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  www.SeaDooManuals.net…
• Page 2
  2000 Shop Manual VOLUME 1 GS/GTI/GTS/GTX/XP GSX RFI/GTX RFI www.SeaDooManuals.net…
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  Legal deposit: National Library of Quebec trimester 2000 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. 2000 Technical Publications Bombardier Inc.
• Page 4
  TABLE OF CONTENTS ‘ PAGE SECTION SUBSECTION SAFETY NOTICE ……………………..WHAT’S NEW ……………………….INTRODUCTION ……………………… SERVICE TOOLS 01 — Table of contents …………..01-01-1 02 — Mandatory service tools…………01-02-1 AND PRODUCTS 03 — Optional service tools…………..01-03-1 04 — Service products …………… 01-04-1 MAINTENANCE 01 — Table of contents …………..
• Page 5
  02 — Direct action suspension …………11-02-1 HULL/BODY 01 — Table of contents …………..12-01-1 02 — Adjustment and repair ………….. 12-02-1 TECHNICAL DATA 01 — GS ………………… 13-01-1 02 — XP ………………… 13-02-1 03 — GTS ………………. 13-03-1 04 — GTI and GTX…………….13-04-1 05 — GTX RFI and GSX RFI ……………

• Page 6: Safety Notice

  SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair some 2000 SEA-DOO watercraft. See model list below. This edition was primarily published to be used by watercraft mechanic technicians who are already familiar with all service procedures relating to Bombardier made watercraft.

• Page 7: Exhaust System

  WHAT’S NEW WHAT’S NEW THIS SECTION INDICATES PROCEDURES THAT WERE MODIFIED OR NEWLY ADDED IN THIS MANUAL. INTRODUCTION • Self-locking fasteners procedure. • Loctite application procedure. • Tightening torques chart. SERVICE TOOLS AND PRODUCTS Added the following new tools: • VCK (Vehicle Communication Kit) for all models •…

• Page 8: Technical Data

  WHAT’S NEW TECHNICAL DATA • Updated specifications for each model. WIRING DIAGRAMS • Updated wiring diagrams for each model. SMR2000_001_00A2.FM www.SeaDooManuals.net…

• Page 9: Hull Identification Number

  2000 watercraft models. It is located on floorboard at the rear of the water- craft. MODEL MODELS NUMBER GS ………… 5644 GS International ……5827 GSX RFI ……….. 5645 GSX RFI International ….. 5654 XP …………. 5651 XP International ……

• Page 10
  INTRODUCTION ENGINE IDENTIFICATION 947 Engine NUMBER (E.I.N.) The Engine Identification Number is located on the upper crankcase on MAGNETO side. 717 Engine The Engine Identification Number is located on the upper side of the magneto housing. 1. Engine Identification Number (E.I.N.) F01D01A TYPICAL ARRANGEMENT OF THIS…
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  INTRODUCTION VIII SMR2000_001_00A2.FM www.SeaDooManuals.net…
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  INTRODUCTION XP Model Only All Others Models SMR2000_001_00A2.FM www.SeaDooManuals.net…

• Page 13: General Information

  INTRODUCTION LIST OF ABBREVIATIONS USED GENERAL INFORMATION IN THIS MANUAL The use of RIGHT and LEFT indications in the text, always refers to driving position (when sitting on DESCRIPTION watercraft). Alternate Current Air Pressure Sensor Air Temperature Sensor Capacitor Discharge Ignition Crankshaft Position Sensor Cooling System Indicator Direct Current…

• Page 14
  INTRODUCTION ILLUSTRATIONS AND THREADLOCKER PROCEDURES Uncovered Holes (bolts and nuts) The illustrations show the typical construction of the different assemblies and, in all cases, may not reproduce the full detail or exact shape of the parts shown, however, they represent parts which have the same or a similar function.
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  INTRODUCTION 1. Clean threads (bolt and hole) with solvent. Preassembled Parts 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.
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  INTRODUCTION NOTE: If it is difficult to readjust, heat screw with GASKET COMPOUND a soldering iron (232°C (450°F)). All Parts STRIPPED THREAD REPAIR Stripped Threads 1. Release agent A00A3SA 2. Stripped threads 3. Form-A-Thread 1. Proper strength Loctite 4. Tape 2.
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  INTRODUCTION MOUNTING ON SHAFT CASE-IN COMPONENTS Mounting with a Press Metallic Gaskets A00A3UA A00A3VA 1. Bearing 1. Proper strength Loctite 2. Proper strength Loctite 3. Shaft 1. Clean inner housing diameter and outer gasket diameter. Standard 2. Spray housing and gasket with Loctite Primer N 1.

• Page 18: Tightening Torques

  INTRODUCTION TIGHTENING TORQUES N•m FASTENER SIZE (8.8) Lbf•ft Tighten fasteners to torque mentioned in explod- ed views and text. When they are not specified refer to following table.The table also gives the metric conversion. N•m FASTENER SIZE (8.8) Lbf•in N•m FASTENER SIZE (8.8) Lbf•ft SMR2000_001_00A2.FM…

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  INTRODUCTION N•m FASTENER SIZE (8.8) Lbf•ft N•m FASTENER SIZE (8.8) Lbf•ft TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTS Technical Publications Bombardier Inc. Valcourt (Quebec), Canada SMR2000_001_00A2.FM www.SeaDooManuals.net…

• Page 20: Table Of Contents

  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS MANDATORY SERVICE TOOLS ………………. 01-02-1 ENGINE ……………………..01-02-1 COOLING/FUEL/OIL SYSTEMS ………………01-02-4 PROPULSION SYSTEM………………… 01-02-5 WORKSHOP ……………………01-02-6 OPTIONAL SERVICE TOOLS ………………..01-03-1 ENGINE ……………………..01-03-1 COOLING/FUEL/OIL SYSTEMS ………………

• Page 21: Mandatory Service Tools

  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) MANDATORY SERVICE TOOLS ENGINE Degree wheel Bearing pusher Sleeve set P/N 529 035 607 P/N 420 876 501 A) P/N 529 035 542 (20 mm sleeve) B) P/N 529 035 543 (21 mm sleeve) F00B074 APPLICATION…

• Page 22
  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) Puller Alignment support plate kit VCK (Vehicle Communication Kit) P/N 529 035 547 P/N 529 035 506 P/N 529 035 676 1) Alignment plates A)P/N 529 035 507 B)P/N 529 035 508 2) Support P/N 529 035 511 A00C1A4…
• Page 23
  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) Engine leak tester kit Handle Puller plate P/N 295 500 352 P/N 420 877 650 P/N 529 035 533 Pump only P/N 529 021 800 A00C3V4 APPLICATION Use with pushers (P/N 290 876 609 and 290 877 740).

• Page 24: Cooling/Fuel/Oil Systems

  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) COOLING/FUEL/OIL SYSTEMS Gear holder Coupler hose P/N 420 277 905 P/N 295 500 258 41 cm (16 in) F01E0Z4 APPLICATION A00C164 GTS model. APPLICATION 717 engine. Fuel pressure gauge P/N 529 035 591 Pliers P/N 295 000 070…

• Page 25: Propulsion System

  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) 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 the All models.

• Page 26: Workshop

  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) WORKSHOP Tool board P/N 295 500 608 F00A0S4 APPLICATION All models. 01-02-6 SMR2000-002_01_02A.FM www.SeaDooManuals.net…

• Page 27: Optional Service Tools

  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (OPTIONAL SERVICE TOOLS) OPTIONAL SERVICE TOOLS ENGINE Coil centering tool Distance gauge Dial indicator (TDC gauge) P/N 420 876 922 P/N 295 000 143 A) P/N 529 034 800, 14 mm B) P/N 529 034 900, 15.4 mm C) P/N 529 035 100, 11.5 mm D) P/N 529 035 000, 7.5 mm A00B4E4…

• Page 28
  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (OPTIONAL SERVICE TOOLS) Timing mark pointer Slide hammer puller Gear/bearing puller P/N 295 000 135 Not sold by Bombardier P/N 290 877 665 Snap-on: Handle CJ93-1 Hammer CJ125-6 Claws CJ93-4 F01J0Z4 APPLICATION 717 and 787 engines.
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  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (OPTIONAL SERVICE TOOLS) Feeler gauge 45° MPEM programmer Not sold by Bombardier P/N 529 035 718 Snap-on FB 300 A F01B1K4 A01B5B4 APPLICATION APPLICATION 717 and 787 RFI engines. All models. Steering cable tool Piston ring compressor (2) P/N 295 000 145 A) P/N 290 876 965 (88 mm)

• Page 30: Cooling/Fuel/Oil Systems

  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (OPTIONAL SERVICE TOOLS) COOLING/FUEL/OIL SYSTEMS Pump gauge tester Spring compressor Flushing adapter P/N 295 000 114 P/N 529 035 504 P/N 295 500 473 F01B0X4 APPLICATION All models except RFI models. F00B104 APPLICATION Lighted adjustable mirror All models except GTS.

• Page 31: Propulsion System

  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (OPTIONAL SERVICE TOOLS) PROPULSION SYSTEM Fitting Machinist’s square P/N 295 000 086 Not sold by Bombardier Snap-on PMF 122 F01B0Z4 F02B064 APPLICATION APPLICATION All models. GTS model. Slide hammer puller Fitting remover Not sold by Bombardier Not sold by Bombardier Snap-on: Handle…

• Page 32: Watercraft Handling

  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (OPTIONAL SERVICE TOOLS) WATERCRAFT HANDLING Dolly (with wheels) Lift kit P/N 295 000 126 P/N 295 100 044 F01B014 Beach wheels (set of 2 wheels) F00B0Z4 P/N 295 000 005 APPLICATION All models. Tie-down 1.50 m (5 ft) long P/N 295 100 103…

• Page 33: Service Products

  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 04 (SERVICE PRODUCTS) SERVICE PRODUCTS 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…

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  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 04 (SERVICE PRODUCTS) Gasket stripper Primer for gasket eliminator Ultra Copper High temp sealant P/N 413 508 500 P/N 293 800 041 P/N 413 710 300 (500 mL) Loctite (80 g) F01B1W4 A00B3N4 Thread sealant Pipe sealant P/N 293 800 050…
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  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 04 (SERVICE PRODUCTS) Grease BOMBARDIER LUBE 732 Multi-purpose sealant P/N 293 550 005 P/N 293 600 016 P/N 293 800 033 (400 g) (12 x 14 oz) Dow Corning (90 mL) (clear) A00B2L4 F01B1C4 Synthetic grease P/N 293 550 010…
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  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 04 (SERVICE PRODUCTS) BOMBARDIER Formula XP-S The Right Stuff (sealant) synthetic injection oil P/N 293 800 053 P/N 413 710 500 (12 x 1 L) Permatex® (198 g) F01B2G4 BOMBARDIER Formula XP-S synthetic injection oil P/N 413 711 000 (3 x 4 L) F00B0V4 P/N 413 710 700 (205 L)
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  Section 02 MAINTENANCE Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS 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 02-01-1 SMR2000-003_02_01ATOC.FM www.SeaDooManuals.net…

• Page 38: Periodic Inspection Chart

  Section 02 MAINTENANCE Subsection 02 (PERIODIC INSPECTION CHART) PERIODIC INSPECTION CHART NOTE: Servicing period is given in hours. Shaded area shows the maintenance frequency. FREQUENCY EVERY DESCRIPTION FIRST EVERY EVERY 100 HOURS OR 10 HOURS 25 HOURS 50 HOURS SEASONALLY Lubrication/corrosion protection of metallic components Engine ignition timing Spark plug replacement…

• Page 39: Flushing And Lubrication

  Section 02 MAINTENANCE Subsection 03 (FLUSHING AND LUBRICATION) FLUSHING AND LUBRICATION GENERAL CAUTION: This prevents water from exiting through outlet socket. Remove hose pincher after Flushing the cooling system with fresh water is flushing operation. essential to neutralize corroding effects of salt or other chemical products present in water.

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  Connect a garden hose to the flushing adaptor. NOTE: A quick connect adapter can be used to ease garden hose installation. GS, GTS, GTI, GSX RFI AND GTX RFI MODELS 1. Quick connect adapter 2. Flushing adaptor (P/N 295 500 473) 1.
• Page 41
  Wipe up any residual water from the engine. Remove spark plug cables and connect them on F00H0DA the grounding device. GS AND GTI MODELS 1. Spark plug cables on grounding device WARNING Always use spark plug cable grounding de- vice when removing spark plugs.
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  Apply anti-seize lubricant on spark plug threads then reinstall them. Reinstall plug on air intake silencer cover (GS, GTS and GTI models). NOTE: Engine fogging should be done with BOM- BARDIER LUBE lubricant whenever the water- craft is to be stored for a few days or a long period.

• Page 43: Water-Flooded Engine

  Turn fuel valve to OFF position then drain fuel filter bowl. Refer to FUEL CIRCUIT. F00H0DA GS AND GTI MODELS Drain bilge if water is present. 1. Spark plug cables on grounding device Remove spark plug cables and connect them on the grounding device.

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  Section 02 MAINTENANCE Subsection 04 (WATER-FLOODED ENGINE) Spray BOMBARDIER LUBE lubricant (P/N 293 600 016) into spark plug holes. Crank engine again. Reinstall spark plugs and spark plug cables. 787 RFI Engine Remove the filler plug of the counterbalance shaft on the engine crankcase.
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  Section 02 MAINTENANCE Subsection 04 (WATER-FLOODED ENGINE) All Models Except GSX RFI and GTX RFI Turn fuel valve to ON position. Start engine. It may be necessary to use the choke. If engine does not start, repeat previous steps as necessary. GSX RFI and GTX RFI Models Start engine according to normal starting proce- dure.

• Page 46: Storage

  Section 02 MAINTENANCE Subsection 05 (STORAGE) STORAGE Engine Draining All Models Except GSX RFI and GTX RFI Check engine drain hose (lowest hose of engine). Make sure there is no sand or other particles in it and that it is not obstructed so that water can leave the engine.

• Page 47: Cooling System Flushing And Engine Internal Lubrication

  Section 02 MAINTENANCE Subsection 05 (STORAGE) Fuel System PTO FLYWHEEL Sea-Doo Fuel Stabilizer (P/N 413 408 600) or equiv- All Models alent should be added in fuel tank to prevent fuel Remove PTO flywheel guard. deterioration and, if so equipped, carburetor(s) Lubricate PTO flywheel at grease fitting with syn- gumming.

• Page 48: Anticorrosion Treatment

  Section 02 MAINTENANCE Subsection 05 (STORAGE) Battery NOTE: The engine will not have to run during this operation. For battery removal, cleaning and storage, refer to CHARGING SYSTEM. Air Pressure Method Install an air pressure adaptor to the water outlet Watercraft Cleaning located at the rear of the watercraft.

