26
7.5 Nm
(66 lbfin) 20
42
Loctite 43
243 39
16 21 Nm
(16 lbfft)
14
15
2.5 Nm
(22 lbfin)
6 7
19
13
13
5
2.5 Nm
18 (22 lbfin)
17 4
20 Nm
(15 lbfft) 8
F18J0HS
12-02-22 SMR2002-088_12_02A.FM
GENERAL WATERCRAFT IMPELLER

MATERIAL PITCH
MODEL P/N
4
Progressive
Stainless
GTX 4-TEC 271 001 171 pitch
3 steel
13° - 23°
2 JET PUMP INSPECTION ON

5
1 WATERCRAFT
Thus, if access is needed to water inlet area, it will
6 be easy to slide underneath watercraft.
A lift kit can be used to install watercraft on a stand.
F00J0SA
TYPICAL
1. Nozzle
2. Venturi
3. Housing
4. Wear ring
5. Impeller
6. Stator
Cleanness Requirements
Hands, tools, bench, rags must be clean before 1
pump disassembly.
CAUTION: Pump grease tube must be opened
at very last moment to avoid contamination. F01J42A 2
TYPICAL
Impeller Identification 1. Lift kit
2. Work stand
To identify the impellers refer to the following il-
lustration and chart.
Impeller Condition
F02J0VA
F01J0DA
TYPICAL
SMR2002-088_12_02A.FM 12-02-23

This clearance is critical for jet pump performance.
Clearance can be checked from water inlet open-
ing or from venturi side. However, the last method
requires more work.
inlet grate.
To check clearance from venturi side, remove
venturi/nozzle assembly.
wear ring. Measure each blade at its center. For
GTX 4-TEC clearance should not exceed 0.35 mm F01J0FA 1
(.014 in). If clearance is greater, disassemble jet
TYPICAL — MEASURING FROM VENTURI SIDE
pump and inspect impeller and wear ring. Renew
1. Feeler gauge
worn parts.
1
REMOVAL
Pump Assembly
Remove OPAS “U” lever screw, washer and bush-
ings from nozzle.
F01J0EA

1. Feeler gauge
F18J0DA 1
Disconnect steering and reverse cables.

Disconnect OPAS hose from top of pump.
Remove 4 pump retaining nuts.
Pull out pump.
12-02-24 SMR2002-088_12_02A.FM
Reverse Gate Withdraw pivot support.

To remove reverse gate no. 4, put shift lever in
reverse position.
Connecting Rod
Unscrew pivot bolt no. 5. Remove:
– reverse gate
1
– pivot bolt no. 14.
Withdraw connecting rod.
Pivot Triangle
Remove:
– reverse gate
– connecting rod
Pivot Arm
Position shift lever in forward.
Remove:
F16J04A 2 – reverse gate
1. Pivot bolt no. 5 – connecting rod
2. Screw no. 8
– spring no. 17
Remove both reverse gate screws no. 8. – reverse cable
Pivot Support – pivot arm bolts no. 18. Take note of bushing
size for reinstallation.
Withdraw pivot arm no. 19.
Unscrew pivot support bolts no. 13.
1 2
F18J1AA 2 3 1
2. Spring
3. Pivot arm
F18J0JA 4 3
1. Pivot bolt
2. Pivot support
3. Reverse gate
4. Pivot support bolt no. 13
SMR2002-088_12_02A.FM 12-02-25
Nozzle 1
Remove OPAS “U” lever screw, washer and bush-
ings from nozzle.
F18J0KA
1. Steering cable
– OPAS hose
– reverse cable.
F18J0DA 1 Remove 4 retaining screws no. 39 and withdraw
venturi no. 24.
Remove 2 retaining screws no. 21, 2 sleeves no. 22, 1

2 washers no. 23.
Remove nozzle.
Venturi
Remove:
– reverse gate
– nozzle
– pivot arm.
Unplug OPAS hose from plastic elbow.
venturi no. 24.
It’s possible to remove the venturi without remov- 1
F02J0TA
lowing instructions. TYPICAL
1. Remove screws
Disconnect:
– steering cable
12-02-26 SMR2002-088_12_02A.FM
Jet Pump Housing Using a fiber hammer, gently tap cover to release
it from jet pump housing. Use flat screwdriver to
Remove pump as an assembly or remove the fol-
remove cap.
lowing:
– nozzle
– venturi.
Loosen 4 hexagonal nuts no. 24 and remove flat
washers and lock washers from jet pump housing.
Remove jet pump with a wiggle movement.
CAUTION: When removing pump unit, a shim
engine and jet pump alignment will be altered.
NOTE: After jet pump removal, if drive shaft re-
mains in the PTO flywheel, simply pull it out. If
drive shaft is seized in the PTO flywheel, refer to
DRIVE SYSTEM.
DISASSEMBLY F18J0MA
NOTE: Whenever removing a part, visually check Check for presence of water in cone and bearing.
for damage such as: corrosion, crack, split, break, If so, replace oil seal no. 35 and sleeve no. 30.
porosity, cavitation, deformation, distortion, heat- Remove both O-rings no. 37 and circlip.
missing or broken balls in ball bearing, water dam-
age diagnosed by black-colored spots on metal
parts, etc. Renew any damaged part. As a quick
check, manually feel clearance and end play,
Cover
With pump housing in vertical position, remove 3
retaining screws no. 26.
F18J0NA
F18J0LA
F18J0OA
SMR2002-088_12_02A.FM 12-02-27
Impeller NOTE: It may be needed to heat the impeller to

break Loctite bond.
Remove ring no. 3, impeller boot no. 2. Replace
them if damaged.
Mount impeller remover/installer (P/N 529 035 820)
in a vise.
529 035 820
F18J0RA
CAUTION: Never use any impact wrench to loos-

en impeller.
F18J0PA To remove impeller, apply a rotating movement and
pull at same time. Slide impeller out of housing.
Install pump over this tool.
Pull pump housing out.
F18J0QA F18J0SA
Using a 12 mm Allen key, unscrew the impeller.
12-02-28 SMR2002-088_12_02A.FM
Remove shield no. 34.
F18J0VA 529 035 819

F18J0TA
From the outlet side of pump, use the seal/bearing
Use the impeller shaft pusher (P/N 529 035 818) pusher (P/N 529 035 819) to press out the oil seal
to press out impeller shaft no. 28 of pump hous- no. 35.
ing. Bearing no. 33, shaft sleeve no. 30, O-ring
no. 46 and spacer no. 32 will come out with the
impeller shaft.
529 035 819
529 035 818
F18J0WA
Remove large O-ring no. 36 from pump housing.
F18J0UA Wear Ring

CAUTION: Bearing inner race being in 2 parts, Remove the screws retaining wear ring in the jet
bearing may fall apart during removal. pump housing.
Use the seal/bearing pusher (P/N 529 035 819) to Place jet pump housing in a vise with soft jaws. It
press out bearing no. 33 from impeller shaft. is best to clamp housing using a lower ear.
Cut wear ring at two places.
After cutting ring, insert a screwdriver blade be-
tween jet pump housing and ring outside diameter.
Push ring so that it can collapse internally.
Pull ring out.
SMR2002-088_12_02A.FM 12-02-29

Thoroughly clean jet pump housing by applying Impeller
Loctite Stripper (P/N 293 110 004). Allow it some
time to dissolve the old dried Loctite (10 to 15 min- Visually inspect impeller splines. Check for wear or
utes). deformation. Renew parts if damaged.
NOTE: Check also PTO flywheel and drive shaft con-
 WARNING dition. Refer to BOTTOM END and DRIVE SYSTEM.
Technician should wear gloves when using Examine impeller in wear ring for distortion.
this cleaning product.
Check if blade tips are blunted round, chipped or
CAUTION: DO NOT use Loctite Stripper on wear broken. Such impeller is unbalanced and will vi-
ring since it will cause irreparable damage to it. brate and damage wear ring, impeller shaft, shaft
seal or bearings. Renew if damaged.
Wipe Loctite Stripper with a clean cloth.
Make sure surface is cleaned and dried of Loctite 1
Stripper.
scraper.
Carefully check water passages. Blow low pres-
sure compressed air through them and make sure
they are clear.
1
F18J1BA

1
F18J0XA
1. Water passages

and drive shaft splines with Pulley flange cleaner
splines from any residue.
F18J1CA
1. Check for cavitation, deep scratches or other damage
12-02-30 SMR2002-088_12_02A.FM
Wear Ring Excessive play can come either from worn bearing
or damaged jet pump housing bearing surface.
Seal
peller is in good shape, renew wear ring. Carefully inspect seal lips. Make sure that lips are
not worn, distorted, cracked or show signs of any
Ball Bearing and Impeller Shaft other damage. Replace after 100 hours.
WEAR Bearing
IMPORTANT: Make sure to reassemble ball cage, Replace bearing whenever the marks of corrosion
bearing inner and outer races to their original po- and presence of water is found.
sition.
Inspect ball bearing no. 33. Check for corrosion, OPAS Filter
scoring, pitting, chipping or other evidence of wear. OPAS filter is part of plastic elbow no. 45. Check
With your finger nail, feel contact surface of sleeve. for cleanness. Replace or clean it as necessary.
If any irregular surface is found, renew sleeve
no. 30 and seal. ASSEMBLY
Install bearing, then install impeller shaft and ro- Hands, tools, bench, rags must be clean before
tate it. Make sure it turns smoothly. pump disassembly.
RADIAL PLAY CAUTION: Pump grease tube must be opened
Radial play is critical for jet pump unit life span. at very last moment to avoid contamination.
Radial play of impeller shaft is checked with shaft
in housing, with impeller. Plastic Elbow
Retain housing in a soft jaw vise making sure not Install plastic elbow no. 45 at 20° angle to the right.
to damage housing lug. It may exceed inside housing by 1.0 mm (.039 in).
Set a dial gauge and position its tip onto metal end, It may be positioned up to 2.0 mm (.078 in) from
close to end of threads. housing edge.
Move shaft end up and down. Difference between A
highest and lowest dial gauge reading is radial play.
F18J0EA C
A. 20°
B. 2.0 mm (.078 in)
C. 1.0 mm (.039 in)
F18J1DA 1 2
MEASURING IMPELLER SHAFT RADIAL PLAY
1. Dial gauge
SMR2002-088_12_02A.FM 12-02-31
Wear Ring
This model is equipped with large pump. It is im-
portant that the screws retaining wear ring to
housing are installed on this model.
F01J5DA
1. Seal lip
2. Press wear ring
F08J06A
If a press is not readily available, a piece of wood
such as a 2 x 4 in x 12 in long, can be used.
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.
F08J07A
3
To install ring in housing, use a square steel plate
of approximately 180 x 180 mm x 6 mm thick (7 x
7 in x 1/4 in) and a press.
Manually engage ring in housing making sure it is 2
equally inserted all around. Press ring until it seats 1
into bottom of housing.
F01J5EA
1. Piece of wood
3. Wear ring
NOTE: Do not forget, install two retaining screws

on tops of the large pump models.
12-02-32 SMR2002-088_12_02A.FM
Bearing Coat shaft surface with jet pump bearing grease

(P/N 293 550 032) then, install sleeve no. 30 on
Using the seal/bearing pusher (P/N 529 035 819)
impeller shaft no. 28.
press the bearing no. 33 by its inner race on the
impeller shaft no. 28.
Be careful when removing the plastic retainer
from the bearing no. 33 to avoid the inner races
from falling apart. Make sure to reassemble bear-
ing parts to their original position.
The bearing no. 33 can be installed either side.
529 035 819

F18J10A
From the outlet side of pump, press impeller shaft

assembly into housing using shaft pusher (P/N
529 035 818).
F18J0YA
529 035 818
Install spacer no. 32 on shaft no. 28.
Install O-ring no. 46 in sleeve no. 30.
F18J11A
Install circlip and O-rings no. 37.
F18J0ZA
1. O-ring
SMR2002-088_12_02A.FM 12-02-33
Apply 10 cc of jet pump bearing grease (P/N 293 On the outlet side, install 2 O-rings no. 37 in their
550 032) on bearing. respective groove.
Before installing any other parts. pump can be
pressurized to insure proper seal installation. See
PUMP PRESSURIZATION below.
On the impeller side, install shield no. 34.
Apply Loctite 243 on impeller shaft and impeller
threads.
F18J12A
Press oil seal no. 35 using seal/bearing pusher

(P/N 529 035 819) until tool bottoms. Make sure
seal lips are facing up.
1 F18J15A
F18J13A F18J16A
1. Lips facing up
Apply BOMBARDIER Lube on the wear ring sur-
face. Start screwing the impeller on its shaft. If
529 035 819
impeller is too tight, use impeller tool to turn im-
peller to machine wear ring before installing on ve-
hicle. Make sure to turn it smooth enough so that
engine starter should turn it.
Mount impeller remover/installer (P/N 529 035 820)
in a vise.
Install partially screwed impeller on it.
Use a 12 mm Allen key to torque impeller shaft to
Torque impeller to 125 N•m (92 lbf•ft) then remove
tool.
F18J14A
12-02-34 SMR2002-088_12_02A.FM
CAUTION: Never use any impact wrench to tight-

en impeller shaft.
Apply 50 cc of jet pump bearing grease (P/N 293
550 032) in the impeller shaft area.
F00J0KA 1
1. O-rings
F18J17A
Position venturi no. 24 with bailer passages on top.
Apply another 50 cc of jet pump bearing grease Apply Loctite 243 (blue) on threads of screws no. 39.
(P/N 293 550 032) in the impeller cover. Install screws no. 39, lock washers and flat wash-
F18J18A
Install impeller cover with new self-locking screws.

