Инструкция для SEA-DOO Sea-Doo RXT iS 2009, Sea-Doo GTX Limited iS 2009

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Оглавление инструкции
  • Страница 1 из 556
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    2009 Shop Manual RXT® iS™ 255 GTX† LIMITED iS™ 255
  • Страница 3 из 556
    Legal deposit: National Library of Quebec National Library of Canada 2009 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Recreational Products Inc. (BRP) © Bombardier Recreational Products Inc. (BRP) 2009 Printed in
  • Страница 4 из 556
    TABLE OF CONTENTS SAFETY NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . .
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    TABLE OF CONTENTS 02 ENGINE (cont’d) 04 – SUPERCHARGER (cont’d) TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROCEDURES. . . . . . . . . . . . . . . . . . .
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    TABLE OF CONTENTS 02 ENGINE (cont’d) 09 – COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . .
  • Страница 7 из 556
    TABLE OF CONTENTS 03 ELECTRONIC MANAGEMENT SYSTEMS (cont’d) 03 – COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  • Страница 8 из 556
    TABLE OF CONTENTS 04 FUEL SYSTEM (cont’d) 03 – FUEL TANK AND FUEL PUMP (cont’d) PROCEDURES (cont’d) FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 05
  • Страница 9 из 556
    TABLE OF CONTENTS 05 ELECTRICAL SYSTEM (cont’d) 06 – DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.) (cont’d) PROCEDURES (cont’d) D.E.S.S. POST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  • Страница 10 из 556
    TABLE OF CONTENTS 06 STEERING AND PROPULSION (cont’d) 03 – JET PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL . . . . . . . . . .
  • Страница 11 из 556
    TABLE OF CONTENTS 07 BODY AND HULL (cont’d) 02 – BODY (cont’d) PROCEDURES (cont’d) STORAGE COMPARTMENT COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIRRORS . . . . . . . . . . . . . . . . . . . . . . .
  • Страница 12 из 556
    SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair 2009 Sea-Doo® watercraft as describe in the model list in the INTRODUCTION. This edition was primarily published to be used by watercraft mechanical technicians who are already familiar with all
  • Страница 13 из 556
    INTRODUCTION INTRODUCTION This shop manual covers the following BRP made 2009 Sea-Doo watercraft models. MODEL COLOR MODEL NUMBER Topaz mist metallic 1503 HO (255 HP) 189A, 189B Bright yellow GTX Limited iS ENGINE 1503 HO (255 HP) 349A, 349B RXT iS The information and component/system descriptions
  • Страница 14 из 556
    INTRODUCTION The owner/operator is not to, and should not allow anyone to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications. EPA Emission Regulations sbl2009-004-003 ENGINE EMISSIONS INFORMATION
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    INTRODUCTION As many of the procedures in this manual are interrelated, we suggest, that before undertaking any task, you read and thoroughly understand the entire section or subsection in which the procedure is contained. A number of procedures throughout the book require the use of special tools.
  • Страница 16 из 556
    INTRODUCTION TYPICAL PAGE Section 06 ENGINE Subsection 01 (MAGNETO) Subsection title Indicates applicable models. Page heading indicates section and subsection. MAGNETO Models Drop represents a service product to be applied. Loctite 243 Exploded view assists you in identifying parts and their
  • Страница 17 из 556
    INTRODUCTION TYPICAL PAGE Section 03 ENGINE Subsection 09 (MAGNETO SYSTEM) Tittle in bold indicates category of information to be carried out. Reference to a specific section or subsection. GENERAL NOTE: The following procedures can be done without removing the engine. During assembly/installation,
  • Страница 18 из 556
    INTRODUCTION TIGHTENING TORQUE Tighten fasteners to torque mentioned in exploded views and/or text, When they are not specified, refer to following table. 2. Apply the half of the recommended torque value. NOTICE Be sure to use proper tightening torque for the proper strength grade. NOTE: When
  • Страница 19 из 556
    INTRODUCTION FASTENER INFORMATION SELF-LOCKING FASTENERS PROCEDURE 3. Choose proper strength Loctite threadlocker. 4. Fit bolt in the hole. 5. Apply a few drops of threadlocker at proposed tightened nut engagement area. 6. Position nut and tighten as required. Threadlocker Application for Blind
  • Страница 20 из 556
    INTRODUCTION 2. Apply LOCTITE PRIMER N (P/N 293 800 041) on threads and allow to dry. 3. Put 2 or 3 drops of proper strength Loctite threadlocker on female threads and in hole. NOTE: To avoid a hydro lock situation, do not apply too much Loctite. 4. Apply several drops of proper strength Loctite on
  • Страница 21 из 556
    INTRODUCTION 3. Twist bolt when inserting it to improve thread conformation. NOTE: NOT intended for engine stud repairs. Repair of Small Holes/Fine Threads Option 1: Enlarge damaged hole, then follow STANDARD THREAD REPAIR procedure. Option 2: Apply FORM-A-THREAD on the screw and insert in damaged
  • Страница 22 из 556
    INTRODUCTION Threadlocker Application for Case-In Components (Metallic Gaskets) A00A3VA 1 1. Proper strength Loctite 1. Clean inner housing diameter and outer gasket diameter. 2. Spray housing and gasket with LOCTITE PRIMER N (P/N 293 800 041). 3. Apply a strip of proper strength Loctite on leading
  • Страница 23 из 556
    XX smr2009-011
  • Страница 24 из 556
    Section 01 MAINTENANCE Subsection 01 (MAINTENANCE SCHEDULE) MAINTENANCE SCHEDULE The maintenance schedule should be adjusted according to operating conditions and use. NOTE: The schedule provides an equivalence between number of hours and months/year. Maintenance operations should be carried out
  • Страница 25 из 556
    Section 01 MAINTENANCE Subsection 01 (MAINTENANCE SCHEDULE) A: C: I: L: R: FIRST 10 HOURS Adjust Clean Inspect Lubricate Replace 25 HOURS OR 3 MONTHS 50 HOURS or 6 MONTHS 100 HOURS or 1 YEAR 200 HOURS or 2 YEAR O: Operator D: Dealer TO BE PERFORMED BY PART/TASK NOTE ELECTRICAL SYSTEM Spark plug I I
  • Страница 26 из 556
    Section 01 MAINTENANCE Subsection 01 (MAINTENANCE SCHEDULE) A: C: I: L: R: FIRST 10 HOURS Adjust Clean Inspect Lubricate Replace 25 HOURS OR 3 MONTHS 50 HOURS or 6 MONTHS 100 HOURS or 1 YEAR 200 HOURS or 2 YEAR O: Operator D: Dealer TO BE PERFORMED BY PART/TASK NOTE HULL AND BODY Hull I I O Ride
  • Страница 27 из 556
    4
  • Страница 28 из 556
    Section 01 MAINTENANCE Subsection 02 (PRESEASON PREPARATION) PRESEASON PREPARATION Proper vehicle preparation is necessary after the winter months or when a vehicle has not been used during several weeks. Any worn, broken or damaged parts found during the storage procedure should have been
  • Страница 29 из 556
    6
  • Страница 30 из 556
    Section 01 MAINTENANCE Subsection 03 (STORAGE PROCEDURE) STORAGE PROCEDURE SERVICE PRODUCTS Description Part Number BRP FUEL STABILIZER ................................................................. DOW CORNING 111 ..................................................................... LOCTITE 767
  • Страница 31 из 556
    Section 01 MAINTENANCE Subsection 03 (STORAGE PROCEDURE) smo2008-001-053_a TYPICAL 1. Flushing adaptor (P/N 295 500 473) 2. Hose 13 mm (1/2 in) 3. Air hose male adapter NOTICE Failure to drain the exhaust manifold may cause severe damage to this components. Engine Coolant Replacement
  • Страница 32 из 556
    Section 01 MAINTENANCE Subsection 03 (STORAGE PROCEDURE) NOTICE Never cut the locking ties of ignition coil connectors. This would allow mixing the wires between cylinders. 3. Clean ignition coil areas to avoid falling dirt into cylinder. 4. Remove ignition coils. 5. Unscrew spark plugs. 6. Using
  • Страница 33 из 556
    10
  • Страница 34 из 556
    Section 01 MAINTENANCE Subsection 04 (SPECIAL PROCEDURES) SPECIAL PROCEDURES SERVICE TOOLS Description Part Number Page LARGE HOSE PINCHER................................................................ 529 032 500 ........................................... 12 SUCTION PUMP
  • Страница 35 из 556
    Section 01 MAINTENANCE Subsection 04 (SPECIAL PROCEDURES) Supercharger Servicing If there was water in the oil or in the supercharger inlet hose, it is recommended to take the supercharger apart, dry all the components, replace the slip clutch needle bearings and shaft ball bearings. Refer to
  • Страница 36 из 556
    Section 01 MAINTENANCE Subsection 04 (SPECIAL PROCEDURES) 5290325002 WARNING Certain components in the engine compartment may be very hot. Direct contact may result in skin burn. Do not touch any electrical parts or jet pump area when engine is running. smr2009-015-001_a 1. Oil cooler coolant inlet
  • Страница 37 из 556
    14
  • Страница 38 из 556
    Section 02 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) ENGINE REMOVAL AND INSTALLATION SERVICE TOOLS Description Part Number ALIGNMENT SHAFT ADAPTER .................................................... ALIGNMENT SHAFT SUPPORT .................................................... ALIGNMENT
  • Страница 39 из 556
    Section 02 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) 6. Drain cooling system. Refer to COOLING SYSTEM subsection. 7. Cut locking tie securing exhaust water outlet hose and engine blow-by hose. 8. Disconnect the exhaust water outlet hose from the exhaust manifold. 9. Disconnect the hose
  • Страница 40 из 556
    Section 02 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) 13. Connect B.U.D.S. Refer to COMMUNICA- TION TOOLS AND B.U.D.S. SOFTWARE subsection. 14. Release fuel pressure using B.U.D.S. 15. Using the FUEL HOSE DISCONNECT TOOL (P/N 529 036 037) disconnect fuel hose from fuel rail.