• Page 49
  Section 02 MAINTENANCE Subsection 05 (STORAGE) NOTE: On XP model, open rear cover to have ac- cess to engine drain hose. RFI MODELS — 787 ENGINE XP MODEL — 947 ENGINE 1. Hose pincher installed on engine drain hose 1. Hose pincher installed on engine drain hose Disconnect engine water return hose.
• Page 50
  Section 02 MAINTENANCE Subsection 05 (STORAGE) On 947 engine, disconnect the water supply hose Temporarily install a short piece of hose to engine at cylinder head. water outlet at cylinder head. Insert a funnel into hose and pour antifreeze mixed with water (40% water, 60% antifreeze) in engine until the colored solution appears in the engine drain hose.

• Page 51: Troubleshooting Chart

  Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) TROUBLESHOOTING CHART The following is provided to help in diagnosing the probable source of troubles. It is a guideline and should not be assumed to have all causes for all problems. NOTE: On GTX RFI and GSX RFI models, always check for active fault codes recorded in the ECU first. If a fault code is detected, service the fault code first and recheck operating conditions.

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  Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Fuel water-contaminated • Check/siphon and refill • Dirty fuel filter • Clean/replace • Fouled or defective spark plugs • Replace • Water in engine • Check, refer to subsection 02-04 •…
• Page 53
  Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE MISFIRES, RUNS IRREGULARLY OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Fouled, defective, worn spark plugs • Check/verify heat range/gap/replace • Faulty rev limiter or ignition module • Check, refer to subsection 08-02 • Sheared flywheel key •…
• Page 54
  Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE OVERHEATS OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Restricted jet pump water intake • Check/clean Monitoring beeper sounds • Cooling system restriction • Check/flush, refer to subsection 02-03 continuously • Grounded temperature sensor or •…
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  Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE LACKS ACCELERATION OR POWER OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Weak spark • Check/replace, refer to subsection 08-02 • Carburetion, jetting too rich/lean • Check/adjust, refer to subsection 06-04 • Throttle does not open fully •…
• Page 56
  Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ABNORMAL NOISE FROM PROPULSION SYSTEM OTHER OBSERVATION POSSIBLE CAUSE REMEDY • 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 subsection 09-02 •…
• Page 57
  Section 04 ENGINE Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS LEAK TEST……………………..04-02-1 GENERAL ……………………… 04-02-1 PREPARATION ……………………04-02-1 TESTING PROCEDURE ………………… 04-02-1 ENGINE LEAKAGE DIAGNOSTIC FLOW CHART …………04-02-6 REMOVAL AND INSTALLATION………………04-03-1 GENERAL ……………………… 04-03-1 ENGINE REMOVAL………………….04-03-1 CLEANING …………………….

• Page 58: Leak Test

  Section 04 ENGINE Subsection 02 (LEAK TEST) LEAK TEST 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 WARNING 500 780) are available to help diagnose engine problems such as engine seizure, poor perfor- If any fuel leak is found, do not start the en- mance, oil leakage, etc.

• Page 59
  Section 04 ENGINE Subsection 02 (LEAK TEST) F01B2UB 717 ENGINE — REAR VIEW 1. Engine drain hose blocked with a hose pincher 787 RFI ENGINE — REAR VIEW 1. Loop hose and use clamps 2. Hose with clamps. Install pump to the end 3.
• Page 60
  Section 04 ENGINE Subsection 02 (LEAK TEST) Bottom End and Top End Remove the carburetor(s) and gasket(s). Make sure the surface of the intake manifold (717 and 947 engines) or rotary valve cover (787 RFI engine) are clean. Install the intake plate(s) with fasteners from the kit and tighten adequately.
• Page 61
  Section 04 ENGINE Subsection 02 (LEAK TEST) Activate pump and pressurize engine to 34 kPa (5 PSI). CAUTION: Do not exceed this pressure. Wait 3 minutes and check if pressure drops; if so, verify all testing components. If kit components are not leaking, verify engine jointed surfaces as per following areas: –…
• Page 62
  Section 04 ENGINE Subsection 02 (LEAK TEST) F01B32A F01B31A 717 ENGINE 717 ENGINE 1. Oil return hose blocked with hose pincher 1. Pump with reducer and nipple F01B33A F01B34A 787 RFI ENGINE 787 RFI ENGINE 1. Oil return hose blocked with hose pincher 1.

• Page 63: Engine Leakage Diagnostic Flow Chart

  Section 04 ENGINE Subsection 02 (LEAK TEST) ENGINE LEAKAGE DIAGNOSTIC FLOW CHART 717 and 787 RFI Engines 04-02-6 SMR2000-007_04_02A.FM www.SeaDooManuals.net…

• Page 64
  Section 04 ENGINE Subsection 02 (LEAK TEST) 947 Engine 04-02-7 SMR2000-007_04_02A.FM www.SeaDooManuals.net…

• Page 65: Removal And Installation

  Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) REMOVAL AND INSTALLATION GENERAL Electrical Connections It is recommended to disconnect electrical con- On some models, it is not necessary to remove nections prior to disconnecting fuel lines. engine from watercraft to service TOP END, PTO FLYWHEEL or MAGNETO.

• Page 66: Drive System

  Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) Tuned Pipe To remove tuned pipe, refer to EXHAUST SYSTEM. Air Intake Silencer To remove air intake silencer, refer to AIR INTAKE. Carburetor All Models Except GSX RFI and GTX RFI Turn fuel valve to OFF. Disconnect fuel supply and fuel return hoses.

• Page 67
  Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) Remove engine support mount screws. Lifting Engine 717 Engine Engine can be easily lifted using the following sug- gested tools: – Cut porcelain from two old spark plugs. – Weld a lock washer approximately 20 mm (3/4 in) diameter on each spark plug as shown.
• Page 68
  Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) Using a chain block, a hoist or other suitable equip- ment, slightly lift engine to ease the remaining com- ponent removal. CAUTION: Take care not to damage cable or oil injection hoses. Remove rear engine support.

• Page 69: Cleaning

  Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) Disconnect black negative cable from engine crank- CLEANING case. Wipe off any spillage in bilge. Clean with a bilge cleaner. Clean external parts of engine. INSTALLATION Installation of engine in watercraft is essentially the reverse of removal procedures.

• Page 70
  Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) 787 RFI and 947 Engines Apply Loctite 243 (blue) to rear engine support screws and torque to 24 N•m (17 lbf•ft). 1. Plate 2. Support Alignment shaft (P/N 295 000 141). TYPICAL 1.
• Page 71
  Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) – Carefully slide shaft through support. XP Model – Insert shaft end into PTO flywheel. Use: NOTE: Ensure the protective hose and carbon – plate (P/N 529 035 507) for the 155.6 mm (6-1/8 in) jet pump ring (or seal carrier) is removed to check engine alignment.
• Page 72
  Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) CAUTION: Whenever shims are used to correct alignment, never install more than 1.3 mm (0.051 in) shim thickness. 1. Alignment shaft 2. Adaptor Carefully slide shaft through support plate and seal F05I08A carrier.
• Page 73
  Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) 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. REAR ENGINE SUPPORT — 787 RFI AND 947 ENGINES 1.

• Page 74: Magneto System

  Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) MAGNETO SYSTEM 717 Engine PARTS 04-04-1 SMR2000-009_04_04A.FM www.SeaDooManuals.net…

• Page 75
  Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) 787 RFI Engine PARTS 04-04-2 SMR2000-009_04_04A.FM www.SeaDooManuals.net…
• Page 76
  Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) 947 Engine PARTS 04-04-3 SMR2000-009_04_04A.FM www.SeaDooManuals.net…

• Page 77: Disassembly

  Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) 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.

• Page 78
  Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) 1. Crankcase locating lug 2. Mark armature plate at the end of lug – At assembly, align armature plate mark (previ- F01D4CA ously punched) with the end of the correspond- 1. Puller plate ing locating lug on the new crankcase.
• Page 79
  Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) Magneto Flywheel and Ring Gear – Remove screws. – Uncrimp and unsolder BLACK/RED wire from coil. 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.
• Page 80
  Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) 1. Uncrimp and unsolder ground wire (BLACK) 1. Oil pump shaft 2. Uncrimp and unsolder YELLOW and YELLOW/BLACK wires Rotor and Flywheel 787 RFI Engine Remove starter. Refer to STARTING SYSTEM. Magneto Housing Cover NOTE: Crankshaft can also be locked by using the Disconnect water hoses from heat exchanger cover.
• Page 81
  Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) If desired, magneto rotor no. 8 can be removed Insert crankshaft protector to outer end of crank- without removing the engine flywheel no. 3. Re- shaft and fully thread puller in engine flywheel. move the six screws no.
• Page 82
  Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) Stator Assembly Remove oil pump shaft from flywheel nut. 787 RFI Engine Remove holding plate and withdraw plug from cover. Unscrew bolts no. 20 and remove stator no. 9 from magneto cover. F06D23A 1.

• Page 83: Cleaning

  Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) To remove the flywheel/rotor assembly, unscrew nut no. 13 counterclockwise when facing it. F06D0NA 1. Remove screws F06D0MA CLEANING 1. Nut Clean all metal components in a solvent. The flywheel is easily freed from crankshaft with puller (P/N 420 976 235).

• Page 84
  Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) Battery Charging Coil NOTE: Ensure that ring gear contacts magneto flywheel flange. Position new coil, crimp and solder all wires. Whenever replacing either ring gear or magneto Prior to assembly, apply Loctite 243 (blue). flywheel, Gun Kote must be applied to prevent Use magneto coil centering tool (P/N 420 876 922) possible corrosion.

• Page 85: Magneto Flywheel

  Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) The new mark on crankcase will be used for fur- 787 RFI Engine ther assembly positioning as a pre-timing position. Stator Install the stator no. 9 in magneto housing cover no. 1 and torque screws no. 20 to 10 N•m (88 lbf•in).

• Page 86
  Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) Apply Loctite 243 (blue) on nut no. 13. Install nut with lock washer no. 14 and torque to 105 N•m (77 lbf•ft). CAUTION: Never use any type of impact wrench at magneto installation. Crankshaft Position Sensor Install crankshaft position sensor no.
• Page 87
  Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) Rotor and Flywheel Apply Loctite 648 (green) on mating surface of the rotor no. 8. When reinstalling rotor to flywheel no. 3, one of the protrusion end of rotor must be aligned with hole in flywheel.

• Page 88: Top End

  Section 04 ENGINE Subsection 05 (TOP END) TOP END 717 Engine PARTS 04-05-1 SMR2000-010_04_05A.FM www.SeaDooManuals.net…

• Page 89
  Section 04 ENGINE Subsection 05 (TOP END) 787 RFI Engines PARTS 04-05-2 SMR2000-010_04_05A.FM www.SeaDooManuals.net…
• Page 90
  Section 04 ENGINE Subsection 05 (TOP END) 947 Engine PARTS 04-05-3 SMR2000-010_04_05A.FM www.SeaDooManuals.net…

• Page 91: General

  Section 04 ENGINE Subsection 05 (TOP END) GENERAL 787 RFI and 947 Engines On these engines, the RAVE valves are controlled The 2-stroke ROTAX engine rotates counterclock- by the Multi-Purpose Electronic Module (MPEM). wise seen from the rear (PTO flywheel). To open the RAVE valves, the MPEM activates a The 717 and 787 RFI engines have a rotary valve solenoid which directs the positive pressure from…

• Page 92
  Section 04 ENGINE Subsection 05 (TOP END) F06D16S RAVE VALVES OPENED 1. Pulse from crankcase 2. Check valve 3. Positive pressure to solenoid 4. Solenoid activated 5. Positive crankcase pressure to RAVE valves 04-05-5 SMR2000-010_04_05A.FM www.SeaDooManuals.net…
• Page 93
  Section 04 ENGINE Subsection 05 (TOP END) F06D16T RAVE VALVES CLOSED 1. Pulse from crankcase 2. Check valve 3. Positive pressure blocked by the solenoid 4. Solenoid deactivated 5. RAVE valves are opened to atmosphere 04-05-6 SMR2000-010_04_05A.FM www.SeaDooManuals.net…

• Page 94: Disassembly

  Section 04 ENGINE Subsection 05 (TOP END) MAINTENANCE Remove RAVE valve no. 15. There are no wear parts anywhere in the system Remove the cover no. 18 of the valve by releasing and there are no adjustments to be periodically the spring no.

• Page 95
  Section 04 ENGINE Subsection 05 (TOP END) Remove spring no. 30 retaining bellows no. 21 to Unscrew valve piston no. 20 from sliding valve valve piston no. 20. no. 22. NOTE: Hold the sliding valve to prevent it from turning. 1.
• Page 96
  Section 04 ENGINE Subsection 05 (TOP END) Remove supporting ring no. 28. Remove sliding valve no. 22. F06D27A 1. Remove sliding valve 1. Remove supporting ring Remove bellows no. 21. Remove O-ring no. 23. F06D0VA 1. Remove O-ring 1. Remove bellows 04-05-9 SMR2000-010_04_05A.FM www.SeaDooManuals.net…
• Page 97
  Section 04 ENGINE Subsection 05 (TOP END) Cylinder Head Cover and Cylinder Head Loosen nuts no. 33 following the sequence shown in the next photo. Disconnect temperature sensor wire and spark plug cables. Connect spark plug cables on grounding device. 717 Engine Remove air intake silencer and support, refer to AIR INTAKE.
• Page 98
  Section 04 ENGINE Subsection 05 (TOP END) Cylinder Remove cylinder block no. 9. 787 RFI Engine Remove air intake silencer and support, refer to AIR INTAKE. 717 and 787 RFI Engines Remove tuned pipe and exhaust manifold, refer to EXHAUST SYSTEM. Remove screws no.
• Page 99
  Section 04 ENGINE Subsection 05 (TOP END) If the other cylinder has been removed, complete- ly cover its opening with a clean rag. F01D0PA TYPICAL 1. Piston notch F01D43A 1. Openings covered with rag and rubber pad To extract piston pin no. 4, use piston pin puller (P/N 529 035 503) with the appropriate set of 947 Engine sleeves.
• Page 100
  Section 04 ENGINE Subsection 05 (TOP END) – Screw in extracting nut with the movable ex- – Rotate spindle until the shoulder sleeve is tracting ring towards spindle. flushed with the piston recess. 1. Puller 2. Sleeve F00B0LA 3. Shoulder sleeve 4.