Torque to 7 N•m (62 lbf•in).
Venturi
F02J0TA 1
If needed, install new O-rings no. 38 around bailer
passages. 1. Torque screws to 21 N•m (16 lbf•ft)
O-Rings
Install O-rings no. 38 around bailer passages or make
sure they are in place if they were not removed.
SMR2002-088_12_02A.FM 12-02-35
PUMP PRESSURIZATION INSTALLATION

Whenever doing any type of repair on jet pump, a Jet Pump Housing
pressure test should be done to check for leakage.
Make sure that black rubber covered reducer
Proceed as follows: no. 44 is installed as shown.
– Remove impeller cover no. 13. Install pressure CAUTION: Misinstallation can cause overheating
cap (P/N 529 035 843) on pump housing. and damage to exhaust system.
1
to fitting.
– Pressurize pump to a maximum of 70 kPa (10 PSI).
529 035 843
F18J0IA
1. Black rubber covered reducer
Generously apply synthetic grease on drive shaft

splines.
F18J19A
Make sure rubber damper is on drive shaft PTO
end.
– Pump must maintain this pressure for at least 5 Install jet pump. If necessary, wiggle jet pump to
minutes. engage drive shaft splines in impeller.
CAUTION: Repair any leak, failure to correct a CAUTION: Some watercraft require a shim be-
leak will lead to premature wear of pump com- tween hull and pump; if shim has been re-
ponents. moved at pump removal, be sure to reinstall it,
NOTE: If there is a pressure drop spray soapy wa- otherwise engine alignment will be altered.
ter around cover. If there are no bubbles, impeller Apply Loctite 243 (blue) on stud threads of jet
shaft, impeller shaft seal, or jet pump housing is pump housing.
leaking through porosity and has to be replaced.
Jet pump unit has to be disassembled. There may Install flat washers no. 40, lock washers no. 41
be 2 or 3 bubbles coming out from sleeve no. 30/ and nuts no. 25. Tighten nuts of jet pump housing
seal area. This small leak is acceptable. Leaks from in a criss-cross sequence and torque to 31 N•m
other areas must be repaired. (23 lbf•ft).
– Disconnect pump gauge tester and remove pres- NOTE: Slightly lubricate wear ring with BOMBARDIER
sure cap. LUBE lubricant to minimize friction during initial
start.
– Reinstall impeller cover no. 13 with 3 new self-
locking screws.
12-02-36 SMR2002-088_12_02A.FM
Nozzle Pivot Triangle

Insert bushing no. 42 in nozzle no. 20. Install head bolts toward inside.
Insert bushing no. 43 in nozzle no. 20 with its off- NOTE: Make sure the pivot triangle turn freely.
set pointing rearward.
Reverse Gate
1
Install reverse gate with spacer and washer. Torque
NOTE: When installing the reverse gate, pay at-
tention to position its lever behind the reverse
gate support stopper.
F18J0GA
1. Bushing offset
Position their flanges from inside of nozzle.

Insert sleeves no. 22 in bushings no. 42 and no. 43.
Install nozzle on venturi no. 24; position its steer-
ing arm on RH side. Apply Loctite 243 (blue) on F07J07A
screw threads (or use new self-locking screws). 1. Stopper

Install screws no. 21 and washer no. 23 then
torque to 24 N•m (18 lbf•ft). Steering Cable
 WARNING Refer to section, STEERING SYSTEM.
Screws must be torqued as specified. Reverse Cable
Refer to REVERSE SYSTEM.
OPAS
Reconnect OPAS hose. Torque clamp screw to 1.7
N•m (15 lbf•in).
Fasten OPAS “U” lever to nozzle. Apply Loctite 243
(blue) on screw threads (or use new self-locking
screws). Torque screw to 20 N•m (15 lbf•ft).
SMR2002-088_12_02A.FM 12-02-37
DRIVE SYSTEM 0
GTX DI Models
2
3
4
5 1
6
7
8
2 Nm
9 (18 lbfin)
10
13
2 Nm
11 (18 lbfin)
Synthetic
grease 12
Synthetic
grease
13
F18I0LS
SMR2002-089_12_03A.FM 12-03-1
GTX 4-TEC MOdels
5
6
7
8
9
10
11
Loctite
antiseize 15
lubricant
12
16
Synthetic
grease
F18I01S
12-03-2 SMR2002-089_12_03A.FM
GENERAL
Jet pump must be removed to replace any com-
ponents of the drive system. Refer to JET PUMP
for removal procedure.
REMOVAL
GTX DI Models
PTO Flywheel Guard
Remove seat.
Remove plastic wing nuts retaining PTO flywheel
guard no. 1 to engine support.
Detach PTO flywheel guard from engine and with- F01J2AA
1
draw from bilge.
TYPICAL
Large Clamp 1. Closing hooks
GTX DI Models – Squeeze pliers to draw hooks together and dis-

engage windows from locking hooks.
Unfasten large clamp of PTO flywheel boot no. 3
as follows:
– Use pliers (P/N 295 000 069).
F01J0GA
– Insert pointed tips of pliers in closing hooks.
F01J29A 1
TYPICAL
1. Locking hooks
Small Clamp
Unfasten small clamp of PTO flywheel boot as fol-
lows:
SMR2002-089_12_03A.FM 12-03-3
– Use pliers (P/N 295 000 054). 4-TEC Models

oil will flow out. To prevent it, start engine, run at
4000 RPM for 10 seconds and stop engine at this
RPM. This will move oil out of PTO housing into
oil tank.
Remove seat.
Detach coolant expansion reservoir from vent
F01B1TA
tube support then move away.
2 1
– To open clamp, place flat side of plier on clamp
embossment, squeeze and twist plier.
F18L1GB
1. Detach expansion reservoir

2. Remove vent tube support
F02J0PA
Detach vent tube.

Circlip and Floating Ring Remove vent tube support.
Hold floating ring no. 6 and compress boot no. 10; Floating Ring and PTO Seal
then, pull out circlip no. 5 from drive shaft groove.
CAUTION: Strictly follow this procedure other-
1 2 wise damage to component might occur. Lift
splash guard to expose PTO seal assembly. In-
stall PTO seal support tool (P/N 529 035 842) on
bottom of PTO seal assembly as shown.
F06I06A
TYPICAL
2. Remove circlip
F18B01A
1. PTO seal support tool
12-03-4 SMR2002-089_12_03A.FM
F18B03A
Disconnect EGT sensor to make room.

Install drive shaft/floating ring tool (P/N 529 035
1
841) as shown.
F18I04A
1. Insert in groove of PTO seal assembly
Remove jet pump. Refer to JET PUMP section.

Install drive shaft holder (P/N 529 035 871) on
pump support as shown. F18B04A
NOTE: This is necessary so the drive shaft cannot DRIVE SHAFT/FLOATING RING TOOL
move rearwards when using the drive shaft/floating
ring tool.
F18B02A
1. Drive shaft holder
SMR2002-089_12_03A.FM 12-03-5
2 1 1
F18I05A
1. Largest opening here F18I08A

2. Floating ring
1. Largest opening here
Turn screw clockwise so that the tool pushes the 2. Lubricate both O-rings
floating ring rearwards to expose the c-clip. Do not Turn screw clockwise so that the tool pushes the PTO
remove clip at this time. seal forward and the drive shaft to the rear to expose
NOTE: This step is done to ensure floating ring is both O-rings. Lubricate O-rings with BOMBARDIER
free and not stuck on the drive shaft. LUBE (P/N 293 600 016).
Remove drive shaft/floating ring tool and drive NOTE: This is necessary to ease drive shaft re-
shaft holder. moval later.
Reinstall drive shaft/floating ring tool as shown. Remove drive shaft/floating ring tool and PTO seal
support.
Reinstall drive shaft holder tool.
12-03-6 SMR2002-089_12_03A.FM
Remove drive shaft holder tool then drive shaft/

floating ring tool.
NOTE: Use this sequence to minimize the
amount of movement the drive will slide back into
PTO seal assembly.
All Models
Drive Shaft
Simply pull out drive shaft.
4-TEC Models
F18B03A If spillage occurs, clean immediately with the pul-
ley flange cleaner (P/N 413 711 809) to prevent oil
Reinstall drive shaft/floating ring tool as shown. stains.
Push floating ring rearwards to expose C-clip and NOTE: It may require a slight jerk to the rear to
remove it. remove the O-rings from the PTO seal assembly.
2 1
All Models
Boot
Loosen gear clamp no. 11 holding boot, then care-
fully pull boot and carbon ring no. 8 from hull in-
sert.
Carbon Ring
Loosen gear clamp no. 9 then pull carbon ring from
boot no. 10.
INSPECTION
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.
F18I0BA
1. Largest opening here

2. Remove C-clip
SMR2002-089_12_03A.FM 12-03-7
Damper
GTX DI Models
Visually inspect shape of dampers no. 13 for de-
formation or other damage.
4-TEC Models
Discard damper to install a new one.
F01I0FA 1 2 3
TYPICAL Floating Ring and O-Ring
1. Surface condition Inspect condition of O-rings no. 7 and floating ring
2. Groove condition
3. Splines condition contact surface.
4-TEC Models 1
Discard both O-rings to install new ones.
All Models
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 2
in center of shaft. Slowly rotate shaft; difference
between highest and lowest dial gauge reading is
deflection. Refer to the following illustration.
F01I0GA
Maximum permissible deflection is 0.5 mm (.020 in).
1. O-rings
2. Floating ring contact surface
Boot
Inspect the condition of boot. If there is any dam-
age or evidence of wear, replace it.
GTX DI Models
1
To verify the preload of the boot no. 10, proceed
as follows:
NOTE: To verify the boot preload and free length,
jet pump and drive shaft must be installed.
F01J15A 2 Measure boot length when normally installed on
drive shaft. Ensure circlip no. 5 is properly in-
MEASURING DRIVE SHAFT DEFLECTION
stalled into groove.
1. Dial gauge
2. V-blocks
12-03-8 SMR2002-089_12_03A.FM
F00J03A 1 A
F00J04B
1. Boot
A. Measure here 1. Spacer
Push floating ring to compress boot; then, remove NOTE: Drive shaft must be removed to install spacer.
circlip out of drive shaft groove.
4-TEC Models
1 2
Inspect PTO seal assembly. Refer to PTO HOUSING/
MAGNETO section.
All Models
INSTALLATION
the following.
Drive Shaft and Dampers
F06I06A GTX DI Models

1. Push floating ring Install dampers no. 13 on drive shaft no. 12.
2. Remove circlip
NOTE: Make sure dampers were not left in PTO
Slide floating ring far enough forward in order to flywheel or impeller.
release it from carbon ring.
Install drive shaft and jet pump at the same time.
Measure boot free length.
Insert drive shaft through carbon ring no. 8 and
Subtract the installed length measurement from floating ring no. 6.
the free length measurement. A difference of 4 mm
NOTE: Make sure to install floating ring before in-
to 12 mm (5/32 in to 15/32 in) should be obtained.
serting the drive shaft in the PTO flywheel.
If the length is less than 4 mm (5/32 in), install a
While holding jet pump, guide and engage drive
spacer (P/N 293 250 017) between boot and thru
shaft splines in PTO flywheel. Rotate shaft to
hull fitting.
properly index splines. Make sure boot is well po-
sitioned over shaft end.
SMR2002-089_12_03A.FM 12-03-9
Circlip
Push the floating ring to compress the boot. Insert
the circlip no. 5 in the drive shaft groove.
1 2
F01J2BA 1
F06I06A
TYPICAL
1. Closing hooks
2. Insert circlip in the groove – Squeeze pliers. When both large and small win-
Slide the floating ring onto the circlip. dows are directly over the 2 locking hooks,
press those windows down to engage hooks in
Large Clamp windows.
Secure large clamp no. 2 as follows: NOTE: At installation, clamp tail should be in op-
– Use pliers (P/N 295 000 069) as for removal. posite direction of engine rotation.
– Manually engage holding hook in large window. 1
This is a pre-clamping position only.
F01J23B 2
1. Engine rotation (counterclockwise)
2. Tail in opposite direction
F01J23A 2
PRE-CLAMPING POSITION Small Clamp
1. Holding hook To secure small clamp no. 4, place notch side of
2. Large window
plier on clamp embossment and squeeze plier.
– Insert pointed tips of pliers first in closing hooks.
12-03-10 SMR2002-089_12_03A.FM
F02J0PB
F18I0FA 1
1. Squeeze plier
WRONG INSTALLATION
1. Inner sleeve not flush with outer circumference
4-TEC Models
Slightly apply BOMBARDIER LUBE (P/N 293 600
Ensure to install a new damper no. 15 and new O- 016) on O-rings of drive shaft.
rings on drive shaft no. 12.
Apply a thin coat of synthetic grease (P/N 293 550
NOTE: Ensure to install floating ring before insert- 010) on the O-rings of floating ring and on splines
ing the drive shaft on PTO seal assembly. going in impeller. Do not get grease on it’s sealing
Before installing drive shaft, inspect PTO seal as- surface.
sembly. The inner sleeve must be flush with outer
circumference of the assembly. Otherwise, gently
push or tap on inner sleeve until flush.
1 2
F18I0KA
1. Synthetic grease
2. No lubrication
CAUTION: Note that drive shaft features a tell