  • Страница 41 из 556
    Section 02 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) smr2009-016-014_a 1. Cut this locking tie 2. MATS sensor 3. Vehicle harness 23. At the rear of engine, unplug the magneto connector and detach connector housing from ECM support. smr2009-016-017_a 1. Ride plate hoses 2. Water pump
  • Страница 42 из 556
    Section 02 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) smr2009-016-023_a 1. Water outlet hose 2. Exhaust manifold smr2009-016-020_a 1. Rear engine support screw on starboard side 2. Water pump housing 29. Cut locking tie from coolant hose alongside throttle body that retains the vehicle
  • Страница 43 из 556
    Section 02 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) smr2009-016-026_a 1. Ground cable screw on cylinder block 37. Carry on engine lifting to remove it from the body opening. NOTICE Be careful not to scratch body or to hit any component. 38. Install the engine on an engine stand. Check
  • Страница 44 из 556
    Section 02 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) 529 035 719 295 000 141 529036170 ENGINE ALIGNMENT PLATE Trace two thin lines on alignment shaft. One at 739 mm (29-3/32 in) and the other at 742 mm (29-7/32 in). smr2009-016-027_a 1. Engine alignment plate 2. Engine alignment
  • Страница 45 из 556
    Section 02 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) NOTE: Use shim(s) (P/N 270 000 770) for the front engine mount and shim(s) (P/N 270 000 762) for the rear engine mounts. Shims location is between engine mount and engine mount plate. NOTICE Whenever shims are used to correct
  • Страница 46 из 556
    Section 02 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) When alignment and longitudinal position of engine are correct, tighten engine mount screws. Refer to ENGINE MOUNTS in this subsection. Recheck engine alignment. ENGINE MOUNTS If engine mounts have been removed, apply LOCTITE 243
  • Страница 47 из 556
    24
  • Страница 48 из 556
    Section 02 ENGINE Subsection 02 (AIR INTAKE SYSTEM) AIR INTAKE SYSTEM 1.7 N•m (15 lbf•in) Blow-by valve 6 N•m (53 lbf•in) NEW 4 N•m (35 lbf•in) 6 N•m (53 lbf•in) smr2009-017-001_a smr2009-017 25
  • Страница 49 из 556
    Section 02 ENGINE Subsection 02 (AIR INTAKE SYSTEM) 1.2 N•m (11 lbf•in) 1.2 N•m (11 lbf•in) smr2009-017-002_a 26 smr2009-017
  • Страница 50 из 556
    Section 02 ENGINE Subsection 02 (AIR INTAKE SYSTEM) GENERAL Rear Ventilation Box Installation During assembly/installation, use torque values and service products as in the exploded views. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the
  • Страница 51 из 556
    Section 02 ENGINE Subsection 02 (AIR INTAKE SYSTEM) Air Intake Duct Installation Install suspension base. Refer to iS SUSPENSION for complete procedure. Install engine. Refer to ENGINE REMOVAL AND INSTALLATION. After deck extension installation, tighten screws retaining the air intake duct to deck
  • Страница 52 из 556
    Section 02 ENGINE Subsection 02 (AIR INTAKE SYSTEM) smr2009-017-009_a smr2009-017-007_a 1. Rubber latches 1. Air intake silencer 2. Inlet hose groove Install all other removed parts. Remove air intake tube from vehicle. Air Intake Tube Installation The installation is the reverse of the removal
  • Страница 53 из 556
    30
  • Страница 54 из 556
    Section 02 ENGINE Subsection 03 (INTAKE MANIFOLD) INTAKE MANIFOLD SERVICE PRODUCTS Description Part Number Page LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 35 See ELECTRONIC FUEL INJECTION 9 N•m (80
  • Страница 55 из 556
    Section 02 ENGINE Subsection 03 (INTAKE MANIFOLD) GENERAL During assembly/installation, use torque values and service products as in the exploded view. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete
  • Страница 56 из 556
    Section 02 ENGINE Subsection 03 (INTAKE MANIFOLD) smr2009-018-008_a smr2009-018-005_a 1. Ignition coil connectors 2. Fuel injector connectors Unplug the "B" connector from the ECM by pulling the lock. Refer to WIRING DIAGRAM subsection for procedure. Unplug the manifold air pressure sensor (MAPS),
  • Страница 57 из 556
    Section 02 ENGINE Subsection 03 (INTAKE MANIFOLD) Unplug the oil pressure switch (OPS). R1503motr59A smr2009-018-011_a 1. Oil pressure switch (OPS) Lift intake manifold up to pull it out of the mounting brackets. Unscrew ECM retaining screws and remove ECM from its support. R1503motr61A
  • Страница 58 из 556
    Section 02 ENGINE Subsection 03 (INTAKE MANIFOLD) smr2009-018-013_a 1 R1503motr62A INTAKE MANIFOLD 1. Gaskets First, position intake manifold on front mounting bracket then push manifold toward engine to then proceed with rear mounting bracket. When installing the intake manifold, lift up the oil
  • Страница 59 из 556
    36
  • Страница 60 из 556
    Section 02 ENGINE Subsection 04 (SUPERCHARGER) SUPERCHARGER SERVICE TOOLS Description Part Number 4-PIN SOCKET............................................................................... BEARING SUPPORT/PUSHER ...................................................... CAMSHAFT LOCKING
  • Страница 61 из 556
    Section 02 ENGINE Subsection 04 (SUPERCHARGER) Loctite 243 9 N•m (80 lbf•in) Loctite 243 NEW 29 N•m (21 lbf•ft) NEW NEW 29 N•m (21 lbf•ft) Loctite 5910 Loctite 243 9 N•m (80 lbf•in) Engine oil Loctite 243 Engine oil Engine oil 9 N•m (80 lbf•in) Loctite 243 Isoflex grease Topas NB62 Engine oil Super
  • Страница 62 из 556
    Section 02 ENGINE Subsection 04 (SUPERCHARGER) GENERAL During assembly/installation, use the torque values and service products as in the exploded view. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete
  • Страница 63 из 556
    Section 02 ENGINE Subsection 04 (SUPERCHARGER) Remove supercharger and perform the clutch slipping moment test. Inspect bearings and friction clutch. Replace bearings and clutch components as necessary. Separate supercharger housing. NOTE: Since supercharger is disassembled, it is recommended to
  • Страница 64 из 556
    Section 02 ENGINE Subsection 04 (SUPERCHARGER) SUPERCHARGER CLUTCH SLIPPING MOMENT (BENCH TEST) Mount supercharger on the SUPPORT PLATE (P/N 529 035 947). smr2009-025-007_b 1. Camshaft locking tool Check slipping moment counterclockwise by using a torque wrench with actual torque viewer. A mirror
  • Страница 65 из 556
    Section 02 ENGINE Subsection 04 (SUPERCHARGER) ENGINE LACKS ACCELERATION OR POWER (DOES NOT REACH MAXIMUM RPM) 1. Supercharger inlet is dirty - Check and clean supercharger inlet. - Check engine oil. Siphon excess of oil. 2. Supercharger slipping clutch defective - Check slipping clutch moment. -
  • Страница 66 из 556
    Section 02 ENGINE Subsection 04 (SUPERCHARGER) smr2009-020-012_a 1. Air inlet hose 2. Hose clamp Remove air outlet hose from supercharger. smr2008-012-011_a 1. Rubber adapter 2. Exhaust pipe Loosen clamp securing rubber adapter to exhaust pipe. Detach muffler strap. Move muffler back (± 5 cm (2
  • Страница 67 из 556
    Section 02 ENGINE Subsection 04 (SUPERCHARGER) 1 1 1 2 R1503motr250A 1. Upper retaining screw F00B28A Supercharger Disassembly NOTICE Be scrupulous when working on supercharger parts. Supercharger rotation reaches 45 000 RPM. Any modification, improper repair, assembly or damage on the parts, may
  • Страница 68 из 556
    Section 02 ENGINE Subsection 04 (SUPERCHARGER) 2 smr2009-020-006_a 1. Cap nut (left-handed thread) 4. Remove washer, turbine, O-ring and step collar from supercharger shaft. F00B2BA 1 1. Nut 2. Retaining key NOTE: There are 40 loose needle bearings under the gear. Do not reuse. 6. Remove L-ring,
  • Страница 69 из 556
    Section 02 ENGINE Subsection 04 (SUPERCHARGER) 1 NOTE: It may be necessary to heat the housing with a heat gun to release the retaining disc. F00B2CA 1. Supercharger shaft 8. Remove and discard ball bearing from supercharger shaft by using a press and the SUPERCHARGER RETAINING KEY (P/N 529 036
  • Страница 70 из 556
    Section 02 ENGINE Subsection 04 (SUPERCHARGER) A B SPRING WASHER PACKAGE HEIGHT C NEW 10.7 mm to 10.9 mm (.4213 in to .4291 in) SERVICE LIMIT 10.2 mm (.4016 in) Supercharger Assembly NOTICE Every time when supercharger shaft has been removed, both ball bearings have to be replaced. R1503motr360A
  • Страница 71 из 556
    Section 02 ENGINE Subsection 04 (SUPERCHARGER) 1 4 529035947 F00B2FA 1. 2. 3. 4. 2 3 Supercharger shaft Ball bearing Bearing support plate Protrusion of support plate on this side (underneath inner race) 6. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on retaining disc. If a new retaining disc is
  • Страница 72 из 556
    Section 02 ENGINE Subsection 04 (SUPERCHARGER) 529035950 2 3 smr2006-012-032_a 1. 2. 3. 4. 5. F00B2GA Compressor shaft Ball bearing Supercharger housing half Thrust washer Distance sleeve 2 1 1 1. Support plate 2. Bearing support/pusher 3. Protrusion here NOTICE Before pressing in the supercharger
  • Страница 73 из 556
    Section 02 ENGINE Subsection 04 (SUPERCHARGER) 13. Install step collar, O-ring, turbine and washer on supercharger shaft. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on cap nut and temporary finger tight cap nut. NOTE: The cap nut on the supercharger shaft has a left-handed thread. The Loctite has
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    Section 02 ENGINE Subsection 04 (SUPERCHARGER) Supercharger Installation 1. Grease sealing surface between supercharger and PTO housing with SUPER LUBE GREASE (P/N 293 550 030). NOTE: Ensure O-rings are installed. 529035949 27. Tighten the cap nut to 29 N•m (21 lbf•ft). 28. Apply LOCTITE 5910 (P/N
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    Section 02 ENGINE Subsection 04 (SUPERCHARGER) NOTICE Not installing the tool as shown will change the torque applied to the screw. Proper torque and tightening sequence are important. 6. After complete installation of the supercharger, the slipping moment has to be rechecked. Refer to SUPERCHARGER
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    Section 02 ENGINE Subsection 05 (INTERCOOLER) INTERCOOLER SERVICE TOOLS Description Part Number Page LARGE HOSE PINCHER................................................................ 529 032 500 ........................................... 55 VACUUM/PRESSURE PUMP
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    Section 02 ENGINE Subsection 05 (INTERCOOLER) GENERAL Intercooler Cleaning During assembly/installation, use torque values and service products as in the exploded view. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this
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    Section 02 ENGINE Subsection 05 (INTERCOOLER) smr2009-019-009_a 1. Garden hose installed on water outlet 2. High and regular water flow 7. Perform a leak test before installing the intercooler in the watercraft. 529021800 BLEED HOSE FITTING Pressurize the intercooler. PRESSURE TEST Intercooler Leak
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    Section 02 ENGINE Subsection 05 (INTERCOOLER) smr2009-019-005_a FIXED DECK REMOVED FOR CLARITY PURPOSE 1. iS module 2. Retaining latch smr2009-019-003_a 1. Intercooler air inlet hose 2. Intercooler air outlet hose Cut locking ties securing wiring harness to iS module support and front attachment.