• Page 101: Cleaning

  Section 04 ENGINE Subsection 05 (TOP END) – The needles, thrust washers and the sleeve re- The inspection of engine top end should include main in the connecting rod bore and may be the following measurements. used again. TOLERANCES ENGINE NEW PARTS WEAR MEASUREMENT…

• Page 102
  Section 04 ENGINE Subsection 05 (TOP END) 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. If the dif- ference between readings exceed specification, cyl- inder should be rebored and honed or replaced.
• Page 103
  Section 04 ENGINE Subsection 05 (TOP END) Adjust and lock a micrometer to the specified val- Position the dial bore gauge at 16 mm (5/8 in) be- ue on the piston dome. low cylinder top edge. 1. Micrometer set to the piston dimension With the micrometer set to the piston dimension, F01D0KA adjust a cylinder bore gauge to the micrometer di-…

• Page 104: Assembly

  Section 04 ENGINE Subsection 05 (TOP END) 947 Engine All Engines Due to the semi-trapez rings, it is not possible to GASKET IDENTIFICATION accurately measure ring/piston groove clearance. THICKNESS HOLES Ring End Gap 0.3 mm (.012 in) Position ring halfway between exhaust port and 0.4 mm (.016 in) top of cylinder.

• Page 105
  Section 04 ENGINE Subsection 05 (TOP END) Install a new gasket no. 24. It must be installed at 947 Engine the same time as the sliding valve no. 22. Install the supporting ring no. 28 with the bevel Position the valve housing no. 25 onto the cylinder side facing the O-ring no.
• Page 106
  Section 04 ENGINE Subsection 05 (TOP END) 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. A01C01A 1. Exhaust side NOTE: On the 787 RFI and 947 engines, the ex- 1.
• Page 107
  Section 04 ENGINE Subsection 05 (TOP END) – 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.
• Page 108
  Section 04 ENGINE Subsection 05 (TOP END) 717 and 787 RFI Engines 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. 1.
• Page 109
  Section 04 ENGINE Subsection 05 (TOP END) Cylinder Base Gasket Slide cylinder over piston. 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…
• Page 110
  Section 04 ENGINE Subsection 05 (TOP END) Line up dowels with corresponding holes in cylin- der block. F01D45A 717 ENGINE 1. Aligning cylinders using exhaust manifold 1. Dowel To easily slide cylinder block over pistons, use ring 787 RFI Engine compressor (P/N 290 876 965).

• Page 111: Cylinder Head

  Section 04 ENGINE Subsection 05 (TOP END) 1. O-rings Apply Loctite 518 in O-ring groove of cylinder sleeves. 787 Engine Install cylinder head. Prior installation, apply synthetic grease below screw head and Loctite 518 on screw threads. 947 Engine Install M10 x 105 screws on exhaust side and the Apply Loctite 243 (blue) on the threads of the cyl- M10 x 73.5 on opposite side.

• Page 112: Adjustment

  Section 04 ENGINE Subsection 05 (TOP END) Cylinder Head Cover 947 Engine Turn the red plastic knob no. 17 until it is fully tight- 717 and 787 Engines ened. Install cylinder head cover no. 1. Apply Loctite 243 (blue) below head of screws no.

• Page 113
  Section 04 ENGINE Subsection 05 (TOP END) 1. Remove both spark plugs and bring one piston to Top Dead Center a using a TDC gauge. 1. Top of spark plug hole NOTE: The liquid level in cylinder must not drop for a few seconds after filling.

• Page 114: Bottom End

  Section 04 ENGINE Subsection 06 (BOTTOM END) BOTTOM END 717 Engine PARTS 04-06-1 SMR2000-011_04_06A.FM www.SeaDooManuals.net…

• Page 115
  Section 04 ENGINE Subsection 06 (BOTTOM END) 787 RFI Engine PARTS 04-06-2 SMR2000-011_04_06A.FM www.SeaDooManuals.net…
• Page 116
  Section 04 ENGINE Subsection 06 (BOTTOM END) 947 Engine PARTS 04-06-3 SMR2000-011_04_06A.FM www.SeaDooManuals.net…

• Page 117: Disassembly

  Section 04 ENGINE Subsection 06 (BOTTOM END) DISASSEMBLY Engine has to be removed from watercraft and top end has to be disassembled to open bottom end. Refer to REMOVAL AND INSTALLATION and TOP END. PTO Flywheel 717 Engine To remove PTO flywheel no. 1, the crankshaft TYPICAL must be locked.

• Page 118
  Section 04 ENGINE Subsection 06 (BOTTOM END) Install special tool. GSX AND GTX MODELS 1. Loosen Allen screws TYPICAL 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.
• Page 119
  Section 04 ENGINE Subsection 06 (BOTTOM END) Remove coupler no. 20. Starter Drive Assembly Install puller plate (P/N 529 035 533) and extension 947 Engine 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.
• Page 120
  Section 04 ENGINE Subsection 06 (BOTTOM END) F06D0JA 1. Carburetor flange Remove reed valves no. 28 from crankcase. 787 RFI ENGINE 1. M10 x 75 flanged screws Crankcase 2. M8 x 55 flanged screws Before opening the bottom end, remove the fol- 947 Engine lowing parts: Place engine upright on crankcase magneto side.
• Page 121
  Section 04 ENGINE Subsection 06 (BOTTOM END) All Engines NOTE: Do not needlessly remove crankshaft bear- ings. Put engine back on a support. Insert a pry bar be- tween crankcase lugs to separate halves. Remove end seal(s). CAUTION: Be careful to precision machined sur- faces.
• Page 122
  Section 04 ENGINE Subsection 06 (BOTTOM END) 787 RFI Engine All Engines 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.
• Page 123
  Section 04 ENGINE Subsection 06 (BOTTOM END) 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- F04B03A shaft.

• Page 124: Cleaning

  Section 04 ENGINE Subsection 06 (BOTTOM END) To remove gear no. 14, first trace an index mark on the gear and counterbalance shaft. NOTE: There is no Woodruff key to position the gear on the counterbalance shaft. An index mark must be traced to ease assembly procedure.

• Page 125
  Section 04 ENGINE Subsection 06 (BOTTOM END) 1. Main journal alignment here To accurately check if crankshaft is twisted on cen- ter main journal, proceed as follows: – Remove magneto housing cover. – Remove flywheel nut (and magneto rotor for the 787 RFI and 947 engines).
• Page 126
  Section 04 ENGINE Subsection 06 (BOTTOM END) Such misalignment may cause a crankshaft hard Crankshaft Deflection to be manually turned. Verification can be done by All Models measuring deflection each end of crankshaft. If deflection is found greater than specified toler- MEASUREMENT MAG SIDE PTO SIDE…
• Page 127
  Section 04 ENGINE Subsection 06 (BOTTOM END) Remove crankshaft bearings and check deflection Connecting Rod Big End Axial Play again on V-shaped blocks as illustrated. CONNECTING ROD BIG END AXIAL PLAY NEW PARTS WEAR MODEL LIMIT (MIN.) (MAX.) 0.390 mm 0.737 mm 1.2 mm 947 engine…
• Page 128
  Section 04 ENGINE Subsection 06 (BOTTOM END) Starter Drive Bearing Reed Valve 947 Engine Only 947 Engine Only Check bearing no. 23 of starter drive assembly Check reed valve petals no. 29 for cracks or other no. 27 in crankcase. defects.

• Page 129: Assembly

  Section 04 ENGINE Subsection 06 (BOTTOM END) NOTE: Distance should be the same on both sides. Bent stopper as required to obtain the proper dis- tance. ASSEMBLY Assembly is essentially the reverse of disassem- bly procedures. However pay particular attention to the following.

• Page 130
  Section 04 ENGINE Subsection 06 (BOTTOM END) 947 Engine Seals are positioned with the outer lip in the crank- case recess. F00D0MA 1. Keyway 2. Long flange toward the crankshaft counterweight Crankshaft Seal All Models F06D1LA When installing seal assembly no. 5, apply a light 1.
• Page 131
  Section 04 ENGINE Subsection 06 (BOTTOM END) Counterbalance Shaft If notches are not aligned with the crankcase, re- move the gear and repeat the procedure until the 787 RFI Engine notches are properly aligned. Press gear no. 14 onto counterbalance shaft no. 13 947 Engine taking care to align both marks previously traced.
• Page 132
  Section 04 ENGINE Subsection 06 (BOTTOM END) Place seals no. 17 in their respective positions. 947 ENGINE F06D1OA 1. Marks must be aligned 1. Seal in place Turn by hand the crankshaft and counterbalance Crankcase shaft. Make sure they do not interfere with the crankcase.
• Page 133
  Section 04 ENGINE Subsection 06 (BOTTOM END) 947 Engine Make sure all locating dowels are in place. Torque 2 M10 crankcase screws to 40 N•m (30 lbf•ft). F06D1PA 1. Dowel Counterbalance Shaft Bearing Cover 787 RFI Engine Install the bearing cover no. 19 with its hollow side toward the bearing.
• Page 134
  Section 04 ENGINE Subsection 06 (BOTTOM END) As a final step, torque only M10 screws no. 8 of As a final step, torque only the M10 x 73.5 bolts crankcase to 40 N•m (30 lbf•ft) as per following se- to 40 N•m (30 lbf•ft) as per following sequence. quence.
• Page 135
  Section 04 ENGINE Subsection 06 (BOTTOM END) Starter Drive Bearing Apply Loctite 648 on mating surface of PTO fly- wheel and coupler. 947 Engine Apply Loctite 243 (blue) to Allen screws no. 21 of To install bearing no. 23 of starter drive assembly, coupler and torque to 23 N•m (17 lbf•ft).

• Page 136: Rotary Valve

  Section 04 ENGINE Subsection 07 (ROTARY VALVE) ROTARY VALVE 717 and 787 RFI Engines PARTS 04-07-1 SMR2000-012_04_07A.FM www.SeaDooManuals.net…

• Page 137: General

  Section 04 ENGINE Subsection 07 (ROTARY VALVE) GENERAL The following verification procedures such as clear- ance of rotary valve cover or rotary valve shaft gear backlash can be performed without removing engine from watercraft. However engine must be removed from water- craft to work on rotary valve shaft/components.

• Page 138: Disassembly

  Section 04 ENGINE Subsection 07 (ROTARY VALVE) 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.

• Page 139
  Section 04 ENGINE Subsection 07 (ROTARY VALVE) 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.

• Page 140: Cleaning

  Section 04 ENGINE Subsection 07 (ROTARY VALVE) 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. –…

• Page 141: Assembly

  Section 04 ENGINE Subsection 07 (ROTARY VALVE) ASSEMBLY Seal Apply lithium grease on seal lips. Position seal Assembly is essentially the reverse of disassem- no. 11 with shielded portion against shaft splines. bly procedures. However pay particular attention to the following. Bearing Bearing Install ball bearing as illustrated.

• Page 142
  Section 04 ENGINE Subsection 07 (ROTARY VALVE) 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 717 and 787 RFI Engines Snap Ring…
• Page 143
  Section 04 ENGINE Subsection 07 (ROTARY VALVE) There is no identification code on the valve. To find out the duration, place an angle finder on the valve and measure the valve cut-out angle or use the following template. 04-07-8 SMR2000-012_04_07A.FM www.SeaDooManuals.net…

• Page 144: Rotary Valve Timing

  Section 04 ENGINE Subsection 07 (ROTARY VALVE) 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 MAG side piston.

• Page 145
  Section 04 ENGINE Subsection 07 (ROTARY VALVE) – For closing mark, first align 360° line of degree wheel with TOP of MAG side inlet port. Then, find 65° line on outer scale of degree wheel and mark crankcase at this point. 65°…

• Page 146: Exhaust System

  Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) EXHAUST SYSTEM 717 Engine PARTS 04-08-1 SMR2000-013_04_08A.FM www.SeaDooManuals.net…

• Page 147
  Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) 787 RFI Engine PARTS 04-08-2 SMR2000-013_04_08A.FM www.SeaDooManuals.net…
• Page 148
  Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) 947 Engine PARTS 04-08-3 SMR2000-013_04_08A.FM www.SeaDooManuals.net…

• Page 149: Removal

  Disconnect water supply hose and water injection Remove seat(s). hose. Remove rear vent hose support from body opening. Disconnect tuned pipe bleed hose. GS AND GSX RFI 1. Rear vent hose support TYPICAL Remove seat support (GTI, GTX RFI and GTX). 1. Bleed hose removed 2.

• Page 150
  Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) 787 RFI Engine Remove air intake silencer. Disconnect water supply hose and water injection hose at tuned pipe. Loosen hose clamp no. 1 retaining exhaust hose no. 3 to tuned pipe cone. 1. Disconnect hose from outlet fitting Disconnect the water injection hose at tuned pipe head no.
• Page 151
  Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) Loosen clamp no. 1 retaining exhaust hose no. 3 Loosen Allen screw retaining carburetor bracket to tuned pipe cone no. 5. to tuned pipe head. F06D2DA F06D14A 1. Loosen clamp 1. Loosen Allen screw Loosen and remove clamp no.

• Page 152: Exhaust Manifold

  Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) Loosen bolt no. 20 of tuned pipe head above the Remove the stud no. 21 from “Y” manifold. engine magneto. Use a M10 x 1.5 screwtap to clean the 4 threaded holes on the “Y” manifold and the 2 threaded holes on tuned pipe.

• Page 153: Tuned Pipe Repair

  Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) Footwell Type Resonators NOTE: Some models are equipped with both types or resonators (GTX RFI and GTX). TYPICAL 1. Water supply hose 2. To injection fitting on tuned pipe Disconnect retaining strap no. 2 of muffler. Pull muffler no.

• Page 154: Installation

  Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) Test 787 RFI Engine Apply Loctite 518 on 2 screws no. 12. On the oth- – Use compressed air at 124 kPa (18 PSI) to pres- er screws no. 12, apply Molykote 111 on threads. surize tuned pipe.