tale groove. If exposed after installation, the in-
stallation is wrong and PTO seal assembly will
F18I0EA 1 be pressed into crankshaft splines which could
CORRECT INSTALLATION rub a hole in seal thus creating an oil leak.
1. Inner sleeve flush with outer circumference
SMR2002-089_12_03A.FM 12-03-11
When properly aligned, maintain PTO seal assembly

in the proper position and tap shaft end until it bot-
toms against engine. At this time, the tell tale MUST
NOT be visible. This validate the correct position.
F18I0GA 1
1. Tell tale groove F18I0HA 1 2 3
1. PTO seal support
Install PTO seal assembly. 2. Drive shaft end
3. Insert floating ring on shaft end
Install PTO seal support tool on PTO seal assembly.
Slide drive shaft far enough to install floating ring. 3 1
F18I02A
Continue pushing drive shaft towards engine care- F18I0IA 2

fully guiding it in the PTO seal then in crankshaft GOOD INSTALLATION
splines. 1. PTO seal assembly
2. Shaft pushed in, hiding tell tale groove
Then, push drive shaft until it bottoms against the 3. Inner sleeve flush with outer circumference
engine.
While someone is pushing drive shaft, slide float-
ing ring rearward and guide drive shaft in PTO seal
assembly. It may be necessary to move PTO seal
assembly up and down to position it in the same
axis as the drive shaft.
12-03-12 SMR2002-089_12_03A.FM
3 1 2 1
F18I06A
1. Largest opening
2. Install C-clip
F18I0JA 2
Remove drive shaft/floating ring tool, drive shaft
WRONG INSTALLATION holder then PTO seal support.
1. PTO seal assembly
2. Tell tale groove visible NOTE: Pushing boot no. 10 rearwards will ease
3. Inner sleeve NOT flush with outer circumference removal of PTO seal support tool.
Install drive shaft holder tool. Now ensure everything is properly positioned: Tell
tale is not exposed, inner sleeve is flush with outer
circumference of PTO seal assembly and C-clip is
not exposed.
If tell tale mark is exposed, push PTO seal assem-
bly rearwards to fully extend it.
If inner sleeve is not flush, gently tap it until it is
flush.
Reposition splash guard.
Reconnect EGT sensor.
Install jet pump. Refer to JET PUMP section.
Check engine oil level. Refill as necessary.
F18B03A
Run watercraft then ensure there is no oil leak in
PTO seal area.
Install Drive shaft/floating ring tool as shown. En-
sure PTO seal support is still in place.
Push floating ring rearwards and install C-clip.
SMR2002-089_12_03A.FM 12-03-13
LUBRICATION
PTO Flywheel
GTX DI Models
Using a grease gun, carefully lubricate PTO fly-
wheel with synthetic grease (P/N 293 550 010),
until boot is just beginning to expand. At this point,
immediately stop greasing.
F01I0BB
12-03-14 SMR2002-089_12_03A.FM
REVERSE SYSTEM 0
2.5 Nm
(22 lbfin)
5 2.5 Nm Synthetic
(22 lbfin) grease
Loctite
243 7 2.5 Nm
(22 lbfin)
Loctite 243
9 10
Silicone Silicone
sealant sealant 3
2
7 3.3 Nm
Loctite 243 (29 lbfin)
Silicone Loctite 243
sealant
6
9
2.5 Nm
(22 lbfin)
Loctite 243
8
10
4 Nm
(35 lbfin) 4
12
11 10 Nm
(89 lbfin)
2 2.6 Nm
(23 lbfin)
F18J1GS
SMR2002-090_12_04A.FM 12-04-1
DISASSEMBLY 3 4
Reverse Gate
To remove reverse gate, refer to JET PUMP sec-
tion.
Reverse Cable
Unscrew bolt no. 1, washers and the elastic stop
nut retaining reverse cable no. 2 on pivot arm.
1 2
F18J1IA 2 1
1. Engine cooling air intake hose
2. Air intake locking device
3. Interior lever
4. Reverse cable support
On the interior lever no. 3, unscrew the elastic stop

nut and the washer retaining the reverse cable.
Remove the bracket no. 6.
NOTE: Before removing reverse cable from hull,
note cable routing for reinstallation.
F18J1HA 3 4 5
1. Reverse cable
2. Pivot arm
3. Bolt
4. Washer
5. Elastic stop nut 1
Unscrew the cable lock no. 11 then remove the
half rings no. 12. 2
Remove the seat and the glove box. Refer to HULL/
BODY. 3
Push the engine cooling air intake hose toward the
front of the vehicle to get more access to the in-
terior lever and the reverse cable support.
To release the engine cooling air intake hose press
down the air intake locking devices and move the
hose.
4
There are two air intake locking devices; one above
and one underneath the hose. F18J1JA
DO NOT REMOVE the engine cooling air intake 1. Interior lever

hose completely. 2. Elastic stop nut and Washer
3. Reverse cable
4. Bracket
12-04-2 SMR2002-090_12_04A.FM
Interior Lever INSPECTION

Detach the reverse cable from interior lever no. 3. Visually inspect parts for wear or cracks on friction
Unscrew the shift lever retaining bolt no. 4, wash- parts. Replace all defective parts.
er and nut, then remove interior lever.
ASSEMBLY
Shift Lever
Unscrew the shift lever retaining bolt no. 4, wash- bly procedures. However pay particular attention
er and nut. to the following.
Disengage the shift lever slots from interior lever Insert interior lever cursor into reverse cable sup-
tabs, then remove the shift lever no. 5. port slider and make that the cursor slides freely
in the slider.
1 2
F18J1KA 4 3 1 2
1. Shift lever retaining bolt
2. Shift lever slot
3. Interior lever tab
4. Shift lever
F18J1LA
Reverse Cable Support 1. Interior lever cursor

2. Reverse cable support slider
Remove:
– shift lever Interior Lever
– interior lever Apply synthetic grease on the interior lever pivot
and in the reverse cable support hole.
– bracket no. 6
Install the interior lever in a rotating movement.
– bolts no. 7.
Engage properly the interior lever tabs in the shift
Withdraw reverse cable support no. 8. lever slots.
Handle Housing cise. Forward and reverse positions should be
Remove: easy to select with a detent position between
– shift lever each.
– interior lever
– reverse cable support
– bolts no. 9.
Then, remove handle housing no. 10.
SMR2002-090_12_04A.FM 12-04-3
ADJUSTMENT
 WARNING
When adjusting reverse cable, assure that le-
Place reverse gate in the up position.

Turn the joint at the end of reverse cable and place
the hole in pivot arm and joint face to face.
Secure with bolt, washers, spacer and elastic stop
nut. Torque to 7 N•m (62 lbf•in).
12-04-4 SMR2002-090_12_04A.FM
TABLE OF CONTENTS 0
STEERING SYSTEM .............................................................................................................. 13-02-1
DISASSEMBLY................................................................................................................... 13-02-2
ASSEMBLY......................................................................................................................... 13-02-5
OFF-POWER ASSISTED STEERING SYSTEM (O.P.A.S.)................................................ 13-02-7
GENERAL ........................................................................................................................................... 13-02-8
SIDE VANE ......................................................................................................................... 13-02-8
CYLINDER SUPPORT ASSEMBLY ................................................................................... 13-02-9
TIE ROD .............................................................................................................................. 13-02-10
SEALED TUBE ................................................................................................................... 13-02-11
FILTER ................................................................................................................................ 13-02-11
VALVE................................................................................................................................. 13-02-11
WATER HOSE .................................................................................................................... 13-02-12
CROSS SUPPORT PLATE ................................................................................................. 13-02-12
ALIGNMENT .......................................................................................................................... 13-03-1
SMR2002-095_13-01ATOC.FM 13-01-1
STEERING SYSTEM 0
All Models
3
2 37 26 Nm
9 (19 lbfft)
11 7 Nm
(62 lbfin) 36
21 19
7 1
5 10 8
15
7 4
6
5 6
10 Nm
13 17
14
18
26
12
29 20
22
Body Synthetic
grease
27
38
Loctite 243
6 Nm 31
(53 lbfin) 28 25
Loctite 243 6 Nm
2.5 Nm (53 lbfin)
3 Nm 30 (22 lbfin)
(26 lbfin)
24
2.5 Nm
6 Nm 23
(53 lbfin) 35
33 34
32 10 Nm
(89 lbfin)
31
F18K09S
SMR2002-091_13_02A.FM 13-02-1
DISASSEMBLY Remove 4 tapping screws no. 7.

To remove handle grip no. 1, pull out cap no. 2 and
remove screw no. 3.
Pull out grip and remove grip insert from handlebar
no. 4.
F18K0CA 2 1
1. Tapping screw
2. Handle bar housing
Remove handlebar housing cover no. 8 and throt-

F18K0AA 2 1
tle handle housing no. 11.
1. Handle grip
Unhook throttle cable from throttle handle no. 9.
2. Remove screw Pry out the throttle cable housing from throttle
NOTE: Verify grip insert for damage. handle housing no. 10.
Steering Cover
Remove grips no. 1.
Loosen set screws no. 5 of handlebar housings
no. 6.
F18K0DA 2 1 3
1. Throttle cable
2. Throttle handle housing
3. Throttle cable handle
Remove 6 screws no. 12 and flat washers no. 13

F18K0BA 1
each side of cover.
1. Set screw
13-02-2 SMR2002-091_13_02A.FM
Remove lower steering cover no. 14.

2
F18K0EA 1 2 F18K0GA 1
1. Steering cover 1. Screws
2. Screws 2. Steering padding
Unscrew DESS switch nut using safety lanyard

switch tool (P/N 529 034 600).
Handlebar
Remove upper steering cover no. 15. Remove steering cover and steering padding as
mentioned above.
Remove 4 nuts no. 20 to remove handle bar no. 4
from steering stem no. 22 and steering clamp
no. 21.
F18K0FA 1
1. DESS switch nut 1
Steering Padding
F18K0HA 2 3 4
Remove steering cover as mentioned above.
1. Nuts
Remove 2 screws no. 16 and flat washers no. 18. 2. Handlebar
3. Steering stem
Remove steering padding no. 17. 4. Steering clamp
Cable Support
Loosen bolts no. 22 and remove retaining block
no. 24.
SMR2002-091_13_02A.FM 13-02-3
Remove cable support no. 27.
Steering Support
Cut locking tie securing wiring harness boot.
F18K0IA 1
1. Retaining block
Loosen bolts no. 25 each side of steering support

no. 26.
F07K04A 1 2
1 2
1. Boot
2. Locking tie
Disconnect the throttle and choke cables from car-

buretor levers.
Disconnect the wiring harnesses leading out of
steering stem and cut locking tie.
1 2
F07K02A
1. Steering support
2. Bolt
1 2
F07K05A
1. Tie rap
2. Connectors
F07K03A
1. Steering support
2. Bolts
13-02-4 SMR2002-091_13_02A.FM
Disconnect the steering cable from the steering Steering Stem Arm and Support
stem arm no. 28.
Remove bolts no. 30 retaining steering stem arm
no. 28 to support no. 31.
1 2
1
2
F07K06A
F07K08A 2
1. Steering stem arm
2. Steering cable 1. Steering stem arm
2. Bolts
Remove bolts no. 25 retaining cable support
no. 27 to steering support no. 26. Remove steering stem arm and support.
Remove lock nuts no. 29 from steering retaining Steering Cable
strip studs.
Disconnect steering cable no. 31 from steering
stem arm no. 28.
Remove retaining block no. 24.
Disconnect ball joint no. 35 from jet pump nozzle.
Remove ball joint no. 35 and jam nut from cable.
Loosen nut no. 34, then remove half rings no. 33
and O-ring no. 32.
NOTE: To loosen nut, use steering cable tool (P/N 295
000 145).
Remove steering cable from watercraft.
ASSEMBLY
F18K0JA 2 1 Assembly is essentially the reverse of disassem-
1. Steering support bly procedures. However, pay particular attention
2. Retaining strip studs to the following.
Remove steering support no. 26 with handlebar, CAUTION: Apply all specified torques and ser-
wiring harnesses and cables. vice products as per main illustration at the be-
ginning of this subsection.
SMR2002-091_13_02A.FM 13-02-5

When installing the grip insert no. 36 in the han-
dlebar no. 4, ensure that it is properly inserted in
the slot at the end of the handlebar tubing. 2
2
F07K09A
1. Keyways
2. Integrated flat key
Replace lock nuts no. 38 by new ones.