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    Section 02 ENGINE Subsection 05 (INTERCOOLER) Remove plastic rivets and rubber pad. smr2009-019-050_a THROUGH THE LH REAR OPENING 1. Plastic rivet 2. Rubber pad Remove and discard screw securing the attachment to the hull. smr2009-019-051_a THROUGH THE LH REAR OPENING 1. Retaining screw 2. Washer
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    58
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    Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) EXHAUST SYSTEM SERVICE TOOLS Description Part Number Page FLUSHING CONNECTOR ADAPTER ............................................ 295 500 473 ........................................... 62 SERVICE PRODUCTS Description Part Number Page LOCTITE 243
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    Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) 9 N•m (80 lbf•in) 11 N•m (97 lbf•in) 16 N•m (142 lbf•in) Loctite 243 Loctite 567 (pipe sealant) 7.5 N•m (66 lbf•in) 8 N•m (71 lbf•in) 4 N•m (35 lbf•in) Loctite 518 16 N•m (142 lbf•in) See EFI subsection 4 N•m (35 lbf•in) 5 N•m (44 lbf•in) GTX LIMITED
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    Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) GENERAL During assembly/installation, use torque values and service products as in the exploded view. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete
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    Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) help to clean up sand, salt, shells or other particles in water jackets (exhaust system, intercooler and hoses. Exhaust system flushing should be performed when the watercraft is not expected to be used further the same day or when the watercraft is
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    Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) 4. Gently disconnect the hose from blow-by valve. smr2009-016-005_a 1. Exhaust hose clamp smr2009-016-003_a 1. 2. 3. 4. 5. 8. Detach retaining strap. Cut this locking tie Water outlet hose (exhaust system) Blow-by hose Blow-by valve Exhaust manifold
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    Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) smr2008-013-025_a 1. Exhaust manifold mark 2. Exhaust pipe mark smr2008-013-026_a Step 1: Lift adjuster tab Step 2: Move adjuster outward Using the rear opening, slide the muffler in hull. Align the exhaust pipe flange to the exhaust manifold. Rotate
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    Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) Move the coolant expansion tank aside and cut locking tie retaining the starter cable (RED) to exhaust hose. Remove exhaust hose from resonator. Cut locking tie retaining bailer hose elbow fittings to exhaust hose. Remove front exhaust hose from
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    Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) smr2008-013-035_a 1. Bulge 2. Middle of the opening Install the rubber adapter on exhaust pipe. Ensure rubber adapter is properly seats against exhaust pipe shoulder. smr2008-013-037_a 1. Middle of rubber adapter strip 2. Center of the muffler bulge
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    Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) 3. Disconnect the exhaust manifold water outlet hose. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on threads of screws. To help holding the manifold while installing screws, first insert the exhaust manifold into the exhaust pipe then, install the
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    Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) Resonator Installation Installation is the reverse of the removal procedures. However, pay attention to the following. After installation, ensure there is no water or exhaust gas leak when the engine is running. Test run the engine while supplying
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    Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) PTO HOUSING AND MAGNETO SERVICE TOOLS Description Part Number 3-PIN MAGNETO HARNESS ADAPTER........................................ BLIND HOLE BEARING PULLER SET........................................... HANDLE
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    Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) Oil 9 N•m (80 lbf•in) 9 N•m (80 lbf•in) Loctite Loctite 243 243 Oil Isoflex grease Topas NB 52 Loctite 243 9 N•m (80 lbf•in) Isoflex grease Topas NB 52 NEW NEW 15 N•m (133 lbf•in) +50° Oil Loctite 648 250 N•m (184 lbf•ft) smr2008-014-007_b
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    Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) GENERAL NOTE: It is good practice to check for fault codes using the B.U.D.S. software as a first troubleshooting step. Refer to the MONITORING SYSTEM AND FAULT CODES subsection. Always carry out electrical tests on components before
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    Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) WARNING Always disconnect battery cables exactly in the specified order, BLACK negative cable first. 2. Remove the moving deck and deck extension. Refer to BODY subsection. 3. Drain the engine oil. Refer to LUBRICATION SYSTEM subsection. 4.
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    Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) Slightly lift aft end of engine and insert a safely block under the engine to secure it in this position. Remove LH rear engine support. smr2009-016-015_b 1. Magneto connector 2. ECM 3. Throttle body Place rags under PTO housing to prevent
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    Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) PTO Housing Inspection Inspect PTO housing for cracks or any other damages. Replace if necessary. Inspect the needle bearing in the PTO housing used to support the starter drive assembly shaft. NOTE: Clean all disassembled metal components
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    Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) smr2005-034-100_a TYPICAL 1. Thrust washer 2. Disc springs 3. Starter drive assembly NOTE: When installing a NEW starter drive assembly, oil the shaft and gear splines with engine oil. Install a new PTO housing gasket. NOTE: When installing
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    Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) Reinstall LH engine support. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on screw threads then torque to 24 N•m (18 lbf•ft). Remove block under engine. Install both rear engine support screws. Carry out an engine alignment, refer to the
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    Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) Crimp Oetiker clamp using OETIKER PLIERS (P/N 295 000 070). PTO COUPLING PTO Coupling Removal Lock crankshaft. Refer to CYLINDER BLOCK subsection for the procedure. Remove PTO seal as described in previous procedure. Unscrew coupling from
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    Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) smr2009-016-015_b 529036117 Starter Drive Bearing Installation Prior to assembly grease starter drive bearing with ISOFLEX GREASE TOPAS NB 52 (P/N 293 550 021). Install starter drive bearing in PTO housing using the STARTER DRIVE SEAL PUSHER
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    Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) STATOR OUTPUT VOLTAGE TEST TEST ENGINE SPEED TERMINAL VOLTAGE (AC) 1 and 2 4000 RPM 1 and 3 Approx. 50 Vac 2 and 3 If voltage is lower than specification, carry out a STATOR CONTINUITY TEST and a STATOR INSULATION TEST. See procedures in
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    Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) smr2009-022-101_c STATOR INSULATION TEST 1. Connect adapter to magneto stator connector 2. Leave vehicle harness disconnected Read resistance. STATOR INSULATION TEST TERMINAL RESISTANCE @ 20°C (68°F) Any YELLOW wire and engine ground
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    Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) Recheck reading on reference tooth to ensure gauge has not changed position (gauge should still read zero). NOTE: The maximum allowable difference between teeth is 0.15 mm (.006 in). If the reading exceeds the maximum allowable difference,
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    Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) 4 3 3 2 2 1 1 1 R1503motr53A TYPICAL 1. Rotor retaining screws 2. Rotor 3. Trigger wheel Rotor and Trigger Wheel Installation For installation, reverse the removal procedure. However, pay attention to the following. Align the trigger wheel
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    Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) STARTER DRIVE Starter Drive Removal Remove the PTO housing and ring gear as described in this subsection. Remove starter drive assembly. If any part of the assembly shows signs of abnormal wear, cracks, broken teeth or malfunction (sprag
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    84
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    Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) LUBRICATION SYSTEM SERVICE TOOLS Description Part Number ADAPTER HOSE ........................................................................... ECM ADAPTER TOOL................................................................... FLUKE 115
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    Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) 9 N•m (80 lbf•in) NEW Engine oil Loctite 243 NEW Loctite 243 9 N•m (80 lbf•in) Engine oil 16 N•m (142 lbf•in) 18 N•m (159 lbf•in) NEW 9 N•m (80 lbf•in) Loctite 243 Engine oil Loctite 243 NEW 9 N•m (80 lbf•in) Engine oil Loctite 243 Engine oil 9
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    Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) 9 N•m (80 lbf•in) Engine oil Loctite 243 9 N•m (80 lbf•in) NEW 11 N•m (97 lbf•in) Engine oil 9 N•m (80 lbf•in) 3 N•m (27 lbf•in) Left hand thread Loctite 243 Loctite 243 NEW NEW Loctite 243 9 N•m (80 lbf•in) Engine oil 19 N•m (14 lbf•ft) Engine
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    Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) ENGINE LUBRICATION CIRCUIT Legend 1 2 Pressurized oil Scavenged oil Blow-by gas 3 4 5 6 8 7 9 10 11 12 13 smr2009-023-100_en 1. Oil dipstick 2. Rocker arm (intake) 3. Rocker arm (exhaust) 4. Hydraulic valve lifter 5. Camshaft 6. Piston pin 7.