• Page 155
  Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) 947 Engine CAUTION: Damage to bushings and/or sleeve will eventually cause stress to tune pipe and may Apply Molykote 111 on threads of Allen screws cause cracking. no. 12. Make sure that gasket no. 16 is properly located Install and hand tighten Allen screws no.
• Page 156
  Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) 787 RFI 947 Engine Ensure rubber bushings no. 19 and sleeve no. 18 Make sure to install the sealing ring no. 15 on are not damaged and are properly installed into tuned pipe cone if it was removed. tune pipe support(s).
• Page 157
  Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) Torquing Sequence: Torque all screws by hand. Do not torque yet. Torque the 3 screws no. 7 to 6 N•m (53 lbf•in) and the nut no. 8 to 3 N•m (27 lbf•in), using the polygonal key (P/N 529 035 505), as per the follow- ing illustration.
• Page 158
  Section 05 COOLING SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS CIRCUIT, COMPONENTS AND CARE………………. 05-02-1 CIRCUIT ……………………..05-02-8 COMPONENTS ……………………05-02-12 CARE ……………………..05-02-15 05-01-1 SMR2000-014_05_01ATOC.FM www.SeaDooManuals.net…

• Page 159: Circuit, Components And Care

  Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) CIRCUIT, COMPONENTS AND CARE GSX RFI and GTX RFI Models PARTS 05-02-1 SMR2000-014_05_02A.FM www.SeaDooManuals.net…

• Page 160
  Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) GS and GTI Models PARTS 05-02-2 SMR2000-014_05_02A.FM www.SeaDooManuals.net…
• Page 161
  Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) GTS Model PARTS 05-02-3 SMR2000-014_05_02A.FM www.SeaDooManuals.net…
• Page 162
  Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) XP and GTX Models PARTS 05-02-4 SMR2000-014_05_02A.FM www.SeaDooManuals.net…
• Page 163
  Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) 717 Engine 05-02-5 SMR2000-014_05_02A.FM www.SeaDooManuals.net…
• Page 164
  Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) 787 RFI Engine 05-02-6 SMR2000-014_05_02A.FM www.SeaDooManuals.net…
• Page 165
  Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) 947 Engine 05-02-7 SMR2000-014_05_02A.FM www.SeaDooManuals.net…

• Page 166: Circuit

  Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) 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 Engine A Serial Cooling System is utilized on the 717 en- gine, which offers an efficient cooling of the com- bustion chamber to prevent the possibilities of…

• Page 167
  Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) Draining of the cooling system is accomplished by a drain hose located at the lowest point of the cir- cuit. 1. Heat exchanger water supply hose 2. Quick connect hose fitting The water coming out of the magneto heat ex- changer is evacuated at the exhaust outlet for noise reduction.
• Page 168
  Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) Water circulates through the one piece cylinder head which features improved combustion cham- ber and better spark plug cooling. 1. Engine water outlet Water circulates in the water outlet hose and is Water enters cylinder block water jackets and is expelled out of the cooling system through a fit- directed to the water jackets of the exhaust man-…
• Page 169
  Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) Bleeding of the cooling system is accomplished by The lower hose of the valve is the water supply the bleed hose located at the uppermost point of and the upper hose is the regulated injection water the circuit at the tuned pipe.

• Page 170: Components

  Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) All Models Fitting Spigot CAUTION: Never modify cooling system ar- On some models, the fitting spigot no. 2 installed rangement, otherwise serious engine damage on the water outlet hose is used to flush cooling could occur.

• Page 171: Water Flow Regulator Valve

  Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) Water Flow Regulator Valve A water flow regulator valve is mounted on mod- els with the 787 RFI and 947 engines so that they can produce the maximum horsepower output and yet maintain the necessary diameter of the injection fitting at the tuned pipe head for unob- structed water flow.

• Page 172
  Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) Adjustment The water flow regulator valve has been calibrated at the factory and should not be modified. NOTE: Water flow regulator valves ordered from the parts channel are also calibrated. 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…

• Page 173: Care

  10. AGE. Remove valve no. 9 and bellows no. 10. GS, GTS and GTI Models When servicing the hull, always rotate watercraft counterclockwise (seen from the rear). Rotating watercraft on the opposite side could allow resid- ual water in tuned pipe to enter the engine and cause damage.

• Page 174: Towing The Watercraft In Water

  CAUTION: When finished towing the water- craft, the hose pincher must be removed before operating it. F02E04A GS, GTS AND GTI MODELS 1. Hose pincher on water supply hose 05-02-16 SMR2000-014_05_02A.FM www.SeaDooManuals.net…

• Page 175
  Section 06 FUEL SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS FUEL CIRCUIT……………………06-02-1 GENERAL ……………………… 06-02-6 REMOVAL……………………… 06-02-6 INSPECTION ……………………06-02-10 ASSEMBLY……………………. 06-02-11 FUEL SYSTEM PRESSURIZATION ………………. 06-02-11 AIR INTAKE ……………………..06-03-1 REMOVAL……………………… 06-03-4 ASSEMBLY……………………. 06-03-5 CARBURETOR ……………………06-04-1 GENERAL ………………………
• Page 176
  Section 06 FUEL SYSTEM Subsection 01 (TABLE OF CONTENTS) REMOVAL AND INSTALLATION ………………06-05-19 THROTTLE POSITION SENSOR (TPS)…………….06-05-19 AIR TEMPERATURE SENSOR (ATS) …………….06-05-19 AIR PRESSURE SENSOR (APS) ………………06-05-19 WATER TEMPERATURE SENSOR (WTS) ……………. 06-05-19 CRANKSHAFT POSITION SENSOR (CPS)……………. 06-05-19 FUEL PUMP ASSEMBLY ………………..

• Page 177: Fuel Circuit

  Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) FUEL CIRCUIT GS and GTI Models PARTS 06-02-1 SMR2000-015_06_02A.FM www.SeaDooManuals.net…

• Page 178
  Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) GTX Model PARTS 06-02-2 SMR2000-015_06_02A.FM www.SeaDooManuals.net…
• Page 179
  Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) XP Model PARTS 06-02-3 SMR2000-015_06_02A.FM www.SeaDooManuals.net…
• Page 180
  Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) GTS Model PARTS 06-02-4 SMR2000-015_06_02A.FM www.SeaDooManuals.net…
• Page 181
  Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) GTX RFI and GSX RFI Models PARTS 06-02-5 SMR2000-015_06_02A.FM www.SeaDooManuals.net…

• Page 182: General

  Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) GENERAL When replacing fuel lines on SEA-DOO water- craft, be sure to use “B1” hoses as available from Bombardier parts department. This will ensure WARNING continued proper and safe operation. Whenever repairing the fuel system, always verify for water infiltration in reservoir.

• Page 183
  Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) Unscrew the fuel filter bowl no. 2 counterclock- Fuel Baffle Pick Up wise then pull toward the bottom. All Models Except GSX RFI and GTX RFI NOTE: The baffle pick up has an integrated fuel sender for the fuel gauge.
• Page 184
  Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) Remove vent tube. 1. Remove vent tube F02F1NA Disconnect fuel filler hose no. 5 from fuel tank. 1. Remove fuel filter Disconnect the fuel lines from baffle pick up and loosen lower clamp no. 10. NOTE: Identify fuel line positions to ease reas- sembly.

• Page 185: Fuel Tank

  WARNING All Models Fuel is flammable and explosive under cer- NOTE: On GS and GSX RFI, it is necessary to re- tain conditions. Always work in a well venti- move the engine. Refer to REMOVAL and INSTAL- lated area. Always wipe off any fuel spillage LATION section.

• Page 186: Inspection

  Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) Siphon fuel tank. Fuel Filler Hose Verify fuel filler hose no. 5 for damage. Always en- WARNING sure that clamps no. 4 are well positioned and Fuel is flammable and explosive under cer- tightened.

• Page 187: Assembly

  Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) NOTE: A fuel tank is comprised of 3 components: FUEL SYSTEM PRESSURIZATION the tank, the fuel pick up neck and the filler neck. The necks are injection molded and the tank is WARNING then blow molded over the necks.

• Page 188
  Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) – 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. NOTE: The system must maintain a pressure of 34 kPa (5 PSI) during 10 minutes.

• Page 189: Air Intake

  Section 06 FUEL SYSTEM Subsection 03 (AIR INTAKE) AIR INTAKE GS, GTS and GTI Models PARTS 06-03-1 SMR2000-016_06_03A.FM www.SeaDooManuals.net…

• Page 190
  Section 06 FUEL SYSTEM Subsection 03 (AIR INTAKE) GSX RFI and GTX RFI Models PARTS 06-03-2 SMR2000-016_06_03A.FM www.SeaDooManuals.net…
• Page 191
  Section 06 FUEL SYSTEM Subsection 03 (AIR INTAKE) XP and GTX Models PARTS 06-03-3 SMR2000-016_06_03A.FM www.SeaDooManuals.net…

• Page 192: Removal

  Section 06 FUEL SYSTEM Subsection 03 (AIR INTAKE) REMOVAL 717 and 787 RFI engines Air Intake Silencer Cover Unlock the 6 retaining slides holding air intake si- lencer cover no. 1 and remove cover. TYPICAL 1. Remove support Remove screws no. 10 from flame arrester base TYPICAL then withdraw base.

• Page 193: Assembly

  However pay particular attention to the following. CAUTION: Do not modify air intake system, otherwise calibration will be affected. GS, GTS and GTI Models Flame Arrester Base Apply Loctite 518 on mating surfaces of flame ar- rester base no. 7.

• Page 194
  Section 06 FUEL SYSTEM Subsection 03 (AIR INTAKE) Gasket Inspect condition of gasket no. 9. Make sure to properly install gasket. XP and GTX Models Air Intake Silencer Make sure than gaskets no. 11 are installed into carburetor holes of air intake silencer. Check O-rings no.

• Page 195: Carburetor

  Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR) CARBURETOR Mikuni BN-40i and BN-46i PARTS 06-04-1 SMR2000-017_06_04A.FM www.SeaDooManuals.net…

• Page 196: General

  Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR) GENERAL The following illustration shows which part of the carburetor begins to function at different throttle plate openings. F06F0LA TYPICAL 1. Pulse line 2. Loosen gear clamp Disconnect fuel supply line from fuel pump. F01F13A Disconnect fuel return line.

• Page 197: Cleaning

  Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR) CLEANING The carburetor exterior surfaces should be cleaned with a general solvent and dried with compressed air before disassembly. CAUTION: Be careful at carburetor cleaning not to remove paint. Paint removal will cause carbu- retor to rust very rapidly.

• Page 198
  Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR) 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.

• Page 199: Assembly

  Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR) 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.

• Page 200
  9, check valve housing must be removed. TYPICAL 1. Pump gauge tester 2. Install on inlet nipple 3. Obstruct outlet nipple Refer to the following table for pop-off pressure specifications: POP OFF PRESSURE MODELS min./max. (PSI) GS, GTS, GTI 36/40 XP, GTX 19/23 06-04-6 SMR2000-017_06_04A.FM www.SeaDooManuals.net…

• Page 201: Installation

  Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR) O-Ring When installing O-rings no. 13 of low speed and high speed screws, apply some BOMBARDIER LUBE (P/N 293 600 016) to prevent sticking. Fuel Accelerator Pump Lubricate pump plunger, roller and cam with syn- thetic grease (P/N 293 550 010) and roller shaft with BOMBARDIER LUBE (P/N 293 600 016).

• Page 202: Adjustments

  Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR) ADJUSTMENTS Twin Carburetor Synchronization With idle speed screw not touching throttle lever stopper on MAG carburetor, both throttle plates are in closed position. TYPICAL 1. Throttle lever PTO side 2. Marks CAUTION: Throttle plates must open simulta- neously, otherwise this will cause engine to vi- brate and/or misfire.

• Page 203
  Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR) To adjust, loosen jam nut then turn adjustment nut as necessary. 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- THROTTLE CABLE ASSEMBLY bar.
• Page 204
  Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR) 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. 1.
• Page 205
  Tighten low speed screw until a slight resistance is felt. Then, back it off to the specification as per following chart. WATERCRAFT MODEL LOW SPEED SCREW GS/GTS/GTI 1.0 ± 0.25 turns 717 ENGINE XP/GTX 1.5 ± 0.25 turns 1. High speed screw NOTE: Turning screw clockwise leans mixture and turning screw counterclockwise enriches mixture.
• Page 206
  Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR) Idle Speed Screw NOTE: To adjust idle speed, ensure flame arrester and air intake silencer are installed. Turning screw no. 15 clockwise increases engine Start engine and bring to normal operating temper- idle speed and turning screw counterclockwise ature.
• Page 207
  Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR) Choke Cable Ensure choke lever has a free-play of 0.5 to 2.0 mm (1/64 to 5/64 in). F07F02A TYPICAL 1. Choke lever A. Free play of 0.5 to 2.0 mm (1/64 to 5/64 in) To adjust, loosen jam nut on carburetor bracket, then turn adjustment nut as necessary.

• Page 208: Fuel Injection

  Section 06 FUEL SYSTEM Subsection 05 (FUEL INJECTION) FUEL INJECTION 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.

• Page 209: Introduction

  Section 06 FUEL SYSTEM Subsection 05 (FUEL INJECTION) INTRODUCTION FUEL DELIVERY The Rotax Fuel Injection (RFI) is a semi-direct elec- tronic fuel injection system. Fuel Pump Fuel is injected into each cylinder through the rear transfer port. With this design, the injector is not An electric fuel pump provides fuel pressure and exposed to high combustion pressure, tempera- flow rate to the system.

• Page 210: Fuel Injectors

  Section 06 FUEL SYSTEM Subsection 05 (FUEL INJECTION) 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.

• Page 211: Electronic Management

  Section 06 FUEL SYSTEM Subsection 05 (FUEL INJECTION) ELECTRONIC MANAGEMENT 4. Fail-Safe Function In the event of a sensor malfunction, the ECU will Electronic Control Unit (ECU) use a default operating mode to ensure driveability to shore. A message may be displayed on the Info The electronic fuel injection is equipped with a Center to inform the operator.

• Page 212
  Section 06 FUEL SYSTEM Subsection 05 (FUEL INJECTION) SIGNAL MANAGEMENT 06-05-5 SMR2000-018_06_05A.FM www.SeaDooManuals.net…

• Page 213: Diagnostic Procedures

  Section 06 FUEL SYSTEM Subsection 05 (FUEL INJECTION) DIAGNOSTIC PROCEDURES 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 few seconds, then a new menu will appear on the The latest software designed for the RFI model screen.

• Page 214: Fault Code Tables

  Section 06 FUEL SYSTEM Subsection 05 (FUEL INJECTION) FAULT CODE TABLES ECU Faults FAULT DETECTION FAULT CODE TYPE OF FAULT No fault detected FF FF 88 = no defect 00 = internal defect Electronic Control Unit Internal memory FF FF 1B = not plausible = EEPROM defect Electronic Control Unit EEPROM FF FE…

• Page 215
  Section 06 FUEL SYSTEM Subsection 05 (FUEL INJECTION) B.U.D.S. Fault Codes Versus RFI Fault Codes B.U.D.S. CODES RFI CODES P 0604 FF FF 00 P 0605 FF FF 1B P 1600 FF FF 2B P 1601 FF FD 10 P 1602 FF FD 25 P 0562 02 14 07…

• Page 216: Throttle Body

  Section 06 FUEL SYSTEM Subsection 05 (FUEL INJECTION) COMPONENT INSPECTION Engine problems are not necessarily related to the electronic fuel injection system. It is important to check that the electrical system is functioning properly: – battery – fuses – DESS –…

• Page 217
  Section 06 FUEL SYSTEM Subsection 05 (FUEL INJECTION) Install a fuel pressure gauge (P/N 529 035 591) to Fuel Injector the quick connect fitting of the fuel hose. FUEL PRESSURE GAUGE (P/N 529 035 591) F07F0CA Install the safety lanyard cap on the switch to ac- 1.