Torque bolts no. 30 of steering stem arm to 6 N•m
(53 lbf•in).
Ball Joint
F02K0JA 1 Secure the steering cable ball joint no. 35 to the
1. Grip insert nozzle as per following illustrations.
Install grip no. 1 on handlebar no. 4 matching it to CAUTION: Ensure the ball joint is parallel (± 5°)
the hex form on the grip insert. to the nozzle arm.
Install flat washer no. 37 and screw no. 3.
Install cap no. 2.
1 3 5
F02K0KA
2 4
1. Grip insert
2. Grip
3. Flat washer
4. Screw. Torque to 7 N•m (62 lbf•in) F06K01A 1 2
5. Cap
TYPICAL
CAUTION: Ensure to install flat washer other- 1. Ball joint on top of steering arm
wise screw will damage grip end. 2. Torque nut to 7 N•m (62 lbf•in)
Steering Stem Arm and Support Steering Alignment

Position steering stem arm no. 15 and support For steering alignment procedure, refer to ALIGN-
no. 16 onto steering stem. MENT.
 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.
13-02-6 SMR2002-091_13_02A.FM
OFF-POWER ASSISTED STEERING SYSTEM (O.P.A.S.)
12
19
13 10
1.2 Nm 9
18 (10 lbfin) 11
14 21
Body 12 2.2 Nm
17 36 24
15 25 (19 lbfin)
20
16
22
35
1.7 Nm 5.5 Nm
26 (49 lbfin)
(15 lbfin)
33 Hull
4.5 Nm 26
(40 lbfin) 10 2.2 Nm
1.2 Nm 36 34 (19 lbfin)
(10 lbfin) 31
32 1.7 Nm
9 24 12 (15 lbfin)
2.2 Nm
(19 lbfin) 25 30
23
11 Hull
22 21 27
29
5.5 Nm Hull
(49 lbfin) 2.2 Nm 28 2.2 Nm
8
29 28 6 7 Nm
8 7 (62 lbfin)
23 Hull 1
5
4
6 7
27 3
7 Nm 20 Nm
F18K0KS
(62 lbfin) 2 (15 lbfft)
SMR2002-091_13_02A.FM 13-02-7
GENERAL When throttle is released and engine RPM drops,

the side vanes are automatically lowered thus as-
The Off-Power Assisted Steering (O.P.A.S.) sys- sisting steering control.
tem uses a dual side vanes design that assists the
watercraft steering in deceleration, to redirect water-
craft path when steering is turned after throttle has
been released or engine stopped.
The side vanes on the rear sides of the hull, turn
as the steering is turned to assist the watercraft
turning. At first, carefully experiment turning with
this system.
F18K01A 1
1. Side vane in lower position
F18K03A 1 1
SIDE VANE
1. Side vanes turn following steering movement Disassembly
When engine is running at approximately 75% or Removal procedure for RH and LH side vane no. 9
more RPM, the side vanes are automatically raised is the same.
to upper position since they are not required at that
Turn the steering for removal of tie rod retaining
vehicle speed range.
screw.
Between 30% and 75% engine RPM, side vanes
Remove tie rod retaining screw no. 10 and socket
are gradually raised from lower position to upper
screw no. 11.
position.
F18K0LA 3 4
1. Tie rod screw
F18K02A 1 2. Side vane
3. Cylinder support assembly
1. Side vane in upper position 4. Tie rod retaining stabilizer
13-02-8 SMR2002-091_13_02A.FM
CYLINDER SUPPORT ASSEMBLY

Disassembly
1
Removal procedure for RH and LH cylinder sup-
port assembly is the same.
Remove side vane as mentioned above.
Unscrew bottom nut using OPAS cylinder nut
wrench (P/N 529 035 840).
F18K0MA
1. Socket screw
Lift shaft while holding top of side vane.

Pull side vane out. 2
Adjustment 1
Put the steering in straight ahead position. 3
Measure the portion of tie rod stabilizing fitting
no. 21 exceeding from cylinder support. F18K0NA 4
The exceeding distance of tie rod stabilizing fitting 1. Bottom nut
2. Cylinder support
no. 21 from the cylinder support should be 42 ± 3. Pivot rod
1 mm (1.65 ± .04 in). 4. OPAS cylinder nut wrench
Remove cylinder assembly out of cylinder support.
F18K0OA 4 3 2 1
A 1. Pivot rod
2. Cylinder cap assembly
3. Piston
F18K0ZA
4. Spring
A. 42 ± 1 mm (1.65 ± .04 in)
Unscrew tie rod stabilizing fitting no. 21 from tie
Assembly rod no. 23.
Unscrew 4 socket screws no. 22.
Torque tie rod retaining screw no. 10 to 4.5 N•m
(40 lbf•in).
SMR2002-091_13_02A.FM 13-02-9
– Socket screws no. 22 should be turned 2-3

turns by hand before tightening with tool.
– Replace the cylinder seal ring whenever servicing.
1 1 TIE ROD
Disassembly
Removal procedure for RH and LH tie rod is the
same.
F18K0PA as mentioned above.
1. Socket screw Remove OPAS “U” lever screw no. 2, flat washer
no. 3, bushing no. 4 and venturi bushing no. 5
Remove oetiker clamp no. 25 to remove water
from nozzle.
hose no. 26 from the cylinder support no. 12.
Remove jet pump (refer PROPULSION SYSTEM).
Remove screw no. 6 and washers no. 7 to remove
“U” lever no. 1 from tie rod connecting levers
no. 8.
4
3
F18K0QA 3 1 2
1. Oetiker clamp
2. Water hose
3. Cylinder support
F18K0RA 2 1
Assembly 1. “U” lever screw
2. Screw
Assembly is the reverse process of disassembly, 3. Tie rod connecting lever
make sure of the following when doing assembly: 4. Tie rod
– Always discard old threaded coverrod no. 14 Pull tie rod out from jet pump side.
and replace with new one. Unscrew lever from the tie rod.
Assembly
Torque screw no. 6 to 7 N•m (62 lbf•in).
F18K0YA 1 Torque OPAS “U” lever screw no. 2 to 20 N•m
(177 lbf•in).
1. Replace threaded cover
– Check pivot rod no. 13 for cracks or scratches.
Replace pivot road, if necessary.
13-02-10 SMR2002-091_13_02A.FM
SEALED TUBE Assembly

Disassembly
Apply silicone grease on the screws before installing.
Removal procedure for RH and LH sealed tube
no. 27 is same.
Remove side van, cylinder housing assembly and FILTER
OPAS “U” lever as mentioned above.
Remove jet pump (refer PROPULSION SYSTEM). For removal and installation procedure refer to
PROPULSION SYSTEM.
Remove Phillips screws no. 28 and remove rod
grommet no. 29. OPAS filter is part of plastic elbow no. 30. Check
for cleanness. Replace or clean it as necessary.
VALVE
Disassembly
Remove OPAS “U” lever screw no. 2, flat washer
1 no. 3, bushing no. 4 and venturi bushing no. 5
from nozzle.
Remove jet pump, filter and formed hose no. 32
(refer PROPULSION SYSTEM).
Remove gear clamps no. 35 to remove water hos-
es no. 26 from valve.
F18K0SA 2
1. Phillips screws
2. Rod grommet
Pull sealed tube out with tie rod from inside of

bilge towards jet pump side.
2
F18K0UA 3
1. Gear clamps
2. Valve
3. Water hoses
F18K0TA 1 2
1. Sealed tube
2. Tie rod
SMR2002-091_13_02A.FM 13-02-11
Unscrew bottom nut of valve no. 33 using OPAS WATER HOSE

cylinder nut wrench (P/N 529 035 840).
Disassembly
Removal procedure for RH and LH water hose is
the same.
as mentioned above.
Remove gear clamps no. 35 to remove water
hose no. 26 from valve.
Pull out the water hose no. 26 from exterior.
Assembly
F18K0VA 1 2 make sure of the following when doing assembly:
1. OPAS cylinder nut wrench
– Water hose must be installed from the out side
2. Valve to the inside of hull by turning it, oriented to-
wards valve.
Remove 2 Phillips screws no. 34 from valve collar.
1 (15 lbf•in).
CROSS SUPPORT PLATE

Disassembly
For LH Side Cross Support Plate
Remove gooseneck pipe, exhaust pipe and LH
muffler (refer to EXHAUST SYSTEM).
For RH Side Cross Support Plate
Remove RH muffler (refer to EXHAUST SYSTEM).
For RH and LH Cross Support Plates
F18K0WA
1. Phillips screw as mentioned above.
Remove valve downwards from pump tunnel. Unscrew the screw no. 24.
Assembly
– Check for cracks on formed hose no. 32, 1
change if necessary.
– Make sure that valve must be installed in the
right position.
(15 lbf•in). F18K0XA
1. Remove screw
13-02-12 SMR2002-091_13_02A.FM
Remove cross support plate no. 36 from the inside

of bilge.
Assembly
– Check for cracks and deterioration of screw
threads on cross support plate, change if nec-
essary.
– Apply silicone sealant on cross support plate
when servicing or changing.
1 1
F18K10A
1. Apply silicone sealant
Torque screw no. 24 to 1.2N•m (10 lbf•in).
SMR2002-091_13_02A.FM 13-02-13
ALIGNMENT 0
Position handlebar in straight ahead position by All Models
measuring each side the distance from handlebar Open storage compartment cover and remove bas-
grip end to floorboard. ket (if so equipped).
Loosen 2 bolts retaining block at cable support.
Turn adjustment nut as required.
F01K07A
TYPICAL
1. Measuring handlebar grip end/floorboard distance
1
Check jet pump nozzle position by placing a
straight edge on nozzle outer end. Measure the 3
distance on each side of the straight edge. It must 2
be equalled. F01K18A
ALL MODELS
1. Retaining block
2. Adjustment nut
3. Loosen bolts
All Models
After adjustment, torque retaining block bolts to
6 N•m (53 Ibf•in).
CAUTION: Verify when the handlebar is turned
completely to the left or right side, that there is
no interference with venturi or VTS ring.
1
F01J5ZA
TYPICAL
1. Measure the distance on each side of the straight edge
If necessary, steering alignment adjustment should

be performed at steering cable support.
SMR2002-091_13_03A.FM 13-03-1
TABLE OF CONTENTS 0
ADJUSTMENT AND REPAIR ................................................................................................ 14-02-1
GLOVE BOX ....................................................................................................................... 14-02-5
FRONT SEAT ADJUSTMENT............................................................................................ 14-02-5
STORAGE COMPARTMENT INNER SHELL ..................................................................... 14-02-5
STORAGE COVER SHOCK ................................................................................................ 14-02-8
STORAGE COMPARTMENT COVER ADJUSTMENT ...................................................... 14-02-9
MIRROR.............................................................................................................................. 14-02-10
INFO CENTER (LCD GAUGES) ......................................................................................... 14-02-10
DEFLECTOR AND/OR UPPER GRILL ................................................................................ 14-02-10
FINITION PLATE................................................................................................................. 14-02-11
INLET GRATE ..................................................................................................................... 14-02-11
RIDING PLATE.................................................................................................................... 14-02-11
JET PUMP SUPPORT ........................................................................................................ 14-02-12
DRAIN PLUG INSTALLATION ........................................................................................... 14-02-13
SEAT COVER REPLACEMENT .......................................................................................... 14-02-13
BUMPER REPLACEMENT ................................................................................................. 14-02-14
SPONSON REPLACEMENT .............................................................................................. 14-02-14
DECALS REPLACEMENT .................................................................................................. 14-02-15
HULL AND BODY REPAIR ................................................................................................. 14-02-15
TOOLS AND MATERIALS LIST ......................................................................................... 14-02-18
SMR2002-095_14-01ATOC.FM 14-01-1
ADJUSTMENT AND REPAIR 0

GTX DI and GTX 4-TEC Models (seats)
Loctite
414
Loctite
414
Loctite
414
Loctite
414
Loctite
414
F18L1HS
SMR2002-092_14_02A.FM 14-02-1
GTX DI and GTX 4-TEC Models (Front storage compartment)
Body
Synthetic
Grease
4-TEC Limited Only
Loctite
243
3 Nm
(26 lbfin)
5 Nm
Loctite 243
Loctite
243
F18L1IS
14-02-2 SMR2002-092_14_02A.FM
GTX 4-TEC Model and GTX DI Model (Body-Front View)
GTX 4-TEC
Only
Loctite
29647
7
9
10 12
7 Nm
(62 lbfin)
8
11
Loctite
29647
Body
GTX DI Only
F18L1JS
SMR2002-092_14_02A.FM 14-02-3
GTX 4-TEC Model and GTX DI Model (Body-Rear View)
2.5 Nm
(22 lbfin)
Loctite 29647
6
GTX 4-TEC
Limited Only
GTX 4-TEC
or
GTX DI
Loctite
29647
15 7.5 Nm
(13 lbtin)
2 Loctite
5900
3 Loctite 29647
1 10 Nm
1 (88 lbfin)
Loctite
243
4 8 Nm
F18L1KS
(70 lbfin)
14-02-4 SMR2002-092_14_02A.FM
GLOVE BOX STORAGE COMPARTMENT