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    Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) ENGINE LUBRICATION CIRCUIT (CONT'D) 1 34 4 6 3 2 3 5 7 8 9 10 12 11 13 15 14 16 18 17 19 20 21 22 23 24 25 28 29 26 30 27 31 Legend Pressurized oil Scavenged oil Blow-by gas 32 33 smr2009-023-101_en 1. To air intake silencer 2. Rocker arm
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    Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) GENERAL During assembly/installation, use torque values and service products as in the exploded views. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for
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    Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) lmr2007-053-100_a 1. Full 2. Add 3. Operating range Otherwise, add oil until its level is between marks as required. To add oil, unscrew oil cap. Place a funnel into the oil filler neck opening and add the recommended oil to the proper level. Do
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    Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) NOTICE Never crank or start engine when suction pump tube is in dipstick hole. Never start engine when there is no oil in engine. NOTE: So that suction pump tube is located at the proper height to siphon oil, it is suggested to put some
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    Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) Apply engine oil on filter ring, filter cover O-rings and on oil filter screw O-ring. NOTE: In salt water area, it is recommended to coat mating surface of cover with SUPER LUBE GREASE (P/N 293 550 030). Torque oil filter screw to 9 N•m (80
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    Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) Reinstall oil pressure switch. Test at the Cylinder Head Location The oil pressure may be measured from cylinder head if desired. Remove plug located on cylinder head and install gauge. 4. Oil pressure regulator valve sticks open, or spring load
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    Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) PROCEDURES ENGINE RUNNING OIL PRESSURE SWITCH (OPS) Oil Pressure Switch Operation The oil pressure switch activates if engine oil pressure falls between 180 kPa and 220 kPa (26 PSI and 32 PSI). TEST PROBES OPS connector (pin 1) Engine ground
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    Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) OPS CONNECTOR Pin 1 ECM ADAPTER RESISTANCE Pin E3 Close to 0 (continuity) PTO OIL STRAINER NOTE: The oil strainer does not need to be cleaned at every oil change. Clean it during other inspections, especially when the engine is disassembled. PTO
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    Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) R1503motr118A 1 1. Oil inlet to the oil pump smr2006-014-022_a PTO Oil Strainer Installation For installation, reverse the removal procedure. However, pay attention to the following. Clean cylinder block to remove all remaining silicone residues
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    Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) smr2009-023-007_a 1. Oil inlet 2. Oil outlet Suction Pump Oil Strainer Installation For installation, reverse the removal procedure. However, pay attention to the following. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on threads of the suction
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    Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) Oil Pressure Pump Removal 1. Remove engine oil. See procedure in OIL CHANGE in this subsection. 2. Remove the PTO housing. Refer to PTO HOUSING AND MAGNETO subsection. 3. Remove water pump housing and the impeller. Refer to COOLING SYSTEM
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    Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) 1 R1503motr129A 1. Pittings on the teeth Using a feeler gauge, measure the clearance between inner and outer rotors. R1503motr127A TYPICAL NOTICE Be careful not to damage the surface of the rotary seal bore in PTO housing cover. B 8. Remove and
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    Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) 1 R1503motr131A 2 1 1. PTO housing surface 2. Vernier depth gauge R1503motr128A 1. Oil seal Install the new rotary seal by using the WATER PUMP SEAL PUSHER (P/N 529 035 823). 529035823 R1503motr132A 2 1 1. Oil pump outer rotor surface 2. Vernier
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    Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) R1503motr142A 2 1 3. Remove the air intake silencer. Refer to AIR INTAKE SYSTEM subsection. 4. Detach the muffler from the exhaust manifold and move muffler backwards. Refer to EXHAUST SYSTEM subsection. 5. Remove engine support mount screws. 6.
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    Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) 1 R1503motr137A smr2008-015-006_a TYPICAL 1. Oil pump cover 2. Oil pump screws 1. Pittings on the teeth Using a feeler gauge, measure the clearance between inner and outer rotors. 13. Remove oil pump shaft. 14. Remove outer rotor. A B C 1 2
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    Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) R1503motr139A 1 2 smr2009-023-008_a 1. Screws M6 x 25 2. Screws M6 x 45 1. Oil pump housing surface 2. Vernier depth gage Tighten suction pump cover screws as per following sequence. R1503motr140A 1 2 1. Oil pump outer rotor surface 2. Vernier
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    Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) smr2008-015-007_a 1. 2. 3. 4. Banjo bolt Oil spray nozzle Oil spray nozzle support Torx screw Oil Spray Nozzle Inspection Check oil spray nozzle for: – Dirt – Bend – Other damages. Replace if necessary. smr2008-015-008_a A. 1 mm (0.039 in) NOTE:
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    Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) NOTE: When the scope of repair work obligates you to split the cylinder block, take this opportunity to clean the oil spray nozzles. Oil Spray Nozzle Removal Remove cylinder block lower half. Refer to CYLINDER BLOCK subsection. Remove oil spray
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    Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) NOTE: Make sure not to loose thrust washer when removing it from oil separator cover, otherwise thrust washer would fall into the PTO housing. smr2006-014-067_a 1. Camshaft 2. Oil separator cover NOTE: Be careful not to break the holding clips
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    Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) BLOW-BY VALVE Blow-by Valve Description The blow-by valve has two main functions: – It recirculates oil vapors. – It protects the engine in the event the watercraft tip over. To a accomplish the second function, the blow-by valve has a tip over
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    Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) NOTE: After voltage test, clear the fault codes in the ECM using the B.U.D.S. software. Blow-By Valve TOPS Switch Output Voltage Test Remove the blow-by valve. Back-probe TOPS connector and check voltage using the FLUKE 115 MULTIMETER (P/N 529
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    Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) smr2009-023-051 529036166 Check continuity of the blow-by valve TOPS switch circuit as per following table. TOPS SWITCH CONNECTOR ECM ADAPTER Pin 1 Pin F4 Pin 2 Pin G1 Pin 3 When installing the TOPS switch, make sure printed information is
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    Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) Disconnect the TOPS switch connector of the blow-by valve. Unscrew and remove the blow-by valve. Blow air through inlet port. Air must flow freely to the outlet port. smr2009-023-023_a smr2009-023-014_a 1. TOPS switch connector 2. Retaining
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    Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) R1503motr148A 1 1. O-rings smr2009-023-025_a 1. Oil cooler Oil Cooler Removal Remove engine from vehicle. Refer to ENGINE REMOVAL AND INSTALLATION subsection. Disconnect cooling hoses from oil cooler. Remove screws securing oil cooler. Oil Cooler
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    Section 02 ENGINE Subsection 09 (COOLING SYSTEM) COOLING SYSTEM SERVICE TOOLS Description Part Number OETIKER PLIERS........................................................................... OIL SEAL GUIDE........................................................................... TEST CAP
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    Section 02 ENGINE Subsection 09 (COOLING SYSTEM) CLOSED LOOP COOLING SYSTEM Expansion coolant tank Coolant temperature sensor (CTS) activates when temperature exceeds 100°C (212°F) Bleed hose from cylinder head to expansion coolant tank Coolant housing including thermostat opens at 87°C (188°F) and
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    Section 02 ENGINE Subsection 09 (COOLING SYSTEM) VEHICLE COMPONENTS 1.7 N•m (15 lbf•in) 1.7 N•m (15 lbf•in) NEW NEW 1.7 N•m (15 lbf•in) 1.7 N•m (15 lbf•in) 1.7 N•m (15 lbf•in) 1.7 N•m (15 lbf•in) 1.7 N•m (15 lbf•in) NEW 5 N•m (44 lbf•in) 1.7 N•m (15 lbf•in) 4 N•m (35 lbf•in) 4 N•m (35 lbf•in) 4 N•m
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    Section 02 ENGINE Subsection 09 (COOLING SYSTEM) ENGINE COMPONENTS NEW 17 N•m (150 lbf•in) NEW 9 N•m (80 lbf•in) 9 N•m (80 lbf•in) Loctite 243 9 N•m (80 lbf•in) Loctite 243 Left hand threads 3 N•m (27 lbf•in) NEW NEW Engine oil Engine oil 9 N•m (80 lbf•in) Loctite 243 NEW NEW Engine oil Loctite 243
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    Section 02 ENGINE Subsection 09 (COOLING SYSTEM) GENERAL During assembly/installation, use torque values and service products as in the exploded view. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete
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    Section 02 ENGINE Subsection 09 (COOLING SYSTEM) NOTICE Pure antifreeze will freeze at a higher temperature than the optimal water/antifreeze mix. A blend of 40% antifreeze with 60% demineralized water will improve the cooling efficiency. Using water tap instead of demineralized water, would
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    Section 02 ENGINE Subsection 09 (COOLING SYSTEM) INSPECTION COOLING SYSTEM LEAK TEST WARNING To avoid potential burns, do not remove the expansion tank cap or loosen the ride plate drain plug if the engine is hot. smo2009-002-137_a 1. Level between marks when engine is cold Remove the deck
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    Section 02 ENGINE Subsection 09 (COOLING SYSTEM) PROCEDURES PRESSURE CAP Pressure Cap Inspection Using a pressure cap tester, check pressure cap efficiency. If the efficiency is feeble, install a new 90 kPa (13 PSI) cap (do not exceed this pressure). CLAMPS Clamp Replacement To cut or secure
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    Section 02 ENGINE Subsection 09 (COOLING SYSTEM) WATER PUMP HOUSING smr2009-024-105_a 1. Expansion tank hose Disconnect exhaust hose from the resonator. Place hose over muffler. smr2009-024-004_b 1. Water pump housing Water Pump Housing Removal Remove the moving deck. Refer to BODY subsection.