• Page 218: Electronic Management

  Section 06 FUEL SYSTEM Subsection 05 (FUEL INJECTION) 1. Fuel injectors 2. Fuel rail 3. Injector nozzles The resistance should be between 2.3 Ω and 2.5 Ω at temperature of 20°C (68°F). If not within specification, replace the fuel injector(s). If resistance value is incorrect, check wiring har- ELECTRONIC MANAGEMENT ness between AMP plug connector and fuel injec-…

• Page 219
  Section 06 FUEL SYSTEM Subsection 05 (FUEL INJECTION) Check also the resistance between terminal 4 Depress the start/stop button with the safety lan- (BLACK/BROWN wire) and terminal 11 (WHITE/ yard removed to activate the timer. There should BROWN wire) with the throttle plate in idle posi- be 5 Vdc.

• Page 220: Air Temperature Sensor (Ats)

  Section 06 FUEL SYSTEM Subsection 05 (FUEL INJECTION) Air Temperature Sensor (ATS) If resistance is below specifications, replace air temperature sensor (ATS). NOTE: When testing the resistance of the air tem- If resistance is above specifications, disconnect perature sensor (ATS), it is important to check the the connector of the air temperature sensor and ambient temperature.

• Page 221
  Section 06 FUEL SYSTEM Subsection 05 (FUEL INJECTION) The resistance should be between 2.280 kΩ and Check the air pressure sensor resistance. 2.736 kΩ at temperature of 19°C to 21°C (66°F to Disconnect the AMP plug connector number 4 70°F). from the MPEM module.

• Page 222: Rave Solenoid

  Section 06 FUEL SYSTEM Subsection 05 (FUEL INJECTION) Voltage Test Disconnect the AMP plug connector number 4 from the MPEM module. If the sensor resistance value is within specifications, disconnect the plug connector from the APS sensor Check resistance value between terminal 16 and and check the voltage between the PURPLE/BLUE terminal 23 on the plug connector.

• Page 223: Rfi Sensors Resistance Values

  Section 06 FUEL SYSTEM Subsection 05 (FUEL INJECTION) 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 PU/BL and BK/BL 9 and 2 WH/BL and BK/BL 3.4 k — 8.2 k ohms…

• Page 224: Spark Plug Inspection

  Section 06 FUEL SYSTEM Subsection 05 (FUEL INJECTION) TROUBLESHOOTING SUMMARY ENGINE DOES NOT START Disconnecting the battery will erase the fault codes in the ECU memory. If the engine does not start, the following items should be verified in this order: ENGINE STARTS BUT RUNS –…

• Page 225: Adjustment

  Section 06 FUEL SYSTEM Subsection 05 (FUEL INJECTION) ADJUSTMENT THROTTLE POSITION SENSOR Loosen the adjustment of the throttle cable. (TPS) This adjustment is very important. The setting of the TPS will determine the basic parameters for all fuel mapping. NOTE: Adjustment must be done each time the throttle position sensor (TPS) is loosened or re- moved.

• Page 226: Removal And Installation

  Section 06 FUEL SYSTEM Subsection 05 (FUEL INJECTION) REMOVAL AND INSTALLATION THROTTLE POSITION SENSOR FUEL PUMP ASSEMBLY (TPS) Open the front storage compartment cover. Remove the air intake silencer. Remove the storage basket. Remove the flame arrester. Remove the glove box. Remove the air temperature sensor to ease re- Disconnect the wire connector from the fuel moval of the TPS.

• Page 227: Fuel Injector

  Section 06 FUEL SYSTEM Subsection 05 (FUEL INJECTION) Fuel Filter Remove the fuel rail with both fuel injectors. To remove the fuel injector from the fuel rail, pry The fuel filter is not serviceable. Replace the fuel off the retaining clip. pump assembly if the fuel filter must be replaced.

• Page 228
  Section 07 LUBRICATION SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS OIL INJECTION SYSTEM …………………. 07-02-1 GENERAL ……………………… 07-02-8 OIL SYSTEM PRESSURIZATION ………………07-02-8 OIL INJECTION PUMP ………………….07-03-1 OIL PUMP IDENTIFICATION ………………… 07-03-4 REMOVAL……………………… 07-03-4 DISASSEMBLY ……………………07-03-4 CLEANING …………………….

• Page 229: Oil Injection System

  Section 07 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM) OIL INJECTION SYSTEM GTS Model 07-02-1 SMR2000-019_07_02A.FM PARTS www.SeaDooManuals.net…

• Page 230
  Section 07 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM) GS Model 07-02-2 PARTS SMR2000-019_07_02A.FM www.SeaDooManuals.net…
• Page 231
  Section 07 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM) GSX Model 07-02-3 SMR2000-019_07_02A.FM PARTS www.SeaDooManuals.net…
• Page 232
  Section 07 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM) XP Model PARTS 07-02-4 SMR2000-019_07_02A.FM www.SeaDooManuals.net…
• Page 233
  Section 07 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM) GTI Model 07-02-5 SMR2000-019_07_02A.FM PARTS www.SeaDooManuals.net…
• Page 234
  Section 07 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM) GTX Model 27 N•m (20 lbf•ft) 3.5 N•m (31 lbf•in) Dielectric grease 3.5 N•m (31 lbf•in) F07G03S PARTS 07-02-6 SMR2000-019_07_02A.FM www.SeaDooManuals.net…
• Page 235
  Section 07 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM) GSX RFI and GTX RFI Models 07-02-7 SMR2000-019_07_02A.FM PARTS www.SeaDooManuals.net…

• Page 236: General

  Section 07 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM) GENERAL NOTE: Use the same pump included in the EN- GINE LEAK TESTER KIT (P/N 295 500 352). Whenever repairing the oil injection system, al- ways verify for water infiltration in reservoir. Perform also a pressure test of the oil injection system.

• Page 237: Oil Injection Pump

  Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) OIL INJECTION PUMP 717 Engine 07-03-1 SMR2000-020_07_03A.FM PARTS www.SeaDooManuals.net…

• Page 238
  Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) 787 RFI Engine PARTS 07-03-2 SMR2000-020_07_03A.FM www.SeaDooManuals.net…
• Page 239
  Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) 947 Engine 07-03-3 SMR2000-020_07_03A.FM PARTS www.SeaDooManuals.net…

• Page 240: Oil Pump Identification

  Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) OIL PUMP IDENTIFICATION 947 Engine Remove tuned pipe head. Refer to EXHAUST SYS- Pump Lever TEM. Different engines need different pumps. See iden- 787 RFI and 947 Engines tification on lever. Disconnect oil injection pump cable no.

• Page 241: Adjustment

  Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) Oil Pump Gear Refer to CARBURETOR for throttle cable adjust- ment procedure. Install gear no. 3 to oil injection pump shaft. Torque NOTE: On a twin carburetor engine, make sure lock nut no. 4 to 6 N•m (53 lbf•in). carburetors are properly synchronized.

• Page 242
  Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) 787 RFI Engine All Engines CAUTION: As oil injection pump adjustment is Start and bring engine to normal operating temper- dependent on throttle cable position, make ature. sure to perform throttle cable adjustment first. CAUTION: If watercraft is out of water, engine Loosen jam nut and turn cable adjustment nut to must be cooled using the flush kit.

• Page 243: Checking Operation

  Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) CHECKING OPERATION On Watercraft NOTE: Oil line supply must be full of oil. See bleeding procedure above. Start engine and run at idle while holding the pump lever in fully open position. Oil must advance into small oil lines.

• Page 244
  Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) 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.
• Page 245
  Section 08 ELECTRICAL SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS IGNITION SYSTEM…………………… 08-02-1 GENERAL ……………………… 08-02-1 MULTI-PURPOSE ELECTRONIC MODULE (MPEM)…………08-02-3 IGNITION TIMING ………………….08-02-6 IGNITION SYSTEM TESTING PROCEDURE …………..08-02-13 SPARK PLUGS ……………………08-02-17 CHARGING SYSTEM………………….08-03-1 GENERAL ………………………

• Page 246: Ignition System

  717 Engine The flywheel contains 4 permanent magnets and spins around the generating coil. This electric cur- rent flows to the ignition coil (GTS model) or the Multi-Purpose Electronic Module (GS and GTI models). 1. Trigger coil 08-02-1 SMR2000-021_08_02A.FM…

• Page 247: Ignition Coil

  The secondary winding of the ignition coil steps up the low voltage input to high voltage for both spark plugs. GS and GTI Models The ignition coil steps up the voltage input from the Multi-Purpose Electronic Module to high volt- age current for both spark plugs.

• Page 248: Multi-Purpose Electronic Module (Mpem)

  Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) MULTI-PURPOSE ELECTRONIC A wrong safety lanyard is a safety lanyard which is defective or not programmed in the MPEM MODULE (MPEM) memory. The MPEM is directly powered by the battery. It To better understand the antistart feature, refer to has a micro-processor inside of its sealed case.

• Page 249
  Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) If safety lanyard cap is reconnected within 6 sec- GS and GTI Models onds, the current supply to gauges is cut for a brief On these models, the MPEM is also used as a…
• Page 250
  Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) 787 RFI Engine The MPEM is also used with the Rotax Fuel Injec- tion system. F07H07B 1. Electrical box F07H0BA Electrical Box The high amperage/voltage components are locat- ed into the electrical box. The electrical box can be located either at the front or at the rear of the watercraft.

• Page 251: Ignition Timing

  Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) IGNITION TIMING CAUTION: Never crank engine with spark plugs removed unless spark plug cables are connect- Before checking ignition timing with a stroboscop- ed to the grounding device. ic timing light (dynamic test), it is mandatory to 2.

• Page 252
  Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) All Engines 7. From this point, rotate flywheel clockwise to reach proper specification according to en- 5. Install and adjust a TDC gauge (P/N 295 000 gine. Refer to the following chart. 143) in MAG side spark plug hole.
• Page 253
  Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Dynamic Test To check ignition timing, use Bombardier timing light (P/N 529 031 900). F00H0HA 1. Timing light pick-up 717 Engine 3. Start engine and point timing light straight in line with timing tool slot. Bring engine to 6000 RPM. NOTE: To perform this procedure, make sure to use a stroboscopic timing light rated up to 6000 RPM.
• Page 254
  Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) 787 RFI and 947 Engines 1. Connect an induction-type tachometer (P/N 295 000 100) to spark plug wire. F06H07A 1. Timing light straight in line with tool slot CAUTION: If engine is to be run more than a F06H06A few seconds, engine must be cooled using the flush kit.
• Page 255
  Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) To adjust, loosen 3 armature plate retaining screws Example 2 and slightly rotate armature plate in proper direc- When PTO flywheel mark is on left side of timing tion. tool slot, it indicates retarded timing. NOTE: As a guideline, turn the armature plate the same amount needed to align mark on PTO fly- wheel.
• Page 256
  Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) MPEM Programmer – You estimate the correction should be set to 1° (advanced) to align flywheel mark. Back in NOTE: For more information on the programmer, the chart, look to find 1° (advanced). This refer to the MPEM programmer guide (P/N 219 gives number 4.
• Page 257
  Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Proceed as Follows to Adjust the Fixed Timing Function Ignition Timing with the MPEM 1. Connect the communication cable to the Programmer: MPEM programmer and the other end to the safety lanyard switch on the craft. 1.

• Page 258: Ignition System Testing Procedure

  Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Access the BOSH SYSTEM in the MPEM pro- 3. Electrical connections. grammer, then select ADJUSTMENT in the sub- 4. Engine start/stop switch. menu. 5. Safety lanyard switch. Choose IGNITION in the ADJUSTMENT menu. 6.

• Page 259
  Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Timer Verification METER (+) LEAD METER (-) VALUE The timer is integrated into the MPEM. < 1W Always confirm first that the fuses are in good (ring terminal) (female terminal) condition. RED/PURPLE <…
• Page 260
  Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Generating Coil Verification DYNAMIC TEST 1. Connect spark plug cables to grounding device. 717 Engine 2. Disconnect magneto wiring harness connector. STATIC TEST 3. Install the 4-pin magneto harness adapter (P/N 295 Disconnect magneto wiring harness connector.
• Page 261
  Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) 5. Measure resistance; it should be between 190- Primary Winding 300 ohms. GTS Model Due to the integrated CDI module, it is not possi- ble to take any resistance measurement. GSX RFI and GTX RFI F01H5YA 1.

• Page 262: Spark Plugs

  Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Secondary Winding NOTE: Due to the integrated diode, it is not pos- sible to take any resistance measurement of the secondary winding on the GSX RFI and GTX RFI models. The spark plug caps must be removed from high tension cables, because they are resistor caps.

• Page 263
  Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) The “hot” type plug has a longer insulator nose Spark Plug Analysis and transfers heat more slowly away from its firing end. It runs hotter and burns off combustion de- posits which might tend to foul the plug during prolonged idle or low speed operation.
• Page 264
  Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Spark Plug Chart TORQUE SPARK ENGINE N•m PLUG mm (inch) (lbf•ft) 0.5 — 0.6 787 RFI 24 (17) BR8ES (.020 — .024) NOTE: Refer to next page for NGK Spark Plug Symbol Explanation. 08-02-19 SMR2000-021_08_02A.FM www.SeaDooManuals.net…
• Page 265
  Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) NGK Spark Plug Symbol Explanation CROSSCUTS AND GAP STYLES OF SPARK PLUGS Standard Projected Taper V-Type Surface Type Insulator Type Seat Type Discharge Type A01E1PS 08-02-20 SMR2000-021_08_02A.FM www.SeaDooManuals.net…

• Page 266: Charging System

  Section 08 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) CHARGING SYSTEM 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.

• Page 267
  ADAPTER RESISTANCE to be in the rectifier/regulator. PART NAME WIRE COLOR (Ω) GS, GTS and GTI Models Battery YELLOW with 0.05 — 0.6 If there is no charging at the battery with the pre- charging coil YELLOW/BLACK ceding voltage test, the following test can also be performed.
• Page 268
  Section 08 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) DYNAMIC TEST STATIC TEST: INSULATION 1. Disconnect the magneto wiring harness connec- 1. Disconnect the magneto wiring harness connec- tor. tor. 2. Install the 6-pin magneto harness adapter (P/N 2. Install the 4-pin magneto harness adapter (P/N 295 000 136).