GTX 4-TEC and GTX DI INNER SHELL
Lift the glove box top cover and pull the glove box GTX DI and GTX 4-TEC
locking device.
Pull the glove box out of body.
To remove inner shell, proceed as follows:
FRONT SEAT ADJUSTMENT CAUTION: Failure to follow this order may lead
to damaging inner plastic studs.
Seat Retainer – Open storage cover.
NOTE: Apply Loctite 243 on threads of lock pin – Remove access panel.
pin is removed then reinstalled. The threads on – Disconnect multi-function connector.
new lock pin are coated with a self-locking 2
product, do not apply Loctite 243 on threads.
A
2
F07L08A
F18L1MA 1
GTX SERIES — FRONT SEAT 1. Access panel
1. Lock pin 2. multi-function connector
2. Adjustment nut (Loctite 243). Torque to 6 N•m (53 lbf•in)
A. 33 ± 1 mm (1.30 ± 3/64 in) – Unlock shock rod from circlip and remove washer.
1
3
2 A 1 2
F18L1NA
1. Shock rod
2. Circlip
3. Washer
F06L03A
GTX SERIES — REAR SEAT

1. Lock pin
A. 33.5 ± 1 mm (1-5/16 ± 3/64 in)
SMR2002-092_14_02A.FM 14-02-5
– Remove one long retaining screw (front). – Use a rubber hammer to remove the inner skin
– Remove two short retaining screws locate in from the cover. If the inner skin is too stiff, install
the back lower side and hold cover firmly. a piece of 2x4 against the inner skin and hit it with
the rubber hammer.
1
3
2
1
F18L1QA
1. Storage cover
2. Inner skin
3. Rubber hammer
F18L1OA 2
– Remove connector harness from the inner skin
1. One long retaining screw (front)
2. Short retaining screw (one on each side in the back) by cutting tie-raps.
– Remove storage cover. 1 3
– Remove seven inner skin short screws (flanged
screws).
– Remove two long inner skin screws (hex screws).
3
3
3
2 3
1 F18L1RA 3 2
F18L1PA 1. Inner skin
2. Storage cover
1. Storage cover 3. Connector harness
2. Inner skin
3. Inner skin short screws (x7)
4. Inner skin long screws (x2)
14-02-6 SMR2002-092_14_02A.FM
– Remove compass by removing dart (2).

– Remove temperature sensor from grommet.
1 2
F18L1UA 1
2. Grommet
F18L1SA 3 Install new inner skin in the reverse process.

1. Inner skin For installation, proceed as follows:
3. Compass – Install the compass and secure it with the two
darts.
– Install the temperature sensor in grommet.
– Install the tie-raps around wire harnesses.
– Align inner skin with storage cover and make
sure that the lateral locking hooks in the inner
skin get engaged in the storage cover locking
bracket. If the two lateral locking hooks get
properly aligned and engaged the storage cover
back locking hook will be engaged properly in
the inner skin back locking bracket.
1
F18L1TA 1 2 1
1. Dart (x2)
2. Compass
1
F18L1PB
1. Inner skin lateral locking hook

2. Inner skin back locking bracket
SMR2002-092_14_02A.FM 14-02-7
1 STORAGE COVER SHOCK

To remove storage cover shock proceed as follows:
 WARNING
2
Make sure to have a 2x4 piece of wood around
the work bench to support the storage cover
while changing the cover shock.
– Unlock shock rod from circlip and remove washer.
F18L1VA 3
1. Storage cover lateral locking bracket
2. Inner skin lateral locking hook
1 2
1
F18L1NA
1. Shock rod
2. Circlip
3. Washer
2
– Release the shock from top linkage bracket and
bottom support bracket by inserting a flat screw-
driver in the shock top and bottom locking devices.
F18L1WA
1. Storage cover back locking hook

2. Inner skin back locking bracket
– Secure the inner skin in the storage cover by 1

using the rubber hammer.
– Fasten the seven inner skin short screws and
the two inner skin long screws.
F18L1YA 2
1. Top linkage bracket
2. Shock top locking device
14-02-8 SMR2002-092_14_02A.FM
STORAGE COMPARTMENT
COVER ADJUSTMENT
NOTE: Apply Loctite 243 on threads of lock pin
new lock pin are coated with a self-locking
product, do not apply Loctite 243 on threads.
Adjust lock pin no. 3 as per following specifica-
tions:
F18L1ZA 2 1
1. Bottom support bracket
2. Shock bottom locking device A
2
3
1
F16L0UA 3
FLOATING TYPE
1. Lock pin (apply Loctite 243)
2. Rubber washer
3. Lock nut. Torque to 5 N•m (44 lbf•in)
A. 39.2 ± 1 mm (1-35/64 ± 3/64 in)
2 NOTE: Floating type lock pin is used for these mod-

els. 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.
F18L20A
1. Shock absorber
2. Flat screwdriver
3. Shock top locking device
SMR2002-092_14_02A.FM 14-02-9
MIRROR DEFLECTOR AND/OR UPPER

GTX 4-TEC and GTX DI GRILL
Removal and Installation Removal and Installation
To remove mirror proceed as follows: To remove the deflector and/or the upper grill pro-
– Remove storage compartment inner shell from ceed as follows:
storage cover as described earlier in this section. – Remove storage from storage cover compart-
– Remove two hexagonal screws and flat washers. ment inner shell as described earlier in this sec-
– Remove defective mirror with a knive blade. tion to get access.
– Remove the defective deflector and/or the up-
per grill from plastic retaining clip. Use two
screwdrivers to release the deflector or the grill.
2 2
1 2
F18L21A
1. Mirror
2. Knive blade
– Place the mirror frame in hot water to “soften”

the material to allow mirror installation in its frame.
– Reinstall storage compartment inner shell.
INFO CENTER (LCD GAUGES)

F18L22A 1
GTX DI 1. Inner skin
2. Deflector retaining clips
Info gauges can be pulled directly out from the
storage cover.
GTX 4-TEC

To remove the Info center (Speedometer and LCD
Info gauge) proceed as follows:
– Remove storage compartment inner shell from
storage as described earlier in this section to
get access.
– Push Info Center (LCD Gauges) from the stor-
age cover. If the Info center does not come out
easily use liquid soap.
– Refer to ELECTRICAL section to unplug gauges
from harnesses. F18L23A
– Reinstall new Info center. RELEASE DEFLECTOR

– Reinstall storage compartment inner shell.
14-02-10 SMR2002-092_14_02A.FM
FINITION PLATE INLET GRATE

Removal and Installation Removal and Installation
For GTX 4-TEC and GTX DI Loosen screws and remove inlet grate.
Removal procedure for RH finition with grill and LH NOTE: An impact screwdriver should be used to
finition with grill is same. loosen tight screws.
Remove two darts holding the grill with body. When reinstalling inlet grate, apply Loctite 271 on
Make a hole in the luggage compartment as shown threads.
in the illustration below to get access of finition Follow this sequence referring to the illustration:
plate screw. Hand tighten screw numbers ➀, ➁, ➂ then ➃.
Torque screw numbers ➀, ➁ and ➂ to 11 N•m
(97 lbf•in).
Ø 25 mm
(1 in) Torque screw number ➃ to 26 N•m (19 lbf•ft).
55 mm
(2.2 in) 1
155 mm
(6.1 in)
4 2
F18L29A
3
Remove the screw and remove finition plate.
After installing finition plate, plug (P/N 291 000 279) F18L24A
the finition plate screw hole.

RIDING PLATE
Removal
All Models
Remove inlet grate.
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.
F18L2AA 1 Using a low height hydraulic bottle jack and 2 steel
1. Plug (P/N 291 000 279) plates, pry out riding plate.
For GTX 4-TEC Limited Edition
Removal procedure for RH finition, deflector with
grill and LH finition, deflector with grill is same.
Finition plate is mounted on deflector.
Remove three darts holding deflector and grill.
SMR2002-092_14_02A.FM 14-02-11
6 4
8 2
7 1
F18L25A 1 2
1. Hydraulic bottle jack
2. Riding plate F18L27A 5 3
Cleaning GTX DI MODEL
– Scrape off all excess of sealant from riding plate NOTE: Apply Loctite RTV silicone sealant (P/N 293
and hull. 800 066) as indicated by the shaded area.
– Clean hull surface with acetone based solvent to
eliminate grease, dust and any residue of sealant. JET PUMP SUPPORT
Installation Removal
All Models – Remove jet pump. Refer to JET PUMP.
Apply Loctite RTV silicone sealant (P/N 293 800 066) – Remove inlet grate and riding plate.
as indicated by the shaded areas in the next illustra- – Remove ball joint, boot, nut, half rings and O-rings
tions. Follow also the torquing sequence as shown from steering cable.
in the same illustrations.
6 4
8 2
F05K02A 1
TYPICAL
1. Unscrew nut
7 1
– Remove ball joint, boot, nut, half rings and O-rings
from reverse cable.
F18L26A 5 3
GTX 4-TEC MODEL
14-02-12 SMR2002-092_14_02A.FM
– Disconnect water supply hose, water return

hose and bailer hoses.
– Remove nuts, lock washers and flat washers
3
retaining jet pump support.
2 1
F00L2RA
1. Drain plug
2. Silicone sealant (P/N 293 800 086) around the middle hole and in
the screw holes
3. Torque screws to 2.2 N•m (19 lbf•in)
F07L0AA 1 SEAT COVER REPLACEMENT

TYPICAL Install staples with an electric tacker such as Arrow
1. Remove nuts tacker no. ETN-50 or with a manual tacker such as
– Using a heat gun, heat jet pump support until it Arrow tacker no. T-50.
is possible to pull it. NOTE: For an easier installation, it’s highly recom-
NOTE: Shims may have been installed between mended to use an electric tacker.
support and body. Do not remove these shims, Ensure that the seat rest firmly against a hard sur-
otherwise jet pump alignment will be altered. face such as a piece of wood. This is done to get
the staples completely pushed in place.
Installation
Apply Loctite RTV silicone sealant (P/N 293 800 066)
as indicated by the shaded areas in the next
illustrations. Follow also the torquing sequence as
shown in the same illustrations.
1 2
3
F18L28A 4
GTX DI AND GTX 4-TEC MODELS
1
DRAIN PLUG INSTALLATION F01L3YA 2
Refer to the following illustration to install drain plug TYPICAL
no. 15. 1. Piece of wood
2. ETN-50 (electric) or T-50 (manual)
SMR2002-092_14_02A.FM 14-02-13
After cover installation cut all around the excess

of material.
BUMPER REPLACEMENT
Remove trim no. 1 from side bumper rail no. 2.
Remove screws no. 4 to remove side bumper rail
no. 2.
Mark hole positions on body straight and bow sec-
tions.
1 2
F18L2BA 2 1
1. Sponson
2. Sponson cover
Slide sponson cover towards front to about 15 mm

F18L01A 4 3 and pull it out from sponson.
TYPICAL Unscrew nut no. 10 and remove sponson no. 8.
1. Front bumper
2. Corner bumper 2
3. Straight section
4. Bow section
Slide bumper rail no. 2 under front bumper no. 6.

Using a 4.80 mm (3/16 in) drill bit, drill first hole
through bumper rail no. 2 at front of bow section.
CAUTION: When drilling, be careful not to
damage bumper rail and/or hull.
Position bumper rail no. 2 properly onto body and
cut excess length if necessary.
F18L2CA 1
Slide bumper rail no. 2 in corner bumper no. 3.
1. Sponson
Install trim no. 1 using soapy water. 2. Nuts
Repeat procedure for the other side. Clean any residues of sealant adhesive on hull.
On installation of sponson, apply silicone sealant
SPONSON REPLACEMENT (P/N 293 800 086) around sponson studs.
Removal and installation procedure for RH and LH Apply Loctite 29647 on sponson studs.
sponson is same. Install sponsons no. 8 on hull.
Remove screws no. 11. Tighten nuts no. 10 to 7 N•m (62 lbf•in).
Pryout sponson cover from backend with screw- Clean hull and sponsons of any sealant adhesive
driver. surplus.
 WARNING
must be strictly followed.
14-02-14 SMR2002-092_14_02A.FM
DECALS REPLACEMENT For better adhesion a dry application is recom-