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    Section 02 ENGINE Subsection 09 (COOLING SYSTEM) Check if thermostat is in good condition. Refer to THERMOSTAT in this subsection. Water Pump Housing Leak Test Plug the connections of the oil cooler return hose, coolant tank hose, ride plate return hose and cylinder head return hose with a rag.
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    Section 02 ENGINE Subsection 09 (COOLING SYSTEM) 2 1 1 1 F18E10A F18E13A 1. Screws M6 x 25 2. Screws M6 x 105 1. Impeller NOTICE To prevent leaking, take care that the gaskets are exactly in groove when you reinstall the water pump housing. Tighten screws to 9 N•m (80 lbf•in) using the following
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    Section 02 ENGINE Subsection 09 (COOLING SYSTEM) Thermostat Installation 2 For installation, reverse the removal procedure, paying attention to the following details. Refer to WATER PUMP HOUSING in this subsection. ROTARY SEAL Rotary Seal Inspection 1 Check leak indicator hole for oil or coolant
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    Section 02 ENGINE Subsection 09 (COOLING SYSTEM) 2 NOTE: Never use oil in the press fit area of the oil seal and rotary seal. Push water pump shaft oil seal in place by using thumb. Install the NEW rotary seal using a press and the WATER PUMP SEAL PUSHER (P/N 529 035 823). 1 F18E16A 1. Pusher 2.
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    Section 02 ENGINE Subsection 09 (COOLING SYSTEM) 2 1 F18E1AA 1. Oil seal protector 2. Coolant/oil pump shaft Using the WATER PUMP SEAL PUSHER (P/N 529 035 823) to support the PTO cover, install the coolant/oil pump shaft. 1 2 F18E1BA 1. Coolant/oil pump shaft with oil seal protector 2. Rotary seal
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    Section 02 ENGINE Subsection 10 (CYLINDER HEAD) CYLINDER HEAD SERVICE TOOLS Description Part Number CAMSHAFT LOCKING TOOL........................................................ DRIVE SHAFT ADAPTER............................................................... ENGINE LEAK DOWN TEST KIT
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    Section 02 ENGINE Subsection 10 (CYLINDER HEAD) Isoflex grease Topaz NB52 9 N•m (80 lbf•in) See LUBRIFICATION SYSTEM 9 N•m (80 lbf•in) NEW Engine oil NEW Engine oil NEW Loctite 243 Loctite 243 NEW 9 N•m (80 lbf•in) Loctite 243 9 N•m (80 lbf•in) 20 N•m (15 lbf•ft) + 90o Engine oil Engine oil 9 N•m
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    Section 02 ENGINE Subsection 10 (CYLINDER HEAD) GENERAL WARNING NOTE: When diagnosing an engine problem, always perform an engine leak test. This will help pin-point a problem. Refer to ENGINE LEAK TEST in this subsection for procedures. Always place the vehicle on level surface. Always disconnect
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    Section 02 ENGINE Subsection 10 (CYLINDER HEAD) Leak Test Procedure smr2009-025-003_a 1. Ignition coil 2. Spark plug NOTE: Cylinder numbers are molded on cylinder head cover. 1. Rotate engine crankshaft counterclockwise until the cylinder no. 1 is at Top Dead Center (TDC) compression stroke. 1.1 As
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    Section 02 ENGINE Subsection 10 (CYLINDER HEAD) OBSERVATION CAUSE Excessively worn and/or broken piston rings Air bubbles out of coolant tank Leaking cylinder head gasket Air/water escaping from cylinder-block/head Damaged gasket and/or loosened screws Coolant escaping from water pump housing
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    Section 02 ENGINE Subsection 10 (CYLINDER HEAD) 4. Rocker arm screw not properly tightened - Retighten screws with recommended torquing procedure. 4. Broken rocker arm(s) - Replace defective parts. 5. Faulty chain tensioner - Replace chain tensioner. PROCEDURES 6. Chain guide is worn out - Replace
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    Section 02 ENGINE Subsection 10 (CYLINDER HEAD) Torque screws to 9 N•m (80 lbf•in) as per following illustrated sequence. 7 5 1 3 9 11 smr2008-017-005_a 1. Cylinder head cover screws 5. Remove the cylinder head cover and its gasket. R1503motr152A 8 6 4 2 10 12 CYLINDER HEAD COVER Cylinder Head
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    Section 02 ENGINE Subsection 10 (CYLINDER HEAD) smr2005-036-001_a TYPICAL 1. Spark plug tube 2. Seal to the cylinder head cover 3. Seal to the cylinder head Spark Plug Tube Installation smr2006-016-026_a Torque screws to 9 N•m (80 lbf•in). For installation, reverse the removal procedure. Pay
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    Section 02 ENGINE Subsection 10 (CYLINDER HEAD) 1 3 A R1503motr90A A. Measure rocker arm shaft diameter here ROCKER ARM SHAFT DIAMETER 2 R1503motr84A NEW Rocker Arm Inspection Inspect each rocker arm for cracks and scored friction surfaces. If so, replace rocker arm assembly. Check the rocker arm
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    Section 02 ENGINE Subsection 10 (CYLINDER HEAD) 6 smr2009-025-006_a 5 1 3 2 4 R1503motr93A 1. Position lines 3. Apply engine oil on rocker arm shaft. 4. Position the rocker arm shaft with the notches on top. 2 7. Retorque screws to 20 N•m (15 lbf•ft). 8. Finish tightening screws turning an
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    Section 02 ENGINE Subsection 10 (CYLINDER HEAD) Remove the chain tensioner. Refer to CYLINDER BLOCK subsection. Remove the chain guide. Remove the Allen screws securing the camshaft timing gear. Remove the camshaft timing gear. 1 2 smr2008-017-007_a 1. Chain guide 2. Allen screws 3. Camshaft timing
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    Section 02 ENGINE Subsection 10 (CYLINDER HEAD) 1 1 Camshaft Removal Remove the CAMSHAFT TIMING GEAR, see procedure in this subsection. Remove the ROCKER ARM, see procedure in this subsection. Remove the camshaft lock to remove the camshaft. 1 2 R1503motr95A 1. Position lines NOTICE Ensure to
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    Section 02 ENGINE Subsection 10 (CYLINDER HEAD) Drain coolant, refer to COOLING SYSTEM subsection. Unscrew blow-by valve from cylinder head. Refer to LUBRICATION SYSTEM subsection. Unplug the camshaft position sensors (CAPS). Unplug the coolant temperature sensor (CTS). Disconnect bleeding hose.