• Page 269: Battery

  Section 08 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) Magneto 6. Repeat test with the BLACK wire and either the RED/BLACK or YELLOW/BLACK wires of the 4- 787 RFI Engines pin magneto harness adapter. STATIC TEST: CONTINUITY 7. If the stator is out of specification, replace it. 1.

• Page 270
  Section 08 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) GTX RFI Model Inspection Remove 4 M6 bolts retaining seat support and re- Visually inspect battery casing for cracks or other move upper section from watercraft. possible damage. If casing is damaged, replace battery and thoroughly clean battery tray and close area with water and baking soda.
• Page 271
  Section 08 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) Battery Storage Disconnect and remove battery from watercraft as explained in Removal. Check electrolyte level in each cell, add distilled water up to upper level line. CAUTION: Do not overfill. The battery must always be stored in fully charged condition.
• Page 272
  Section 08 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) 1. Remove the sealing tube from the vent elbow. 4. Readjust the electrolyte level to the UPPER LEVEL line. WARNING Failure to remove the sealing tube could re- sult in an explosion. 2.
• Page 273
  Section 08 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) 6. Disconnect battery charger. WARNING Always charge battery in a well ventilated area. The time required to charge a battery will vary de- pending on some factors such as: – Battery temperature: The charging time is in- creased as the temperature goes down.

• Page 274: Battery Installation

  Section 08 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) NOTE: Some chargers have a polarity protection WARNING feature which prevents charging unless the charg- Always charge battery(ies) in a well ventilated er leads are connected to the correct battery ter- area. minals.

• Page 275: Starting System

  Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) STARTING SYSTEM 717 Engine PARTS 08-04-1 SMR2000-023_08_04A.FM www.SeaDooManuals.net…

• Page 276
  Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) 787 RFI Engine PARTS 08-04-2 SMR2000-023_08_04A.FM www.SeaDooManuals.net…
• Page 277
  Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) 947 Engine PARTS 08-04-3 SMR2000-023_08_04A.FM www.SeaDooManuals.net…

• Page 278: General

  Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) GENERAL MPEM If 2 short beeps are not heard when installing the Causes of troubles are not necessarily related to safety lanyard, refer to DIGITALLY ENCODED SE- starter but may be due to a burnt fuse, faulty bat- CURITY SYSTEM.

• Page 279: Starting System Troubleshooting

  Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) 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.

• Page 280: Starter Removal

  Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) 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.

• Page 281
  Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) 947 Engine Locate index marks on yoke no. 1 and end covers no. 3 and no. 10. 1. Thrust washers Remove the other end cover no. 10 and gasket. 1. Index marks Remove the three washers no.

• Page 282: Cleaning

  Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) Release brush wires of yoke from brush holder Remove brushes. no. 2. To remove bearing and seal in end cover, release Remove brush holder no. 2. tabs of retainer. F06H1KA 1. Retainer 1.

• Page 283: Parts Inspection

  Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) 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.

• Page 284
  Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) 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.

• Page 285: Starter Installation

  Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) 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.

• Page 286
  Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) 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. GTX MODEL 1. Torque nut to 6 N•m (53 lbf•in), apply dielectric grease and install protection cover 2.

• Page 287: Starter Specification

  Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) STARTER SPECIFICATION 717 and 787 RFI Engines 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.

• Page 288: Instruments And Accessories

  Section 08 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) INSTRUMENTS AND ACCESSORIES GENERAL Water Temperature Sensor GTX, GSX RFI and GTX RFI It is possible to activate the instruments when the engine is not running. The water temperature sensor is integrated with the speed sensor located on the ride plate.

• Page 289
  Section 08 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) Tachometer (90 mm) The paddle wheel is protected by the pick-up housing. XP Model F01H3VA 1. Pick-up housing 2. Paddle wheel To check if the speed sensor is operational, dis- connect the speed sensor connector housing from inside bilge.
• Page 290
  Section 08 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) Speedometer (90 mm) This is a LCD multifunction gauge. It features the following functions: XP, GTI, GTX RFI and GTX Models – fuel level – low fuel level – low oil level –…
• Page 291
  Section 08 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) CLOCK SETTING While in the clock mode, press and hold both MODE and SET buttons for 2 seconds. The clock will blink to confirm the setting mode. Press the MODE button to adjust the hours and the SET button to adjust the minutes.
• Page 292
  Section 08 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) WATER TEMPERATURE LOW FUEL RESISTANCE FUEL LEVEL Disconnect the 2-circuit connector housing of the LEVEL RED (Ω) LCD GRAPHIC LIGHT Info Center which contains a BLACK/ORANGE and TAN/ORANGE wires. 0 + 2.2 FULL Connect potentiometer test probes to the BLACK/ 17.8 ±…
• Page 293
  95 ± 4 Fuel/Oil Gauge/Low Oil Warning Light (56 mm) GS, GTS, GTI and XP Models The fuel gauge has a pointer which indicates fuel level in the tank. The low oil warning light is part of the gauge. It will light when injection oil level is low.
• Page 294
  Section 08 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) Accuracy of gauge can be checked with a potenti- Fuel Baffle Pick Up Sender ometer. All Models Except GTX RFI and GSX RFI – Disconnect 2-circuit connector housing of The baffle pick-up has an integrated fuel sender. BROWN/BLACK and BROWN/WHITE wires of To verify fuel sender, a resistance test should be gauge.
• Page 295
  Section 08 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) FUEL LEVEL AND RESISTANCE (GS, GTI 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 ±…
• Page 296
  Section 08 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) When there is enough oil inside the oil tank (and VTS Switch therefore in the sensor reservoir), the sensor de- GSX RFI and XP Models tects the liquid and the light DOES NOT turn on. Always confirm first that the fuse is in good con- When the oil level goes at critical LOW level inside dition.
• Page 297
  Section 08 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) 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…

• Page 298: Digitally Encoded Security System

  Section 08 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM) DIGITALLY ENCODED SECURITY SYSTEM GENERAL The Digitally Encoded Security System (DESS) features an anti-start protection against unautho- rized use of the watercraft. The following components are specially designed for this system: Multi-Purpose Electronic Module (MPEM), safety lanyard cap and safety lanyard switch.

• Page 299
  Section 08 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM) Basic Self-Diagnostic Mode It is self-activated when the safety lanyard cap is being installed on the watercraft switch. It gives imme- diate monitoring. Some codes may occur only when pressing the start/stop button. Refer to the following chart.
• Page 300
  Section 08 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM) Advanced Self-Diagnostic Mode It needs to be enabled manually. Proceed as follows: 1. Remove safety lanyard cap from watercraft switch. 2. Press 5 times on the watercraft start/stop button. NOTE: 1 short beep and 1 long beep must be heard. They validate beginning of diagnostic mode. 3.
• Page 301
  Section 09 PROPULSION SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS JET PUMP ……………………..09-02-1 GENERAL ……………………… 09-02-2 JET PUMP INSPECTION ON WATERCRAFT …………..09-02-2 REMOVAL……………………… 09-02-5 DISASSEMBLY……………………09-02-6 CLEANING ……………………. 09-02-9 PARTS INSPECTION ………………….09-02-9 ASSEMBLY……………………. 09-02-12 PUMP PRESSURIZATION ………………..09-02-19 INSTALLATION ……………………

• Page 302: Jet Pump

  Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) JET PUMP PARTS 09-02-1 SMR2000-026_09_02A.FM www.SeaDooManuals.net…

• Page 303: General

  Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) GENERAL WATERCRAFT IMPELLER MATERIAL PITCH MODEL The jet pump housing is made of plastic. It is a one piece plastic unit, including the stator. Progressive Stainless 204 160 072 pitch The jet pump housing and the stator are made of steel 11°…

• Page 304
  Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) Impeller Condition Condition of impeller no. 20, boot no. 15 and ring no. 16 can be quickly checked from underneath of the watercraft. Remove grate and look through water inlet opening. F01J0EA TYPICAL —…
• Page 305
  Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) All Models Oil Replacement Remove 4 screws retaining venturi to jet pump Remove venturi as described in Oil Inspection. housing. Remove 3 screws retaining cover. GTI and GTX Remove reverse gate and support. All Models Pull nozzle and venturi from jet pump housing.

• Page 306: Removal

  11. Disconnect steering cable from jet pump nozzle Remove 4 retaining screws and withdraw venturi. no. 5. GS, GTS, GTI and GTX Remove 2 retaining screws no. 1, 2 sleeves no. 2, 2 washers no. 4. F02J0TA 1.

• Page 307: Disassembly

  Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) All Models Except GTS DISASSEMBLY Disconnect steering cable from jet pump nozzle. NOTE: Whenever removing a part, visually check Loosen 4 hexagonal nuts no. 6 and remove flat for damage such as: corrosion, crack, split, break, washers and lock washers from jet pump housing.

• Page 308
  Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) All Models Cover With pump assembly in horizontal position, remove 3 retaining screws no. 19. Place container under cover no. 18 to catch oil. Using a fiber hammer, gently tap cover to release it from jet pump housing.
• Page 309
  Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) 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 Push ring so that it can collapse internally.

• Page 310: Cleaning

  Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) CLEANING Examine impeller in wear ring for distortion. Check if blade tips are blunted round, chipped or All Models broken. Such impeller is unbalanced and will vi- Sealant on the jet pump housing can be removed brate and damage wear ring, impeller shaft, shaft with a wire brush (disc) mounted on a drill or a seal or bearings.

• Page 311
  Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) Needle Bearing and Impeller Shaft WEAR Inspect needle bearings no. 23 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.
• Page 312
  Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) Thrust Washer and Thrust Bearing Visually inspect thrust washer no. 25, thrust bear- ing no. 26 and their contact surface. Check for scoring, pitting, flaking, discoloration or other evi- dence of wear. For best inspection, use a 7X mag- nifying glass to check wear pattern.

• Page 313: Assembly

  Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) Anti-Rattle Pusher Check for melted plastic around metal pad. If so, replace it. Check for excessive wear of pad. Seal Carefully inspect seal lips. Make sure that lips are not worn, distorted, cracked or show signs of any other damage.

• Page 314
  Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) GTX and XP models Manually engage ring in housing making sure it is equally inserted all around. Press ring until it seats into bottom of housing. Install retaining screws. Seal and Needle Bearing Bearings no.
• Page 315
  Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) Bearing on impeller side must be 1.5 to 2.5 mm (.060 — .100 in) inside reservoir measured from seal seat. Bearing on venturi side must be 2 to 4 mm (.080 — .157 in) inside reservoir measured from thrust washer seat.
• Page 316
  Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) Thrust Washer CAUTION: Prevent sealant from contacting any needles of bearing. Position jet pump housing no. 9 with the stator Push on tool end with a press until tool flange con- vanes on top. tacts housing.
• Page 317
  Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) Impeller Shaft Apply Loctite 243 (blue) to shaft threads. To prevent seal lip damage when inserting impel- ler shaft, use impeller shaft guide (P/N 295 000 002). F01J1OA Insert tool onto shaft end then carefully install F00J0GA shaft in jet pump housing.
• Page 318
  Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) Install impeller remover/installer tool into impeller Anti-rattle System splines and tighten. Install spring no. 17 on slider no. 28. F00J08A 1. Impeller remover/installer tool CAUTION: Make sure thrust washer and bear- 1. Spring ing are not wedged in shaft groove.
• Page 319
  Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) Install pusher no. 29 into cover. Place the flat side Place housing horizontally as in its operating posi- in front of slider tab. tion so that filler plug is located on top. Remove filler plug from cover.

• Page 320: Pump Pressurization

  O-Rings leaking through porosity and has to be replaced. GS, XP, GTI, and GTX Jet pump unit has to be disassembled. If jet pump has been overhauled, the impeller shaft seal Install O-rings no.

• Page 321: Installation

  F01J0IA 1. Bailer tubes 2. Water supply hose Nozzle GS, GTS, GTI and GTX Insert bushings no. 3 in nozzle no. 5, positioning their flanges from inside of nozzle. Insert sleeves no. 2 in bushings no. 3. F01J21B 1.

• Page 322: Steering Cable

  Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) XP Model Install nozzle/trim ring assembly. Torque screws to 14 N•m (10 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.

• Page 323: Drive System

  Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) DRIVE SYSTEM GS, GTS and GTI Models PARTS 09-03-1 SMR2000-027_09_03A.FM www.SeaDooManuals.net…

• Page 324
  Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) GTX, GSX RFI and GTX RFI Models PARTS 09-03-2 SMR2000-027_09_03A.FM www.SeaDooManuals.net…
• Page 325
  Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) XP Model 09-03-3 SMR2000-027_09_03A.FM PARTS www.SeaDooManuals.net…

• Page 326: General

  Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) 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 All Models Except XP Remove seat(s). Remove vent tube support or seat support (except GTS model).

• Page 327
  Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) All Models Except the 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.
• Page 328
  Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) 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. TYPICAL F08I04A 1.
• Page 329
  Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) Loosen bolts and lock nuts retaining the lower sup- port of the shock absorber. F08L12A 1. Loosen gear clamp F08Q01A Tilt seat. TYPICAL Remove front drive shaft. 1. Remove bolts and lock nuts Loosen 4 screws and remove bottom cover of Seal Carrier of Mid Bearing seat.

• Page 330: Inspection

  Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) 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).

• Page 331: Assembly

  Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) Boot Measure boot free length. Subtract the installed length measurement from To verify the preload of the boot no. 10, proceed the free length measurement. A difference of 4 mm as follows: to 12 mm (5/32 in to 15/32 in) should be obtained.

• Page 332
  Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) Install bearing no. 16 with the bearing/seal install- er tool (P/N 295 000 107). 1. Double-lip seal toward engine F01J51A 2. Double-lip seal with protector toward jet pump 3. Raised edge of lip outwards 1.

• Page 333: Installation

  Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) INSTALLATION Installation is essentially the reverse of removal procedure. However, pay particular attention to the following. XP Model Seal Carrier of Mid Bearing Properly index flanges no. 22 together. Install support plate at rear of watercraft. Install seal carrier and hand tighten nuts no.

• Page 334
  Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) Place grease fitting on the top and torque seal car- Insert drive shaft through carbon ring no. 8 and rier nuts no. 21 in a criss-cross sequence in 2 steps floating ring no. 6. as per following illustration.
• Page 335
  Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) All Models Except the XP – Squeeze pliers. When both large and small win- dows are directly over the 2 locking hooks, Large Clamp press those windows down to engage hooks in Secure large clamp no.

• Page 336: Lubrication

  Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) LUBRICATION PTO Flywheel All Models Except the XP 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.

• Page 337: Reverse System

  Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) REVERSE SYSTEM GTS Model 09-04-1 SMR2000-028_09_04A.FM PARTS www.SeaDooManuals.net…

• Page 338: General

  Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) GENERAL It is not necessary to remove reverse system from watercraft for servicing. However reverse system re- moval is necessary to replace reverse support. DISASSEMBLY Remove storage tray from watercraft. Press on vent tube upper part to enable to with- draw tube from body.