mended, however, to ease decal installation a mild
Removal solution of soapy water can be sprayed over sur-
face where decal will be installed.
Using a heat gun warm up one end of decal for a
few seconds until decal can roll off when rubbing Remove back protective film from decal and align
with your finger. decal with marks. When well aligned squeegee
decal beginning at center and working outward us-
Pull decal slowly and when necessary apply more ing firm, short, overlapping strokes.
heat to ease removal on the area that has to be
peeled off. Remove front protective film once decal has ad-
hered to hull.
If decal tears while pulling off, it has to be heated
for a few seconds longer. If decal tends to stretch INSTALLATION ON PLASTIC
while pulling off, stop heating and wait a few sec- (storage cover)
onds to let it cool, then peel it off. Clean surface with isopropyl alcohol.
Using a pencil and the decal as a template, mark
Installation the area where decal will be located.
There are 2 types of decals used on watercraft. One Apply an activator (P/N 293 530 036) to prepare the
has a protective film on back side and the other has surface using a clean cloth. After a few seconds,
a protective film on both sides. They are used on 3 when the activator evaporates, the surface is ready.
types of materials; plastic, gelcoat and metal.
CAUTION: Do not use soapy water to locate de-
DECALS HAVING A PROTECTIVE FILM ON cal on plastic parts.
BACK SIDE ONLY
Remove back protective film from decal and care-
These decals usually contain written information fully align decal with marks. When well aligned
(ex.: warning) and are used on gelcoat or metal. squeegee decal beginning at center and working
Clean surface with a good solvent such as ACRYLI- outward using firm, short, overlapping strokes.
CLEAN DX 330 from PPG or equivalent (refer to Remove front protective film once decal has ad-
manufacturer instructions). hered.
Using a pencil and the decal as a template, mark
the area where decal will be located. HULL AND BODY REPAIR
Remove half of the decal back protective film and
align decal with marks. Start sticking it from center General
and remove the other half of the film to stick it Gelcoat is the smooth and durable cosmetic finish
completely. Carefully squeegee decal beginning at which coats the fiberglass hull and body of a Sea-
center and working outward using, firm, short, Doo watercraft. It also provides a protective barri-
overlapping strokes. er against water and sun. It consists of a mixture
DECALS HAVING A PROTECTIVE FILM ON of resin, pigment (coloring), fillers, monomers and
BOTH SIDES catalyst which is sprayed into the mold.
These decals usually contain graphics and are used The body and hull of the Sea-Doo are constructed
on gelcoat or plastic. of chopped fiberglass, saturated with resin. It is
sprayed on the layer of gelcoat along with pieces
INSTALLATION ON GELCOAT of fiberglass mat, cloth and woven rowing which
Clean surface with a good solvent such as ACRYLI- are added at required areas. This type of construc-
CLEAN DX 330 from PPG or equivalent (refer to tion is very accommodating for high quality re-
manufacturer instructions). pairs. With patience, the proper techniques and
For best result apply an activator (P/N 293 530 materials, a damaged area can be restored to an
036) to prepare the surface using a clean cloth. original finish.
After a few seconds, when the activator evapo-
rates, the surface is ready.
Using a pencil and the decal as a template mark
SMR2002-092_14_02A.FM 14-02-15
NOTE: Fiberglass repair kit is available through au- SANDING

tomotive or marine suppliers. Gelcoat repair kits Begin block sanding the patch with 320-grit sand-
are available directly to GELCOTE INTERNATION- paper until you come close to the original surface.
AL LTD. Remove dust with a water soaked cloth and con-
tinue sanding with a 400-grit wet paper. Finish wet
 WARNING sanding with a 600-grit to remove deeper scratch-
Protect skin, wear gloves when in contact with es. If needed you can wet sand with finer grit pa-
resin, hardeners and gelcoat. A barrier skin per such as 1000-grit.
cream may also be used. Do not expose area
BUFFING AND WAXING
to open flame or lit cigarette. Some of the ma-
terials are flammable. Protect eyes, wear safety Buff the surface using a heavy duty polisher with
glasses when grinding, sanding or spraying. a buffing pad. Make sure the pad is free of dirt or
Use a dust mask when sanding or grinding. you may damage the gelcoat. Carefully begin buff-
When spraying wear a respirator or paint ing with a white medium compound. Finish off us-
mask. Always read warning labels on products. ing a fine compound. While buffing, pay close at-
Air Bubbles Blisters
Possible cause: Possible causes:
– Air pocket trapped between layers of laminate – Insert catalyst.
and gelcoat.
– Improper catalyst/gelcoat ratio.
PREPARATION OF SURFACE A blister is a visible bump on the watercraft surface
Remove all of the damaged gelcoat surrounding that may not necessarily come right through the
the air bubble with a putty knife or preferably a gelcoat layer. In the case of only a few blisters, follow
carbide grinding tip. Make sure all loose and weak the same repair procedure as for air bubbles. If they
areas are completely removed. Sand a small area are numerous and in close concentration, spray liquid
of the gelcoat surface with 220-grit sandpaper. If gelcoat to achieve proper repair. This procedure is
needed, sand the cavity itself. These areas must covered in MINOR GELCOAT FRACTURES.
have a rough surface to allow the gelcoat putty to
bond properly. Minor Gelcoat Fractures
FILLING THE CAVITY Possible causes:
The prepared surface must be cleaned with ace- – Flexing of fiberglass laminate.
tone on a cloth. Use a gelcoat repair kit. Follow the – Gelcoat thickness.
mixing instructions in the kit when preparing the
gelcoat putty. – Direct result of impact.
Carefully mix the required amount while making In case of fractures which have not penetrated
sure there are no air bubbles in the mixture. With past the gelcoat layer, the repair concerns the
a putty knife, fill the repair area and cover with gelcoat only. If flex cracking or impact are evident,
plastic film. Curing time may depend on tempera- then additional reinforcement may be necessary.
ture, amount of putty and percentage of catalyst. This subject will be covered in COMPOUND
After 2 hours, press lightly on the surface with fin- FRACTURES.
gers to test the hardness. When the area becomes PREPARING THE SURFACES
hard, remove the plastic film.
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.
14-02-16 SMR2002-092_14_02A.FM
Numerous Fractures Compound Fractures

Using a grinder with a 24-grit disk, remove the Possible causes:
gelcoat. Sand the area edge with 220-grit sand-
– Thickness of fiberglass laminate.
paper.
– Direct result of impact.
FILLING THE REPAIR AREA
Compound fractures are those that have gone
Small Fractures past the gelcoated surface and in through the lay-
Refer to the same procedure as in the AIR BUB- ers of fiberglass laminate. Two types of repairs
BLES. have to be performed. The first is to restore the
structural integrity of the damaged area. Fracture
Numerous Fractures Over Large Surface: types can vary from a simple crack to a large hole.
Prepare the area for spray application of liquid Usually, fiberglass reinforcement becomes neces-
gelcoat. Wipe down the surface with acetone. sary, especially if the fracture can be attributed to
Mask the area off to protect the watercraft from weakness. The final part of the repair is the
overspray. gelcoating, which cannot be done until the interior
Mix the needed quantity of gelcoat and catalyst and exterior laminate surfaces have been repaired.
according to suppliers recommendations. The Outside
gelcoat can be thinned with acetone up to 10%. If
Remove the damaged gelcoat and fiberglass with
it needs more consistency you can add cabosil.
a 24-grit disk using a power sander. Grind outward
Make sure that the air supply is free of oil, dirt and at least 2 inches from the fracture to allow the
water. patch to bond to strong material. Cut enough piec-
Test spray the gelcoat mixture on paper to verify es of fiberglass mat necessary to build up the area.
its consistency and pattern. You may have to apply The pieces should be cut so they overlap each oth-
5 or 6 coats to cover the area properly. Overlap er by at least a half inch. For a smoother finish, the
each coat further than the last, leaving at least 30 last layer should be fiberglass cloth. If the fracture
seconds between passes. Avoid trying to coat the is small enough all you may have to do is fill the
surface with only a few heavy coats, this will not area with an epoxy filler.
allow the gelcoat to dry properly. Inside
Apply a coat of polyvinyl alcohol to seal off the air For the interior repair, you can grind more. This will
and protect the gelcoat surface from dust. PVA allow for more fiberglass material which will
speeds up the curing process because gelcoat will strengthen the area. If the fracture opening is too
not cure properly when exposed to air. large after surface preparation, you may need a
SANDING backing support to cover the opening. Cut alternat-
ing pieces of fiberglass mat and cloth in overlap-
Wash the polyvinyl alcohol off with water. De-
ping sizes.
pending on the size of the area repaired, you can
either block sand as per previous procedure or you PATCHING THE REPAIR AREA
may use an air sander. Sand the surface down with
Outside
progressively finer grits of sandpaper until the de-
sired finish is achieved. The outside should be done first. Wipe clean the
area with acetone on a cloth, then mask off area.
BUFFING AND WAXING For a small crack use an epoxy filler in the same
Buff the surface using a heavy duty polisher with way you would use gelcoat repair putty. When lay-
a buffing pad. Make sure the pad is free of dirt or ing up a larger area you will use mat, cloth and
you may damage the gelcoat. Carefully begin buff- fiberglass resin and hardener. Use a clean contain-
ing with a white medium compound. Finish off user to mix the resin, mix only what you will need.
ing a fine compound. While buffing, pay close at- Follow the recommended catalyst ratio.
SMR2002-092_14_02A.FM 14-02-17
Using a clean paintbrush, brush the mixed resin on TOOLS AND MATERIALS LIST
the surface. Place the smallest piece of mat over
the fracture and then wet out the mat. Follow with Tools
the remaining pieces of mat and final layer of
cloth. While wetting the pieces make sure you – safety glasses
work the air bubbles out and saturate all the pieces – air mask
evenly. Try to work quickly, you may only have 15 – white cloths
or 20 minutes. You may clean the brush with ace-
tone. – sanding block
Wait until the repair has hardened before moving – putty knife
on to the interior repair. If the size of the opening – plastic film
is too large for the pieces to maintain the proper – stirring stick
shape, you will have to use a backing support. It is
a shaped piece of cardboard that fits flush to the – cover sheets (for Sea-Doo)
interior surface and has a plastic layer on the repair – scissors
side. It is held in place by tape or a support. – buffing pad
Inside – heavy-duty polisher
Wipe down the area with acetone on a cloth. Ap- – power sander
ply the same procedure as for outside repair when
– paint brush
laminating the alternating pieces of fiberglass ma-
terial. If a backing support was used, remove it – plastic container (mixing)
before starting the repair. After the area has hard- – spray gun
ened, remove sharp edges of material from sur-
– plastic squeegee.
face. If required paint the surface.
SANDING Materials
Outside – fiberglass mat
This surface will have to be prepared for applica- – fiberglass cloth
tion of gelcoat. The size of the area will determine – polyester resin
the gelcoating procedure to be used. Refer to the
repair procedure for MINOR GELCOAT FRAC- – cardboard
TURES. – masking tape
BUFFING AND WAXING – sandpaper (100-grit, 220-grit, 320-grit, 400-grit,
600-grit, 1000-grit)
Refer to the buffing and waxing for MINOR
GELCOAT FRACTURES. – 24-grit sanding disks
– gelcoat putty
– liquid gelcoat
– acetone
– cabosil
– epoxy filler
– medium compound (white)
– fine compound (white)
– wax.
14-02-18 SMR2002-092_14_02A.FM
Subsection 01 (GTX DI MODELS)
GTX DI MODELS 0
ENGINE GTX DI
Engine type BOMBARDIER-ROTAX 947 DI, 2-stroke
Exhaust system
Water injection fitting (cone) Not applicable
Water injection fitting (muffler) 3 mm (.118 in)
Exhaust valve RAVE
Oil injection pump Direct driven
Lubrication
Oil injection type BOMBARDIER
Formula XP-S DI (synthetic DI injection oil only)
Stroke 78.20 mm (3.079 in)
Piston ring type and quantity 2 semi-trapez chrome coated steel rings
New 0.55 - 0.7 mm (.022 - .028 in)
Ring end gap
Ring/ New 0.044 - 0.089 mm (.002 - .003 in)
piston groove clearance Wear limit 0.22 mm (.0087 in)
Piston/ New (minimum) 0.12 mm (.0047 in)
cylinder wall clearance Wear limit 0.22 mm (.0087 in)
Crankshaft deflection MAG side: 0.050 mm (.002 in); PTO side: 0.030 mm (.001 in)
Rotary valve timing
Connecting rod/piston pin New 0.001 - 0.014 mm (.00039 - .00055 in)
radial clearance Wear limit 0.017 mm (.00067 in)
Type Piston
SMR2002-093_15_01A.FM 15-01-1
ELECTRICAL GTX DI
Ignition system type Digital Inductive
Spark plug
Gap 1.1 mm (.04 in)
5.39 ± 0.30 (.212 ± .011) (direct)
measured through direct injector hole
mm (in) 7.87 ± 0.30 (.310 ± .011) (indirect)
TDC setting (BTDC)
measured through spark plug hole
Degrees 27 ± 1.5 @ 1450 RPM
Generating coil 190 - 300 Ω
Battery charging coil 0.1 - 1 Ω
Primary 0.45 - 0.55 Ω
Ignition coil
Secondary 6.8 - 10.2 kΩ without high tension leads
Main 30 A
Injection system (INJ) 15 A
Charging system (REG) 25 A
Fuses Information center (ACC) 2A
Fuel pump (FP) 15 A
Battery 25 A
VTS system (VTS) Not applicable
FUEL SYSTEM GTX DI