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    Section 02 ENGINE Subsection 10 (CYLINDER HEAD) 1 smr2009-025-010_a 1. Oil orifices R1503motr98A 1. Cylinder head screws M6 Remove the cylinder head screws M11 securing cylinder head to cylinder block. Cylinder Head Inspection Check for cracks between valve seats or other damages, if so, replace
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    Section 02 ENGINE Subsection 10 (CYLINDER HEAD) NOTICE Each installation of the cylinder head requires a new cylinder head gasket. Using a gasket twice will cause engine damage, even if the engine had not run. 2 1 Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on threads of screws M6. Install screws M6
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    Section 02 ENGINE Subsection 10 (CYLINDER HEAD) 2 1 smr2008-017-009_a 1. 2. 3. 4. Valve cotters Valve spring retainer Inner valve spring Outer valve spring Valve Spring Inspection R1503motr103A 1. Valve spring compressor clamp 2. Valve spring compressor cup R1503motr104A LOCATE VALVE SPRING
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    Section 02 ENGINE Subsection 10 (CYLINDER HEAD) NOTE: Valve cotters must be properly engaged in valve stem grooves. 1 R1503motr105B 1. Position of the valve spring VALVES R610motr125A Valve Removal Valve Inspection Remove valve spring. Push valve stem then pull valves out of valve guides. 1 2
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    Section 02 ENGINE Subsection 10 (CYLINDER HEAD) Valve Face and Seat 2 3 A 1 R1503motr107A R610motr126A A. Valve stem diameter VALVE STEM DIAMETER NEW Exhaust 5.946 mm - 5.960 mm (.2341 in - .2346 in) Intake 5.961 mm - 5.975 mm (.2347 in - .2352 in) SERVICE LIMIT Exhaust Intake 5.93 mm (.233 in)
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    Section 02 ENGINE Subsection 10 (CYLINDER HEAD) INTAKE 55° B A 35° A 45° 35° 45° 55° R1503motr260A A. Valve seat outer diameter INTAKE V01C1HA VALVE SEAT OUTER DIAMETER A. Valve face contact width B. Valve seat contact width Valve Seat Grinding NOTE: The valve seats may be reground with a valve
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    Section 02 ENGINE Subsection 10 (CYLINDER HEAD) VALVE GUIDES 1 Valve Guide Replacement NOTICE Do not heat cylinder head for this procedure. NOTICE The sharp edge near the top of the valve guide must be machined away. Otherwise it will foul the valve guide hole in the cylinder head and destroy the
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    Section 02 ENGINE Subsection 10 (CYLINDER HEAD) 1 A R1503motr255A TYPICAL 1. Punch Check valve guide bore for abreased material. The inlet and exhaust valve guides have the same length and are interchangeable. NOTE: If valve guide has caused scoring during extraction, replace the cylinder head.
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    Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) CYLINDER BLOCK SERVICE TOOLS Description Part Number CRANKSHAFT LOCKING TOOL .................................................... HANDLE ........................................................................................ PISTON CIRCLIP
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    Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) Loctite 243 Engine oil Isoflex grease Topas NB 52 9 N•m (80 lbf•in) 23 N•m (17 lbf•ft) 21 Loctite 243 Engine oil 22 Loctite 243 19 20 19 23 N•m (17 lbf•ft) 17 N•m (150 lbf•in) 18 Engine oil 9 N•m (80 lbf•in) Loctite 243 Engine oil 16 Loctite 243 17
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    Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) 9 8 Engine oil 10 8 Engine oil Engine oil 4 260 N•m (191 lbf•ft) 23 Engine oil 4 Loctite anti-seize Engine oil Engine oil Engine oil 12 Engine oil Engine oil 45 N•m 11 (33 lbf•ft) + 90° 6 13 Engine oil 6 Engine oil 5 Engine oil 15 Engine oil Engine
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    Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) GENERAL When disassembling parts that are duplicated in the engine, (e.g.: pistons, connecting rods etc.), it is strongly recommended to note their position (cylinder 1, 2 or 3) and to keep them as a “group”. If you find a defective component, it
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    Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) Timing Chain Removal 2 3 Remove: – Engine oil (refer LUBRICATION SYSTEM subsection) – Engine from vehicle (refer to ENGINE REMOVAL AND INSTALLATION subsection) – Cylinder head (refer to CYLINDER HEAD subsection) – PTO housing (refer to PTO HOUSING
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    Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) 1 1 3 R1503motr27A R1503motr08A 1. Connecting rod screws NOTE: Before removing the connecting rod caps, mark them to remember the right position when reassembling. 3. Pull piston with connecting rod out of the cylinders. 4. Remove one piston circlip
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    Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) 2 1 A R610motr76A R610motr73A A. Connecting rod big end bearing 1. Bore gauge 2. Connecting rod CONNECTING ROD BIG END DIAMETER CONNECTING ROD SMALL END DIAMETER NEW 23.01 mm - 23.02 mm (.9059 in - .9063 in) SERVICE LIMIT 23.07 mm (.908 in) If the
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    Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) 1 PISTON PIN DIAMETER NEW 22.996 mm - 23.000 mm (.905 in - .906 in) SERVICE LIMIT 22.990 mm (.905 in) Measure connecting rod small end diameter (refer to CONNECTING RODS INSPECTION above) to check connecting rod small end radial play. Piston
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    Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) NOTE: Make sure the cylinder bore gauge indicator is set exactly at the same position as with the micrometer, otherwise the reading will be false. Position the dial bore gauge 62 mm (2.44 in) above cylinder base, measuring perpendicularly (90°) to
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    Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) NOTICE Failure to strictly follow this procedure may cause screw to loosen and lead to engine damage. Knowing that the screws have been stretched from the previous installation, it is very important to use new screws at assembly. 1 1 R1503motr30A 1.