• Page 339: Assembly

  Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) Remove 2 Allen screws, lock nut and washer hold- ing guide plate and support. F02J09A 1. Screw (each side) TYPICAL ASSEMBLY 1. Guide plate 2. Allen screw 3. Screw and washer Assembly is essentially the reverse of disassem- bly procedures.

• Page 340
  Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) Reverse Support Shift Lever For installation of reverse support no. 6, torque NOTE: Always install shift lever no. 3 with its screw to 8 N•m (71 lbf•in) and Allen screws to open end facing left side of watercraft, then push 2 N•m (18 lbf•in).

• Page 341: Adjustment

  Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) Shift Lever Lubrication Pull shift lever in REVERSE position. Lubricate sliding block support sliding area and tri- angular lever with synthetic grease. Also, lubricate sliding washer and shift lever stem. F02J0GA TYPICAL 1.

• Page 342
  Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) If reverse gate needs to be readjusted, it can be done at support with adjustment nuts. Turn cable nuts to obtain position. NOTE: If reverse gate adjustment is not done ad- equately, performance and steering control will be reduced at reverse position.
• Page 343
  Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) GTI, GTX and GTX RFI Models 09-04-7 PARTS SMR2000-028_09_04A.FM www.SeaDooManuals.net…

• Page 344: Disassembly

  Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) 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.

• Page 345: Inspection

  Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) Remove bolt no. 12 and lock nut no. 13 retaining Reverse Cable Support reverse cable end to interior lever no. 11. Unscrew bolts no. 18 and remove retaining block no. 17. Detach adjustment nut no. 23 from re- verse cable support no.

• Page 346
  Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) Interior Lever and Shift Lever Reverse Gate Install the interior lever no. 11 in a rotating move- When installing the reverse gate, pay attention to ment. Engage properly the interior lever tabs in the position its lever behind the reverse gate support shift lever slots.

• Page 347: Adjustment

  Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) ADJUSTMENT Put shift lever in forward position. Pull shift lever approximately 50 mm (2 in) and push it back slowly in forward position. The pawl lock no. 7 should be engaged in the an- chor no.

• Page 348: Variable Trim System

  Section 09 PROPULSION SYSTEM Subsection 05 (VARIABLE TRIM SYSTEM) VARIABLE TRIM SYSTEM GSX RFI and XP Models 09-05-1 SMR2000-029_09_05A.FM PARTS www.SeaDooManuals.net…

• Page 349: General

  Section 09 PROPULSION SYSTEM Subsection 05 (VARIABLE TRIM SYSTEM) GENERAL All Models Disconnect wiring harnesses. To test VTS control module, motor or switch, refer Pull out VTS assembly no. 6 from bilge. to INSTRUMENTS AND ACCESSORIES. To have access to VTS module, remove seat (ex- DISASSEMBLY cept XP).

• Page 350: Inspection

  Section 09 PROPULSION SYSTEM Subsection 05 (VARIABLE TRIM SYSTEM) INSPECTION Install motor, worm and sliding shaft in VTS hous- ing. Boot Make sure boot no. 3 is in good condition. If it is cracked or teared, replace boot. Worm Inspect threads and splines of worm no. 9 for wear.

• Page 351: Adjustment

  Section 09 PROPULSION SYSTEM Subsection 05 (VARIABLE TRIM SYSTEM) Apply Loctite Primer N (P/N 293 800 041) to threads NOTE: Activate timer to be able to position VTS. of VTS housing and Loctite 243 (blue) to nut no. 4. Install nut with sealing washer and torque to 6 N•m (53 lbf•in) using the VTS socket tool.

• Page 352
  Section 10 STEERING SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS STEERING SYSTEM ………………….10-02-1 REMOVAL AND INSTALLATION ………………10-02-2 DISASSEMBLY……………………10-02-6 ASSEMBLY……………………. 10-02-9 DISASSEMBLY ……………………10-02-12 ASSEMBLY……………………. 10-02-15 ADJUSTABLE STEERING ………………… 10-03-1 DISASSEMBLY……………………10-03-2 ASSEMBLY……………………. 10-03-6 ALIGNMENT …………………….. 10-04-1 10-01-1 SMR2000-030_10_01ATOC.FM…

• Page 353: Steering System

  Section 10 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) STEERING SYSTEM GTS Model PARTS 10-02-1 SMR2000-030_10_02A.FM www.SeaDooManuals.net…

• Page 354: Removal And Installation

  Section 10 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) REMOVAL AND INSTALLATION When installing the grip insert in the handlebar no. 29, ensure that it is properly inserted in the slot at the end of the handlebar tubing. Steering Cover To replace the cover, loosen set screws no. 30 of handlebar housing.

• Page 355
  Section 10 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) NOTE: It is not necessary to disconnect steering CAUTION: Always install large flat washer with cable to remove handlebar and steering stem. the X stamped side facing the lock washer. Inspect bushings no. 28 for wear, cracks, scoring, etc.
• Page 356
  Section 10 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) Disconnect rear ball joint no. 22 of steering cable at jet pump nozzle; then, remove ball joint. From bilge, unscrew nut no. 24 retaining steering cable to hull. Remove half rings no. 25, rubber washer no. 26 and retaining ring no.
• Page 357
  Section 10 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) GS, GSX RFI, GTI and GTX Models PARTS 10-02-5 SMR2000-030_10_02A.FM www.SeaDooManuals.net…

• Page 358: Disassembly

  Section 10 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) 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.

• Page 359
  Disconnect the throttle and choke cables from car- buretor levers. Disconnect the wiring harnesses leading out of steering stem and cut locking tie. F07K03A 1. Steering support 2. Bolts Remove cable support no. 8. GS AND GSX 1. Locking tie 2. Connectors 10-02-7 SMR2000-030_10_02A.FM www.SeaDooManuals.net…
• Page 360
  Section 10 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) GTI AND GTX F07K07A 1. Tie rap 2. Connectors 1. Steering support 2. Bolt Disconnect the steering cable from the steering 3. Lock nut stem arm no. 15. Remove steering support no. 12 with handlebar, wiring harnesses and cables.

• Page 361: Assembly

  Section 10 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) Steering Cable Install flat washer no. 23 and screw no. 3. Torque screw to 7 N•m (62 lbf•in). Disconnect steering cable no. 24 from steering stem arm no. 15. Install cap no. 2. Remove retaining block no.

• Page 362
  GTX Model TYPICAL 1. Ball joint on top of steering arm 2. Torque nut to 7 N•m (62 lbf•in) GS and GTI Models F00J01A TYPICAL 1. Bolt 2. Flat washers 3. Lock nut. Torque to 2 N•m (18 lbf•in)
• Page 363
  Section 10 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) XP Model PARTS 10-02-11 SMR2000-030_10_02A.FM www.SeaDooManuals.net…

• Page 364: Disassembly

  Section 10 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) DISASSEMBLY Remove 2 screws no. 9 and flat washers each side of cover. Handle Grip and Grip Insert To remove handle grip no. 1, pull out cap no. 2 from grip end and remove screw no. 3 and washer no.

• Page 365
  Section 10 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) 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. F08K06A 1. Remove link rod Remove bolt no.
• Page 366
  Section 10 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) 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. Loosen bolts Steering Stem Loosen nuts and bolts retaining steering support Disconnect wiring harnesses, choke and throttle no.

• Page 367: Assembly

  Section 10 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) Remove retaining block no. 20. 1. Apply synthetic grease F08K0KA Steering Stem Arm and Support 1. Cable Support 2. Remove M6 bolts Position steering stem arm no. 15 and support no. 16 onto steering stem no. 14. Disconnect ball joint no.

• Page 368
  Section 10 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) Install flat washer no. 4 and screw no. 3. Torque screw to 7 N•m (62 lbf•in). WARNING Correct torque must be strictly followed. 1. Grip insert 2. Grip 3. Flat washer 4. Torque screw to 7 N•m (62 lbf•in) 5.

• Page 369: Adjustable Steering

  Section 10 STEERING SYSTEM Subsection 03 (ADJUSTABLE STEERING) ADJUSTABLE STEERING PARTS 10-03-1 SMR2000-030_10_03A.FM www.SeaDooManuals.net…

• Page 370: Disassembly

  Section 10 STEERING SYSTEM Subsection 03 (ADJUSTABLE STEERING) DISASSEMBLY Adjustment Handle Set handle bar to its lowest position by turning ad- justment handle no. 26 counterclockwise. While holding adjustment handle no. 26, turn sup- port bushing no. 28 clockwise. 1. Set screw Pull handle bar housings to disengage from steer- ing cover.

• Page 371
  Section 10 STEERING SYSTEM Subsection 03 (ADJUSTABLE STEERING) Remove 2 screws no. 20 each side of cover. Handle Bar Remove 4 elastic stop nuts M8 retaining steering clamp no. 31. 1. Remove screws 2. Upper cover 3. Lower cover 4. Adjuster screws Remove both upper and lower steering covers.
• Page 372
  Section 10 STEERING SYSTEM Subsection 03 (ADJUSTABLE STEERING) Cable Support Loosen bolts no. 9 and remove retaining block no. 10 holding cable adjusting nut to cable support no. 8. F07K03A RIGHT SIDE 1. Steering support 2. Bolts From inside bilge, pull down cable support no. 8 to detach it from steering support no.12.
• Page 373
  Section 10 STEERING SYSTEM Subsection 03 (ADJUSTABLE STEERING) Disconnect the wiring harnesses leading out of steering stem and cut locking tie. Disconnect the steering cable from the steering stem arm no. 15. F07K07A 1. Steering support 2. Bolt 3. Lock nut Remove bolts no.

• Page 374: Assembly

  Section 10 STEERING SYSTEM Subsection 03 (ADJUSTABLE STEERING) Steering Stem and Steering Support Unscrew nut and remove pivot bolt no. 25 retaining steering support no. 24 to steering stem no. 19. Remove adjuster screw from block and detach steering support from steering stem. Unscrew threaded pivots to remove threaded block from steering stem no.

• Page 375
  Section 10 STEERING SYSTEM Subsection 03 (ADJUSTABLE STEERING) Install steering support no. 24 to steering stem no. 19 and secure with pivot bolt no. 25. Install nut and torque to 26 N•m (19 lbf•ft). 1. Pad must not exceed stopper Position handle bar no.

• Page 376: Alignment

  Section 10 STEERING SYSTEM Subsection 04 (ALIGNMENT) ALIGNMENT 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. F01K07A TYPICAL 1.

• Page 377
  Section 10 STEERING SYSTEM Subsection 04 (ALIGNMENT) XP Model To have access to the cable adjustment nut, open upper storage compartment cover and remove storage basket. 1. Remove storage basket TYPICAL — XP MODEL 1. Support 2. Adjustment nut 3. Loosen bolts After adjustment, torque retaining block bolts to 6 N•m (53 Ibf•in).
• Page 378
  Section 11 SUSPENSION Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS DIRECT ACTION SUSPENSION……………….. 11-02-1 REMOVAL …………………….. 11-02-2 INSPECTION ……………………11-02-3 ASSEMBLY……………………. 11-02-3 11-01-1 SMR2000-031_11_01ATOC.FM www.SeaDooManuals.net…

• Page 379: Direct Action Suspension

  Section 11 SUSPENSION Subsection 02 (DIRECT ACTION SUSPENSION) DIRECT ACTION SUSPENSION XP Model PARTS 11-02-1 SMR2000-031_11_02A.FM www.SeaDooManuals.net…

• Page 380: Removal

  Section 11 SUSPENSION Subsection 02 (DIRECT ACTION SUSPENSION) 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.

• Page 381: Inspection

  Section 11 SUSPENSION Subsection 02 (DIRECT ACTION SUSPENSION) Tilt seat upward. Install shock absorber/coil spring assembly in spring compressor tool. Loosen upper gear clamp no. 9 of inner boot no. 5. F08L13A 1. Loosen gear clamp F05L0NA Remove bolt no. 10 and lock nut no. 11 from Compress spring and remove cup no.

• Page 382
  Section 12 HULL/BODY Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS ADJUSTMENT AND REPAIR ………………..12-02-1 SEAT ADJUSTMENT………………….12-02-15 STORAGE COMPARTMENT COVER ADJUSTMENT …………12-02-16 ACCESS PANEL ADJUSTMENT ………………12-02-17 INLET GRATE ……………………12-02-17 RIDING PLATE……………………12-02-17 JET PUMP SUPPORT ………………….12-02-19 DEFLECTOR ……………………

• Page 383: Adjustment And Repair

  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) ADJUSTMENT AND REPAIR GTS Model (bow) PARTS 12-02-1 SMR2000-032_12_02A.FM www.SeaDooManuals.net…

• Page 384
  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GTS Model (stern) PARTS 12-02-2 SMR2000-032_12_02A.FM www.SeaDooManuals.net…
• Page 385
  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GS and GSX RFI Models (bow) PARTS 12-02-3 SMR2000-032_12_02A.FM www.SeaDooManuals.net…
• Page 386
  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GS and GSX RFI Models (stern) PARTS 12-02-4 SMR2000-032_12_02A.FM www.SeaDooManuals.net…
• Page 387
  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GTI, GTX RFI and GTX Models (bow) PARTS 12-02-5 SMR2000-032_12_02A.FM www.SeaDooManuals.net…
• Page 388
  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GTI, GTX RFI and GTX Models (stern) PARTS 12-02-6 SMR2000-032_12_02A.FM www.SeaDooManuals.net…
• Page 389
  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GTI, GTX RFI and GTX Models (cover) PARTS 12-02-7 SMR2000-032_12_02A.FM www.SeaDooManuals.net…
• Page 390
  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GTI, GTX RFI and GTX Models (seat) PARTS 12-02-8 SMR2000-032_12_02A.FM www.SeaDooManuals.net…
• Page 391
  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) XP Model (bow) PARTS 12-02-9 SMR2000-032_12_02A.FM www.SeaDooManuals.net…
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  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) XP Model (stern) PARTS 12-02-10 SMR2000-032_12_02A.FM www.SeaDooManuals.net…
• Page 393
  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) XP Model (seat) PARTS 12-02-11 SMR2000-032_12_02A.FM www.SeaDooManuals.net…
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  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) XP Model (suspension) PARTS 12-02-12 SMR2000-032_12_02A.FM www.SeaDooManuals.net…
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  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) XP Model (front cover) PARTS 12-02-13 SMR2000-032_12_02A.FM www.SeaDooManuals.net…
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  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) XP Model (rear cover) 12-02-14 PARTS SMR2000-032_12_02A.FM www.SeaDooManuals.net…

• Page 397: Seat Adjustment

  1. Lock pin 2. Adjustment nut (Loctite 271) A. 39 ± 1 mm (1-35/64 ± 3/64 in) GS AND GSX RFI MODELS 1. Lock pin 2. Adjustment nut (apply Loctite 271) A. 33.5 ± 1 mm (1-5/16 ± 3/64 in) GTI, GTX RFI AND GTX MODELS —…

• Page 398: Storage Compartment Cover Adjustment

  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) STORAGE COMPARTMENT COVER ADJUSTMENT Adjust lock pin no. 3 as per following specifica- tions: F07L09A GTI, GTX RFI AND GTX MODELS 1. Lock pin (apply Loctite 243) 2. Rubber washer 3. Flat washers A.