Fuel injection type Orbital Direct Fuel Injection,
twin throttle body (46 mm (1.81 in))
Fuel pressure 105.2 PSI - 108 PSI
Idle speed (in water/out of water) 1450 ± 50 RPM
Throttle Position Sensor (TPS) 1.6 kΩ - 2.4 kΩ
Crankshaft Position Sensor (CPS) 5 volts
Manifold Air Temperature Sensor (MATS) 2.28 kΩ - 2.74 kΩ
Water Temperature Sensor (WTS) 2.28 kΩ - 2.74 kΩ
Exhaust Gas Temperature Sensor (EGT) 2.28 kΩ - 2.74 kΩ
Manifold Air Pressure Sensor (MAPS) 0 Ω (continuity between terminals 3 and 1)
Knock Sensor (KS) 5 MΩ
RAVE solenoid 24 Ω
Fuel injector 1.7 Ω - 1.9 Ω
Direct injector 1.0 Ω - 1.6 Ω
Fuel
15-01-2 SMR2002-093_15_01A.FM
COOLING GTX DI
Thermostat None
PROPULSION GTX DI
Oil type POLYOLESTER OIL 75W90 GL5
New 0.0 - 0.4 mm (.000 - .016 in)
Impeller/wear ring clearance
DIMENSIONS GTX DI
CAPACITIES GTX DI
Fuel tank reserve (from low level signal) 9.8 L (2.6 U.S. gal)
SMR2002-093_15_01A.FM 15-01-3
MATERIALS GTX DI
Hull Composite
PERFORMANCE GTX DI
Estimated pump power 52.2 kW (70 HP)
Fuel tank without reserve 60 minutes
Cruising time at full throttle Fuel tank reserve 12 minutes
(from low level signal)
15-01-4 SMR2002-093_15_01A.FM
Subsection 02 (GTX 4-TEC MODELS)
GTX 4-TEC MODELS 0

ENGINE GTX 4-TEC
BOMBARDIER-ROTAX 1503 4-TEC, 4-stroke,
Engine type Over Head Camshaft (OHC), liquid cooled
Number of valves 12 valves with hydraulic lifters (no adjustment)
Bore Standard 100 mm (3.9 in)
Stroke 63.4 mm (2.49 in)
Displacement 1493.8 mm (58.81 in)
Compression ratio 10.6 ± 0.4
Maximum HP RPM 7300 ± 100 RPM
Lubrication Dry sump with replaceable oil filter
Oil filter CHAMPION
Exhaust system Type Water cooled, water injected with regulator
Intake valve opening 10° BTDC
Intake valve closing 45° ABDC
Exhaust valve opening 50° BBDC
Exhaust valve closing 5° ATDC
New minimum 5.961 mm (.2347 in)
Intake New maximum 5.975 mm (.2352 in)
Valve stem diameter
Exhaust New maximum 5.960 mm (.2346 in)
Valve guide diameter New maximum 6.018 mm (.2369 in)
New nominal 41.02 mm (1.615 in)
Inner
Wear limit 38.8 mm (1.499 in)
Valve spring free length
New nominal 45.45 mm (1.789 in)
Outer
Wear limit 43 mm (1.693 in)
New nominal 1.1 to 1.3 mm (.043 to .051 in)
Intake
Valve seat contact width
New nominal 1.25 to 1.55 mm (.049 to .061 in)
Exhaust
Rocker arm bore diameter New maximum 20.020 mm (.7881 in)
Rocker arm shaft diameter New maximum 19.993 mm (.7871 in)
Cylinder head screw Service limit 148.5 mm (5.846 in)
1st Rectangular
Piston ring type and quantity 2nd Taper-face
3rd Oil scraper ring
SMR2002-093_15_02A.FM 15-02-1
ENGINE GTX 4-TEC

Rectangular 0.15 mm (.006 in)
Taper-face New minimum 0.15 mm (.006 in)
Oil scraper ring 0.15 mm (.006 in)
Ring end gap Rectangular 0.3 mm (.012 in)
Taper-face New maximum 0.3 mm (.012 in)
All Wear limit 1.5 mm (.06 in)
Rectangular 0.025 mm (.001 in)
Taper-face New minimum 0.015 mm (.0006 in)
Ring/ Rectangular 0.07 mm (.0028 in)
piston groove clearance
Taper-face New maximum 0.06 mm (.0024 in)
All Wear limit 0.15 mm (.006 in)
New (minimum) 0.024 - 0.056 mm (.001 - .0022 in)
Piston/cylinder wall clearance
Front New maximum 24.960 mm (.9827 in)
Camshaft bearing journal
New minimum 39.892 mm (1.5705 in)
PTO and center New maximum 39.905 mm (1.5711 in)
Front New maximum 25.013 mm (.9848 in)
Camshaft bore
PTO and center New maximum 40.016 mm (1.5754 in)
Intake New maximum 31.590 mm (1.2437 in)
Cam lobe
Exhaust New maximum 31.809 mm (1.2523 in)
Crankshaft axial clearance
New maximum 0.22 mm (.0087 in)
Connecting rod big end clearance Wear limit 0.09 mm (.0035 in)
Crankshaft journal diameter New maximum 50.000 mm (1.9685 in)
Crankshaft radial clearance Wear limit 0.007 mm (.0028 in)
Connecting rod big end diameter Service limit 45.080 mm (1.7740 in)
Connecting rod big end clearance Service limit 0.09 mm (.0035 in)
Connecting rod big end axial play New maximum 0.287 mm (.0113 in)
Crankshaft deflection 0.050 mm (.002 in)
15-02-2 SMR2002-093_15_02A.FM
ENGINE GTX 4-TEC

Connecting rod small end diameter New maximum 23.020 mm (.9063 in)
Piston pin diameter New maximum 23.000 mm (.9055 in)
Piston pin bore clearance Wear limit 0.080 mm (.0035 in)
Balance shaft journal diameter New maximum 32.000 mm (1.2598 in)
Balance shaft radial clearance Wear limit 0.07 mm (.0028 in)
Balance shaft axial clearance
New maximum 0.25 mm (.0098 in)
ELECTRICAL GTX 4-TEC

Ignition system type DI (Digital Induction)
Ignition timing Not adjustable
Make and type NGK DCPR8ES
Spark plug
Gap 0.75 mm (.030 in)
Generating coil N.A.
Battery charging coil 0.1 - 1.0 Ω
Primary 0.45 - 0.55 Ω
Ignition coil
Secondary 6.8 - 10.2 kΩ
Engine RPM limiter setting 7650 RPM
Battery 12 V, 30 A•h
TOPS 10 A
Battery fuse 30 A
Cylinder 1, ignition coil and injection 10 A
Electric bilge pump (optional) 3A
Fuse
Starting system, electric fuel pump 10 A
EMS, start/stop circuit 5A
Main 30 A
MPEM 5A
Information center 1A
SMR2002-093_15_02A.FM 15-02-3
FUEL SYSTEM GTX 4-TEC

Rotax EMS (engine management system)
Fuel injection type Multipoint Fuel Injection.
Single throttle body (52 mm (2.05 in))
Fuel pressure 42 PSI - 45 PSI
Idle speed (in water/out of water) 1800 ± 50 RPM
Throttle Position Sensor (TPS) 1.6 kΩ - 2.4 kΩ
Crankshaft Position Sensor (CPS) 5 volts
Camshaft Position Sensor (CAPS) 12 volts
Camshaft Position Sensor (CAPS) 1.2 kΩ
Manifold Air Temperature Sensor (MATS) 2.28 kΩ - 2.74 kΩ
Coolant Temperature Sensor (CTS) 2.28 kΩ - 2.74 kΩ
Exhaust Gas Temperature Sensor (EGT) 2.28 kΩ - 2.74 kΩ
Manifold Air Pressure Sensor (MAPS) 0 Ω (continuity between terminals 3 and 1)
Knock Sensor (KS) 5 MΩ
Oil Pressure Switch (OPS) 0 Ω, if oil pressure is greater than 26 - 32 PSI
Oil Separator Pressure Switch (OSPS) 0 Ω, if blow-by pressure is less than 6 PSI
TOPS valve 1.27 Ω - 2.47 Ω
Fuel injector 11.4 Ω - 12.6 Ω
Type Super unleaded gasoline
Fuel
COOLING GTX 4-TEC

Type Liquid cooled. Closed loop for engine - open loop
for exhaust system
Ethylene-glycol 50%/50% antifreeze/water.
Coolant Coolant containing corrosion inhibitors for internal
combustion aluminum engines
Thermostat 87°C (188°F)
Monitoring beeper setting 110°C (230°F)
15-02-4 SMR2002-093_15_02A.FM
PROPULSION GTX 4-TEC

Jet pump type Axial flow single stage. Greased bearings
Reverse system Yes
O.P.A.S. system Yes
Sea-Doo grease (P/N 293 550 032),
Grease type 10 mL front bearing, 50 mL rear of bearing,
50 mL in pump cap
Impeller outside diameter 155.3 ± 0.3 mm (6.122 ± .0118 in)
New 0.0 - 0.4 mm (.000 - .016 in)
Impeller/wear ring clearance
Impeller material Stainless steel
DIMENSIONS GTX 4-TEC

CAPACITIES GTX 4-TEC

Engine oil 3 L (3.2 U.S. gal) oil change w/filter
4.5 L (1.5 U.S. gal) total
Cooling system (coolant) 5.5 L (4.8 U.S. qrt) total
Fuel tank (including reserve) 60 L (15.3 U.S. gal)
Fuel tank reserve (from low level signal) 15 L (4 U.S. gal)
SMR2002-093_15_02A.FM 15-02-5
MATERIALS GTX 4-TEC

Hull Composite
Steering cover Thermoplastic
Impeller housing/stator/venturi/nozzle Plastic/stainless steel/aluminum/aluminum
Air intake silencer N.A.
Steering padding N.A.
PERFORMANCE GTX 4-TEC

Estimated pump power 57 kW (76.44 HP)
Maximum fuel consumption at wide open throttle 41.1 L/h (10.8 U.S. gal/h)
Fuel tank without reserve 55 minutes
Cruising time at full throttle Fuel tank reserve
(from low level signal) 17 minutes
15-02-6 SMR2002-093_15_02A.FM
WIRING DIAGRAMS 0
WIRE COLOR CODES DEUTSCH CONNECTORS
First color of a wire is the main color. Second color Removal
is the tracer.
To remove Deutsch connectors from engine con-
Example: YELLOW/BLACK (YL-BK) is a YELLOW
nector bracket, remove coolant container, slide a flat
wire with a BLACK tracer.
screwdriver between the connector bracket and the
Deutsch connectors and remove connectors.
WIRE DIGIT CODES
MPEM and Vehicle Electrical System
First number indicates in which connector the
wire is plugged in.
Second number indicates the position of the wire
in the connector.
The letter at the end of the number (if applicable)
indicates a common circuit in the MPEM printed
circuit with another wire bearing the same letter.
Example: 2-18 (g)
The first number indicates that the wire is posi-
tioned in the connector no. 2 of the MPEM. 2 1
F18Z0IA
The second number indicates that the wire is po-

1. Coolant plastic container bracket
sitioned in the terminal no. 18. 2. Coolant plastic container
The letter (g) indicates a common circuit with an-
other wire(s) bearing the same letter (g) in the cir- 2
cuit.
EMS ECU
GTX 4-TEC Models
On the EMS ECU, circuits are identified by a letter
followed by a number.
The letter indicates in which connector the wire is
plugged in.
The number indicates the position of the wire in
the connector.
The connector “A” is connected to the engine wir-
ing harness. F18Z0JA 1
The connector “B” is connected to the watercraft 1. Engine connector bracket
wiring harness. 2. Deutsch connectors
SMR2002-094_16_01A.FM 16-01-1
3 2 2
F18Z0KA 1 F18Z0MA 1 2
1. Engine connector bracket 1. Release button
2. Deutsch connectors 2. Deutsch connectors
3. Flat screwdriver
To disconnect two Deutsch connectors, slide a flat

screwdriver between each other to disengage,
press the release button and disconnect them.
1
F18Z0NA 2 1
1. Deutsch connectors
2. Press release button
All Models
F18Z0LA 2 Deutsch connectors are used to connect wiring
harness to the magneto and to the VCK.
1. Flat screwdriver
2. Deutsch connectors
3 1
3
2
4
F00H1CA
1. Male housing
2. Female housing
3. Secondary lock
4. Sealing cap
16-01-2 SMR2002-094_16_01A.FM
CAUTION: Do not apply dielectric grease on con- – Pry back the retaining tab while gently pulling
tacts inside plug connector. wire back until contact is removed.
To remove wire contacts from housing, proceed
1
as follows:
– Using a long nose pliers, pull out the lock.
V01G0QA 1
FEMALE CONNECTOR HOUSING
1. Retaining tab
To install:
– For insertion of signal contact, make sure the
V01G0OA 1 lock is removed.
FEMALE HOUSING – Insert contact into appropriate circuit cavity and
1. Female lock push as far as it will go.
– Pull back on the contact wire to be sure the re-
tention fingers are holding the contact.
– After all required contacts have been inserted,
the lock must be installed.
1 1
V01G0PA 1
MALE HOUSING
1. Male lock F04H6LA
NOTE: Before extraction, push wire forward to re- 1. Wire identification numbers
lieve pressure on retaining tab.
– Insert a 4.8 mm (.189 in) wide screwdriver blade
SMR2002-094_16_01A.FM 16-01-3
Deutsch 6 pin Connector Electrical Box

 WARNING
Ensure all terminals are properly crimped on
wires and connector housings are properly fas-
tened.
AMP PLUG CONNECTOR

All Models
1 1
These connectors are found on the MPEM.
When servicing electrical system, special care
must be taken when working with AMP Plug Con-
nectors in order to prevent any malfunction of the
system.
F04H6KA
Description
6-PIN CONNECTOR
1. Wires identification numbers 5
PACKARD CONNECTOR 9
Packard connectors are used to connect electrical
harnesses and gauges. 1
7 4
1 3
89
F00H0WB 6
C B A
AMP PLUG CONNECTOR
1. Plug assembly
2. Cover assembly
3. Mating seal
F04H45A 4. Wedge lock
5. Header assembly
VIEW OF A 3-POSITION PACKARD CONNECTOR 6. Seal plug
7. Power wire
1. Identification letters 8. Signal wire
9. Locking tab
To remove terminal from Packard connector hous-
ing, use Snap-on TT600-4 tool.
F01B1JA
16-01-4 SMR2002-094_16_01A.FM
Removal
To remove the plug connector from the header as-
sembly, press both tabs and pull plug.
F00H0NA
Step 1 : Press tabs (both sides)

Step 2 : Pull plug
Installation
Apply a thin coat of DEOXIT contact lubricant (P/N F00H12A 1
293 550 015) to the pins of the header on the
1. Mechanically keyed
MPEM only.
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.
CAUTION: The wedge lock should never be re-
moved from the connector for insertion or re-
moval of the signal wire contacts.
1 2
1
F00H11A
1. Apply a thin coat of DEOXIT contact lubricant
CAUTION: Do not apply lubricant excessively.

Care must be taken so that the lubricant will not
come in contact with the mating seal; the seal
may loose its sealing capacities. Do not apply
lubricant on contacts inside plug connector.
Each plug assembly is mechanically keyed to mate
only with identical mechanical keyed header on
the MPEM.
F00H0OA
1. Screwdriver between wedge lock and connector

2. Locking tab
SMR2002-094_16_01A.FM 16-01-5
Repeat the same steps for the other locking tab

1
retaining the wedge lock.
The wedge lock is now in the open position.
F00H0RA
F00H0PA
1. Pull locking tab (both sides)

1. Wedge lock opened
Before extraction, push wire forward to relieve pres-
While rotating the wire back and forth over a half sure on retaining tab.
turn (1/4 turn in each direction), gently pull the wire
until the contact is removed. Insert a 4.8 mm (.189 in) wide screwdriver blade
F00H0QA
1. Rotate wire back and forth

2. Pull wire
Power Wire Contact

NOTE: The wedge lock must be removed to ex-
tract power contact.
Open the wedge lock.
Pull both locking tabs and remove wedge lock
from plug assembly. F00H0ZA
Pry back the retaining tab while gently pulling wire

back until contact is removed.
16-01-6 SMR2002-094_16_01A.FM
Contact Crimping 1
The size of the wires must be 20 to 16 AWG with
a wire insulation diameter having a minimum di-
mension of 1.7 mm (.067 in) and a maximum di-
mension of 2.78 mm (.106 in).
The wire strip length 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 sur-
face within 25 mm (1 in) from the tip of the con-
tact must be smooth.
All contacts in AMP plug connectors must be
crimped using the crimping tool (P/N 295 100 164).
F00H10A 2
CAUTION: If contacts are not crimped using the
1. Seal plug
proper crimping tool, the wire seal may be dam- 2. Wire seal
aged.
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.
F00B0EA
Insert contact into appropriate circuit cavity and
push as far as it will go.
CRIMPING TOOL (P/N 295 100 164)
Pull back on the contact wire to be sure the reten-
All circuits are sealed by a diaphragm in the rubber tion fingers in the housing are holding the contact
wire seal. When installing wire contacts in plug properly.
connector, the diaphragm is pierced as the contact After all required contacts have been inserted, the
passes through it. wedge lock must be closed to its locked position.
If the diaphragm is pierced and the cavity is not
used, install a seal plug, large end first, into circuit
cavity as far as it will go.
NOTE: It is suggested that all unused circuit cavi-
ties be sealed with a seal plug, even if they are not
pierced.
SMR2002-094_16_01A.FM 16-01-7
IDENTIFICATION OF MAIN FUSE HOLDER JOINT

CONNECTOR PINS CONNECTOR
AMP Connectors of MPEM DI Models
The fuse holder is located in the rear electrical box.
26 25 24
F12H0ZA 1
23 16 1. Main fuse holder joint connector
15 9 NOTE: In the following illustrations, the joint insu-

lator has been removed for clarity purpose only. It
8 1 is not necessary to remove it to separate the joint.
The same procedure is to be used each side of the
joint.
Insert the Deutsch joint connector tool (no. 114010)
F04H6RA
on the wire and push tool toward the joint to re-
lease it. While holding the joint insulator, push the
AMP Connectors of Wiring Harness tool until it bottoms. It is now unlocked. Maintain-
ing the pressure with the tool, pull the wire out.
F12H10A
1. Deutsch joint connector tool (no. 114010)
F04H6GA
2 1
F12H11A
1. Hold the insulator

2. Push the tool until it bottoms
16-01-8 SMR2002-094_16_01A.FM
Crimping and Installation Tools

Required
To install EMS ECU connector terminal pins or ter-
minal wire, three tools are required; EMS ECU
crimping tool, EMS ECU extraction tool and a stan-
F12H12A 1 2 dard flat screwdriver.
1. While holding tool pressure, pull wire until terminal releases
2. Joint connector
For installation, simply push the wire in the con-

nector. You should hear a locking “click”. Try to
pull the wire out to ensure terminal is properly
locked. If not, remove the wire and bend the tabs
inside the joint connector to allow proper locking. 3
Recheck.
2
EMS ECU CONNECTORS
1
4-TEC Models Only
F18Z03A
There are two EMS ECU connectors used on the
4-TEC models and they are connected on the 1. EMS ECU crimping tool
2. EMS ECU connector terminal extraction tool
EMS ECU. The engine harness female connector 3. Standard flat screwdriver
is connected on the module male connector “A”
and the watercraft system control harness female Defective Terminal Removal
connector is connected to the module male con-
Unlock the terminal cover by disengaging the ter-
nector “B”. The engine connector has 41 pins.
minal cover locking device on both side with a flat
screwdriver.
2
2
1
1
F18Z02A
1. EMS ECU
2. A connector (engine harness)
3. B connector (watercraft system harness) F18Z04A
1. Terminal connector cover

2. Terminal cover locking device
SMR2002-094_16_01A.FM 16-01-9
Lift wire harness and note the terminal pinout

number.The EMS ECU connector has 41 termi-
nals. The pins are splited in three groups; 1 to 13,
1 14 to 28 and 29 to 41. Make sure you have located
the proper terminal.
F18Z05A
1. Terminal connector cover

2. Terminal cover locking device 2
Lift the cover by pushing it forward.
F18Z08A
1. Wire harness
2. Terminal pinout numbers
1 Once the defective terminal is identified, unlock

the red terminal locking plate by using the flat
screwdriver and release the locking device at each
end of the connector. Remove the red terminal
locking plate by sliding it outside the connector.
F18Z06A
1. Cover
Cut both tie raps.
2 1
F18Z09A
1. First locking device

2. Red terminal locking plate
F18Z07A
1. Tie raps
16-01-10 SMR2002-094_16_01A.FM
Release the defective terminal from connector

with the extraction tool. Align the extraction tool
pin properly with the terminal cavity and push the
tool downward. That will release the wire with the
terminal.
1 2
2
1 3
F18Z0AA
1. Second locking device

F18Z0DA
1. Terminal cavity
2. Extraction tool
1 3. Extraction tool pin
F18Z0BA
Remove the red terminal locking plate and acquire

the EMS ECU extraction tool.
2
1
F18Z0EA
1. Extraction tool
2. Connector terminal housing
F18Z0CA 1
2. EMS ECU extraction tool
SMR2002-094_16_01A.FM 16-01-11
2
3
1
F18Z0HA
1 1. Crimping tool swivel

2. Crimping tool
3. Wire
F18Z0FA 2
1. Connector terminal housing
CAUTION: Probe on top of terminal only. Do not
2. Defective wire and terminal try to probe inside terminal or to use a paper
clip to probe inside terminal, it can damage the
If the wire is in good condition but the terminal is square-shaped terminal.
rusted or corroded, remove defective terminal and
crimped a new one. If wire and terminal are defec- CAUTION: Do not disconnect the EMS ECU con-
tive, acquire a new genuine wire and new terminal nector needlessly. They are not designed to be
and crimp them together as follow. disconnected/reconnected frequently.
IMPORTANT: Use genuine wires only. Otherwise Lubrication
wires will not fit properly.
Apply a thin coat of DEOXIT contact lubricant (P/N
Terminal and Wire Crimping 293 550 015) to the pins of the header on the EMS
ECU only.
To crimp a new terminal to a good wire, acquire
the EMS ECU crimping tool. Install the new termi-
nal in the crimping tool swivel. Close the swivel in
place. Place the wire on terminal barrel and crimp
the wire firmly.
2 3
1
F18Z0GA Callout
1. New terminal
2. Crimping tool swivel
3. Crimping tool
16-01-12 SMR2002-094_16_01A.FM
GTX DI MODEL
12 VOLTS DISTRIBUTION
MODEL GTX DI 2002
F18Z0P
GTX 4-TEC MODEL
MODEL GTX 4-TEC 2002 TOPS VALVE
12 VOLTS DISTRIBUTION
INFORMATION
CENTER
OPS
(NORMALY OPEN) OSPS
(NORMALY CLOSED)
CPS IDLE BY PASS
VALVE
COMMUNICATION LINK
D.E.S.S. AUXILIARY MODULE
TPS
MAPS
CTS
EMS MATS
ENGINE
CONNECTOR ECU
EGT
COMMUNICATION LINK
TOPS VALVE
COMMUNICATION LINK
F18Z0O

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2002

GTI, GTI LE, GTX, GTX RFI,

National Library of Quebec

All rights reserved. No parts of this manual may be reproduced in any

Loctite® is a trademark of Loctite Corporation

SECTION SUBSECTION PAGE

SAFETY NOTICE .................................................................................................................................. III

01 SERVICE TOOLS 01 - Table of contents ...................................................................... 01-01-1

02 MAINTENANCE 01 - Table of contents ...................................................................... 02-01-1

03 TROUBLESHOOTING 01 - Troubleshooting chart ............................................................... 03-01-1

04 ENGINE 01 - Table of contents ...................................................................... 04-01-1

05 ENGINE 01 - Table of contents ...................................................................... 05-01-1

06 ENGINE 01 - Table of contents ...................................................................... 06-01-1

07 COOLING SYSTEM 01 - Table of contents ...................................................................... 07-01-1

08 FUEL SYSTEM 01 - Table of contents ...................................................................... 08-01-1

09 LUBRICATION 01 - Table of contents ...................................................................... 09-01-1

10 ELECTRICAL 01 - Table of contents ...................................................................... 10-01-1

11 PROPULSION 01 - Table of contents ...................................................................... 11-01-1

12 STEERING SYSTEM 01 - Table of contents ...................................................................... 12-01-1

13 SUSPENSION 01 - Table of contents ...................................................................... 13-01-1

14 HULL/BODY 01 - Table of contents ...................................................................... 14-01-1

15 TECHNICAL DATA 01 - GTI and GTI LE models............................................................. 15-01-1

16 WIRING DIAGRAMS 01 - Wiring diagrams........................................................................ 16-01-1

All Models 787 RFI Engine

*A letter may also be used as a digit.

Bold face number

Page numbering system:

Sub-title with part

Section 06 FUEL SYSTEM

Title indicates main

Sub-sub-title in this All Others Models

Letters are used for

Bold numbers in the

LIST OF ABBREVIATIONS USED GENERAL INFORMATION

When performing service on all 1999 and more re-

LOCTITE APPLICATION Blind Holes

1. Clean threads (stud and hole) with solvent. Adjusting Screw

1. Adjust screw to proper setting.

STRIPPED THREAD REPAIR

Standard Thread Repair NOTE: Avoid grinding.

Mounting in Tandem TIGHTENING TORQUES

N•m FASTENER SIZE (8.8) Lbf•ft

OPTIONAL SERVICE TOOLS ................................................................................................ 01-03-1

SERVICE PRODUCTS ............................................................................................................ 01-04-1

MANDATORY SERVICE TOOLS 0

NOTE: This tool is also used for

Starter drive bearing pusher

Piston circlip installer

B) P/N 529 035 563 F12B0M4 APPLICATION

(21 mm sleeve) APPLICATION

Puller Puller ass’y Adapter

Alignment support plate kit

P/N 296 000 025 APPLICATION

P/N 296 000 027 Oil seal pusher

All models. APPLICATION

Impeller shaft holder

Impeller shaft guide

Jet pump bearing remover F08B024

P/N 295 000 144

OPAS cylinder nut wrench

OPTIONAL SERVICE TOOLS 0

Cylinder aligning tool All models. APPLICATION

11.5 mm (.453 in) Dial indicator (TDC gauge) APPLICATION