• Page 399: Access Panel Adjustment

  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) ACCESS PANEL ADJUSTMENT RIDING PLATE XP Model Removal Adjust lock pin no. 3 of access panel as per follow- All Models Except some GTX ing specifications: Remove inlet grate. Remove jet pump. Refer to JET PUMP. Remove the speed sensor from the riding plate (if applicable).

• Page 400
  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) F07L0DA Cleaning GS, GTI , GTX, GSX RFI AND GTX RFI MODELS Scrape off all excess of sealant from riding plate and hull. Clean hull surface with acetone based solvent to eliminate grease, dust and any residue of sealant.

• Page 401: Jet Pump Support

  Fol- low also the torquing sequence as shown in the same illustrations. F05K02A GS MODEL TYPICAL 1. Unscrew nut Remove ball joint, boot, nut, half rings and O-rings from reverse cable (GTI, GTX RFI and GTX models).

• Page 402: Deflector

  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) DEFLECTOR GS, GTI and GTX Models Removal Using a heat gun, heat deflector and pry it using a piece of wood. Installation Apply Loctite The Right Stuff Gasket as indicated by the shaded area in the following illustration.

• Page 403: Seat Removal

  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) SEAT REMOVAL XP Model Loosen 4 screws and remove bottom cover no. 17 of seat. F08L13A 1. Gear clamp Remove bolt and lock nut from shock absorber up- per support. F08L11A 1. Remove cover Loosen gear clamp of outer boot;…

• Page 404: Seat Cover Replacement

  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) SEAT COVER REPLACEMENT 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.

• Page 405: Sponson Replacement

  XP Model Remove seat (access cover for the XP). Disconnect throttle and choke cables at carburetor Remove air vent tube support (GS and GSX RFI). linkage. Remove seat support (GTI, GTX RFI and GTX). Disconnect wiring harnesses of start/stop button, monitoring beeper, safety lanyard switch and Remove muffler.

• Page 406: Decals Replacement

  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) DECALS REPLACEMENT Using a pencil and the decal as a template mark the area where decal will be located. Removal For better adhesion a dry application is recom- mended, however, to ease decal installation a mild Using a heat gun warm up one end of decal for a solution of soapy water can be sprayed over sur- few seconds until decal can roll off when rubbing…

• Page 407
  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) 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 through regular channel. paper until you come close to the original surface. Remove dust with a water soaked cloth and con- WARNING tinue sanding with a 400-grit wet paper.
• Page 408
  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) PREPARING THE SURFACES BUFFING AND WAXING Buff the surface using a heavy duty polisher with Small Fractures a buffing pad. Make sure the pad is free of dirt or Open the cracks up with a sharp triangular can you may damage the gelcoat.

• Page 409: Tools And Materials List

  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) PATCHING THE REPAIR AREA TOOLS AND MATERIALS LIST Outside Tools The outside should be done first. Wipe clean the – safety glasses area with acetone on a cloth, then mask off area. For a small crack use an epoxy filler in the same –…

• Page 410: Thru-Hull Fitting Installation

  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) THRU-HULL FITTING INSTALLATION For hull insert repair proceed as follows: Cut plastic hull insert flush with hull using a saw. 1. Knurled surface 2. Inner bore Install aluminum insert into plastic hull insert. NOTE: Align aluminum insert as much as possible with PTO flywheel.

• Page 411
  Section 13 TECHNICAL DATA Subsection 01 (GS MODEL) GS MODEL ENGINE GS (5644/5827) Engine type BOMBARDIER-ROTAX 717 Induction type Rotary valve Type Water cooled, water injected Exhaust system Water injection fitting (head) 3.5 mm (.139 in) Water injection fitting (cone) 3.5 mm (.139 in)
• Page 412
  Section 13 TECHNICAL DATA Subsection 01 (GS MODEL) ELECTRICAL GS (5644/5827) Magneto generator output 160 W @ 6000 RPM Ignition system type Digital CDI Make and type NGK BR8ES Spark plug 0.5 — 0.6 mm (.020 — .024 in) mm (in) 2.59 ±…
• Page 413
  Section 13 TECHNICAL DATA Subsection 01 (GS MODEL) PROPULSION GS (5644/5827) 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…
• Page 414
  Section 13 TECHNICAL DATA Subsection 01 (GS MODEL) MATERIALS GS (5644/5827) Hull Composite Inlet grate Aluminum Impeller housing/stator/venturi/nozzle Plastic/plastic/plastic/aluminum Air intake silencer Thermoplastic Flame arrester Multi-layer wire screen Steering padding Thermoplastic Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat Polyurethane foam…
• Page 415
  Section 13 TECHNICAL DATA Subsection 01 (GS MODEL) TIGHTENING TORQUES GS (5644/5827) Exhaust manifold screw 24 N•m (17 lbf•ft) Magneto flywheel nut 145 N•m (107 lbf•ft) Flywheel (PTO side) 110 N•m (81 lbf •ft ) 24 N•m (17 lbf•ft) (3) (4) Crankcase screws 40 N•m…
• Page 416
  Section 13 TECHNICAL DATA Subsection 02 (XP MODEL) XP MODEL ENGINE XP (5651/5655) Engine type BOMBARDIER-ROTAX 947 Induction type Reed valve Type Water cooled, water injected with regulator Water injection fitting 3.5 mm (.139 in) (head) Exhaust system Water injection fitting Not applicable (cone) Water injection fitting…
• Page 417
  Section 13 TECHNICAL DATA Subsection 02 (XP MODEL) ELECTRICAL XP (5651/5655) Magneto generator output 180 W @ 6000 RPM Ignition system type Digital DC-CDI Make and type NGK BR8ES Spark plug 0.5 — 0.6 mm (.020 — .024 in) mm (in) 2.99 (.118) Ignition timing (BTDC) Degrees…
• Page 418
  Section 13 TECHNICAL DATA Subsection 02 (XP MODEL) PROPULSION XP (5651/5655) Propulsion system BOMBARDIER Formula Pump Jet pump type Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive Coupling type Split FR and RR SEA-DOO JET PUMP SYNTHETIC Oil type POLYOLESTER OIL 75W90 GL5 Steering nozzle pivoting angle…
• Page 419
  Section 13 TECHNICAL DATA Subsection 02 (XP MODEL) MATERIALS XP (5651/5655) Hull Composite Inlet grate Aluminum Impeller housing/stator/venturi/nozzle Plastic/plastic/aluminum/aluminum Air intake silencer Thermoplastic Flame arrester Tubular wire screen Steering padding Elastomer thermoplastic with polystyrene foam Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat Polyurethane foam…
• Page 420
  Section 13 TECHNICAL DATA Subsection 02 (XP MODEL) TIGHTENING TORQUES XP (5651/5655) Exhaust manifold screw 40 N•m (30 lbf•ft) Magneto flywheel nut 115 N•m (85 lbf•ft) Flywheel (PTO side) 115 N•m (85 lbf•ft) 27 N•m (20 lbf•ft) (3) (4) Crankcase screws 40 N•m (30 lbf•ft) (3) (4)
• Page 421
  Section 13 TECHNICAL DATA Subsection 03 (GTS MODEL) GTS MODEL ENGINE GTS (5639) 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) Water injection fitting 3.5 mm (.139 in) (cone) Starting system Electric start…
• Page 422
  Section 13 TECHNICAL DATA Subsection 03 (GTS MODEL) ELECTRICAL GTS (5639) Magneto generator output 160 W @ 6000 RPM Ignition system type Digital CDI Make and type NGK BR8ES Spark plug 0.5 — 0.6 mm (.020 — .024 in) mm (in) 2.59 (.102) Ignition timing (BTDC) Degrees…
• Page 423
  Section 13 TECHNICAL DATA Subsection 03 (GTS MODEL) PROPULSION GTS (5639) 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…
• Page 424
  Section 13 TECHNICAL DATA Subsection 03 (GTS MODEL) MATERIALS GTS (5639) Hull Composite Inlet grate Plastic Impeller housing/stator/venturi/nozzle Plastic/plastic/plastic/plastic Air intake silencer Thermoplastic Flame arrester Multi-layer wire screen Steering padding Elastomer thermoplastic with polystyrene foam Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat Polyurethane foam…
• Page 425
  Section 13 TECHNICAL DATA Subsection 03 (GTS MODEL) TIGHTENING TORQUES GTS (5639) Exhaust manifold screws 24 N•m (17 lbf•ft) Magneto flywheel nut 145 N•m (107 lbf•ft) Flywheel (PTO side) 110 N•m (81 lbf•ft) 24 N•m (17 lbf•ft) (3) (4) Crankcase screws 40 N•m (30 lbf•ft) (3) (4)
• Page 426
  Section 13 TECHNICAL DATA Subsection 04 (GTI AND GTX MODELS) GTI AND GTX MODELS ENGINE GTI (5647/5657) GTX (5653/5669) Engine type BOMBARDIER-ROTAX 717 BOMBARDIER-ROTAX 947 Induction type Rotary valve Reed valve Water cooled, water injected Type Water cooled, water injected with regulator Water injection fitting (head) 3.5 mm (.139 in)
• Page 427
  Section 13 TECHNICAL DATA Subsection 04 (GTI AND GTX MODELS) ELECTRICAL GTI (5647/5657) GTX (5653/5669) Magneto generator output 160 W @ 6000 RPM 180 W @ 6000 RPM Ignition system type Digital CDI Digital DC-CDI Make and type NGK BR8ES Spark plug 0.5 — 0.6 mm (.020 — .024 in) mm (in)
• Page 428
  Section 13 TECHNICAL DATA Subsection 04 (GTI AND GTX MODELS) PROPULSION GTI (5647/5657) GTX (5653/5669) 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…
• Page 429
  Section 13 TECHNICAL DATA Subsection 04 (GTI AND GTX MODELS) MATERIALS GTI (5647/5657) GTX (5653/5669) Hull Composite Inlet grate Aluminum Plastic/plastic/plastic/ Plastic/plastic/aluminum/ Impeller housing/stator/venturi/nozzle aluminum aluminum Air intake silencer Thermoplastic Flame arrester Multi-layer wire screen Tubular wire screen Steering padding Thermoplastic Fuel tank Polyethylene…
• Page 430
  Section 13 TECHNICAL DATA Subsection 04 (GTI AND GTX MODELS) TIGHTENING TORQUES GTI (5647/5657) GTX (5653/5669) Exhaust manifold screw 24 N•m (17 lbf•ft) 40 N•m (30 lbf•ft) Magneto flywheel nut 145 N•m (107 lbf•ft) 115 N•m (85 lbf•ft) Flywheel (PTO side) 110 N•m (81 lbf•ft) 115 N•m (85 lbf•ft) 24 N•m (17 lbf•ft)
• Page 431
  Section 13 TECHNICAL DATA Subsection 05 (GTX RFI AND GSX RFI MODELS) GTX RFI AND GSX RFI MODELS GTX RFI GSX RFI ENGINE (5515/5516/5648/5658) (5645/5654) Engine type BOMBARDIER-ROTAX 787 Induction type Rotary valve Type Water cooled, water injected with regulator Water injection fitting (head) 3.5 mm (.139 in) Exhaust system…
• Page 432
  Section 13 TECHNICAL DATA Subsection 05 (GTX RFI AND GSX RFI MODELS) GTX RFI GSX RFI ELECTRICAL SYSTEM (5515/5516/5648/5658) (5645/5654) Magneto generator output 270 W @ 6000 RPM Ignition system type Digital, inductive type Make and type NGK BR8ES Spark plug 0.5 — 0.6 mm (.020 — .024 in) mm (in) 1.02 (.040)
• Page 433
  Section 13 TECHNICAL DATA Subsection 05 (GTX RFI AND GSX RFI MODELS) GTX RFI GSX RFI PROPULSION (5515/5516/5648/5658) (5645/5654) 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…
• Page 434
  Section 13 TECHNICAL DATA Subsection 05 (GTX RFI AND GSX RFI MODELS) GTX RFI GSX RFI MATERIALS (5515/5516/5648/5658) (5645/5654) Hull Composite Inlet grate Aluminum Impeller housing/stator/venturi/nozzle Plastic/plastic/plastic/aluminum Air intake silencer Thermoplastic Flame arrester Multi-layer wire screen Steering padding Thermoplastic Fuel tank Polyethylene Oil injection reservoir Polyethylene…
• Page 435
  Section 13 TECHNICAL DATA Subsection 05 (GTX RFI AND GSX RFI MODELS) GTX RFI GSX RFI TIGHTENING TORQUES (5515/5516/5648/5658) (5645/5654) Exhaust manifold screw 40 N•m (30 lbf•ft) (3) (4) Magneto flywheel nut 105 N•m (77 lbf•ft) Flywheel (PTO side) 110 N•m (81 lbf•ft) 24 N•m (17 lbf•ft)

• Page 436: Wire Color Codes

  Section 14 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) WIRING DIAGRAMS WIRE COLOR CODES First color of a wire is the main color. Second color is the tracer. Example: YELLOW/BLACK (YL-BK) is a YELLOW wire with a BLACK tracer. COLOR CODE WH —…

• Page 437: Packard Connector

  Section 14 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) – 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. MALE HOUSING 1.

• Page 438
  Section 14 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) WARNING Ensure all terminals are properly crimped on wires and connector housings are properly fas- tened. AMP PLUG CONNECTOR All Models Except GTS 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.
• Page 439
  Section 14 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) F00H0OA 1. Screwdriver between wedge lock and connector 2. Locking tab Repeat the same steps for the other locking tab retaining the wedge lock. The wedge lock is now in the open position. F00H12A 1.
• Page 440
  Section 14 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) 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.
• Page 441
  Section 14 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) CAUTION: Do not pierce the diaphragm with a sharp point for electrical troubleshooting. The resulting pinholes in the insulation will allow moisture to penetrate the system and possibly result in system failure. Contact Installation For insertion of signal contact, make sure the wedge lock is in the open position.
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