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    Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) 1 2 2 3 A31C2NA 1. Rectangular ring 2. Taper-face ring 3. Oil scraper ring 1 R1503motr32A NOTICE Ensure that top and second rings are not interchanged. 1. Piston 2. Filler gauge Ring End Gap RING END GAP NEW RECTANGULAR TAPER-FACE 0.35 mm - 0.50 mm
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    Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) Remove: – Intake manifold (refer to INTAKE MANIFOLD subsection) – Spark plugs – Cylinder head cover (refer to CYLINDER HEAD subsection – Crankshaft access plug screw. smr2009-026-004_a 1. Position lines Use a small screwdriver to check if the groove
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    Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) 1 NOTE: Before removing the connecting rod caps, mark them to remember the right position when reassembling. It is recommended to measure connecting rod big end axial play prior to remove connecting rod. Refer to PISTONS AND CONNECTING RODS in this
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    Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) 1 1 2 R1503motr13A R1503motr10A 1. Micrometer 2. Crankshaft area for bearing 1. Crankshaft Crankshaft Inspection Crankshaft Gear Inspection Replace crankshaft if the gears are worn or otherwise damaged. 2 CRANKSHAFT JOURNAL DIAMETER NEW 49.991 mm -
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    Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) CRANKSHAFT PIN RADIAL CLEARANCE SERVICE LIMIT 0.09 mm (.0035 in) Crankshaft Axial Clearance When assembling the cylinder-block, measure the crankshaft axial clearance. 1 R1503motr17A 1 2 1. Mark on balancer shaft 2. Mark on crankshaft For correct
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    Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) 1 1 2 R1503motr16A R1503motr18A 1. Thrust washer 2. Sealing surface 1. Crankshaft locking tool Install cylinder block lower half. Refer to CYLINDER BLOCK in this subsection. Install the crankshaft cover before mounting the engine bracket. Apply
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    Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) 1 2 1 R1503motr109A 1. Screws R1503motr23A 11. Remove cylinder block lower half. 12. Remove thrust washers no. 6. 1. Micrometer 2. Balancer shaft area for bearing BALANCER SHAFT SEAT DIAMETER 1 NEW 31.984 mm - 32.000 mm (1.2592 in - 1.2598 in)
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    Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) Balancer Shaft Installation 2 For installation, reverse the removal procedure. Pay attention to following details. NOTICE Balancer shaft and crankshaft marks have to be aligned. 1 R1503motr22A 1. Thrust washer 2. Sealing surface Install cylinder
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    Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) 1 1 R1503motr18A 1. Crankshaft locking tool CYLINDER BLOCK Cylinder Block Disassembly Remove: – Engine oil (refer to LUBRICATION SYSTEM subsection) – Engine from vehicle (refer to ENGINE REMOVAL AND INSTALLATION subsection) – Cylinder head (refer to
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    Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) Close puller claws so that they can be inserted in end bearing. Holding claws, turn puller shaft clockwise so that claws open and become firmly tight against bearing. Slide puller hammer outwards and tap puller end. Retighten claws as necessary to
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    Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) CRANKSHAFT BEARING INSIDE DIAMETER 50.1 mm (1.9724 in) SERVICE LIMIT Correctly install bearings. Top crankshaft bearing halves have a bore which has to be placed in the upper cylinder block. 1 2 3 R1503motr35A R1503motr34A 1 1. Cylinder block upper
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    Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) Clean oil passages and make sure they are not clogged. Clean all metal components in a solvent. Cylinder block mating surfaces are best cleaned using a combination of the LOCTITE CHISEL (GASKET REMOVER) (P/N 413 708 500) and a brass brush. Brush a
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    Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) Install the crankshaft cover before mounting the engine bracket. Apply engine oil on O-ring and press cover in. Crankshaft cover has to be flush with cylinder block surface. 1 R1503motr19A 2 1. O-ring 2. Crankshaft cover Install the CRANKSHAFT
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 01 (ENGINE MANAGEMENT SYSTEM) ENGINE MANAGEMENT SYSTEM FRONT 1 2 B 3 A MAPS KS ETA OPS CTS TOPS CPS CAPS MATS ECM INJECTOR 1, 2, 3 IGNITION COIL 1, 2, 3 EGTS A B CAPS CPS CTS ECM EGTS Engine Wiring Harness Connector Vehicule Wiring Harness
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 01 (ENGINE MANAGEMENT SYSTEM) 1503 4-TEC CONTROL SYSTEM INPUTS OUTPUTS Relay Throttle accelerator sensor (TAS) Fuel pump Throttle position sensor (TPS) Crankshaft position (CPS) Camshaft position (CAPS) Starter solenoid ENGINE CONTROL MODULE (ECM)
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 01 (ENGINE MANAGEMENT SYSTEM) GENERAL SYSTEM DESCRIPTION There are 7 main systems in interaction with the engine management system: 1. Electronic fuel injection 2. D.E.S.S. system 3. Ignition system 4. Starting system 5. O.T.A.S. (Off-Throttle
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 01 (ENGINE MANAGEMENT SYSTEM) in limp home mode. Refer to MONITORING SYSTEM AND FAULT CODES subsection for more information. 176 smr2009-027
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 02 (iCONTROL SYSTEM) iCONTROL SYSTEM GENERAL The iControl (intelligent Control) system consist of the following systems: – Intelligent Throttle Control (iTC) – Intelligent Brake and Reverse (iBR) – Intelligent Suspension (iS). The gauge is used
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 02 (iCONTROL SYSTEM) For a comprehensive and complete description of this system, refer to IBR and VTS subsection in the PROPULSION section. iS (INTELLIGENT SUSPENSION) The intelligent suspension is a mechanical system of one spring and one shock
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE) COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE SERVICE TOOLS Description Part Number Page MPI-2 DIAGNOSTIC CABLE.......................................................... 710 000 851
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE) CAN LIGHT STATUS WHAT TO DO Light is OFF Check connection between MPI-2 and diagnostic connector of vehicle. Light is RED Check CAN wires/connectors on vehicle. Light is GREEN Message Box: "No Vehicle
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE) Message Box: "Some of the Information Normally Displayed..." If the following message box is displayed in B.U.D.S.: NOTE: Never use the D.E.S.S. POST INTERFACE. smr2009-028-016 1. Click on the OK
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE) ssi2009-002-004_a 1. Diagnostic connector Connect the MPI-2 DIAGNOSTIC CABLE (P/N 710 000 851) to vehicle connector. 529036018 NOTE: An optional MALE-FEMALE EXTENSION SERIAL CABLE (P/N DB9) available
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE) Reading Data in ECM Read ECM by clicking the Read Data button. vmr2006-012-100_aen mmr2006-079-200 MPI-2 INTERFACE CARD CONNECTED TO USB PORT B.U.D.S. is now ready to use. CAUTION If the computer you
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE) NOTE: When selecting the update menu in B.U.D.S., a dialog box will appear and the update file description may give some clue to find the vehicle-related information in BOSSWeb. smr2009-028-003 1. If
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE) NOTE: If there is still a communication problem, refer to COMMUNICATION PROBLEMS WITH B.U.D.S. in this subsection. After the write operation, remove D.E.S.S. key from watercraft D.E.S.S. post to
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) MONITORING SYSTEM AND FAULT CODES GENERAL MONITORING SYSTEM A system monitors the electronic components of the EMS (engine management system), iBR, information center, iS and other components of the
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) – Start engine. – Check if fault code disappeared. The electronic system will react differently depending on the fault type. In severe failure, the engine may not be allowed to be started. In other cases, the
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) PILOT LAMPS (ON) MESSAGE DISPLAY DESCRIPTION MAINTENANCE REMINDER Maintenance required LOW or HIGH BATTERY VOLTAGE Low/high battery voltage LOW-FUEL Low fuel level, approx. 25% tank capacity, 14 L (3.7 U.S.
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) Beeper Signals When one of the below conditions occurs, the monitoring system emits the following beep signals. BEEPER CODES Wrong D.E.S.S. key. Use a D.E.S.S. key that has been programmed for the watercraft.
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) Fault Code Types There are 4 types of fault codes used on the vehicle: – “B” for information center and switches faults (Bxxxx) – “C” for iBR and iS faults (Cxxxx) – “P” for power train faults (Pxxxx) – “U”
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) This will reset the appropriate counter(s) and will also record that the problem has been fixed in the related module memory. SPECIFIC FAULT CODES Several Fault Codes are Active at once If this occurs, check
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT CODE TABLE FAULT MODULE CODE POSSIBLE CAUSE SERVICE ACTION Cluster Left keypad fault (switch kept activated more than 60 seconds) Problem with left keypad The switch may be defective, verify the
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION Damaged sensor, damaged circuit wires, damaged connector or damaged iBR pins. Fault detected when the engine is running or stopped Check system
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE DESCRIPTION Unexpected battery power lost iBR Motor current software breaker Motor current too high Clean and check for damage in the iBR gate and nozzle area. Refer to the Service Manual
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION iBR System disabled and need activation System is locked. Need activation Use B.U.D.S. iBR unlock function. Refer to the Service Manual for more
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION Check for 12 volts on sensor connector pin A. Check continuity for circuits B-H1, B-H3. Check fuse 10 (refer to WIRING DIAGRAM) refer to the Service
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE P0113 P0116 P0117 P0118 P0122 198 ECM ECM ECM ECM ECM DESCRIPTION Intake manifold temperature sensor open circuit or shorted to battery Engine temperature sensor functional problem Engine
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE P0123 P0127 P0201 P0202 P0203 smr2009-029 ECM ECM ECM ECM ECM DESCRIPTION POSSIBLE CAUSE SERVICE ACTION TAS (Throttle Accelerator sensor) 1 fault (short circuit to battery) Damaged sensor,
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE P0217 P0222 P0223 P0231 P0232 200 ECM ECM ECM ECM ECM DESCRIPTION High engine coolant temperature detected TAS (Throttle Accelerator sensor) 2 fault (short circuit to GND) TAS (Throttle
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE P0261 P0262 P0264 P0265 P0267 smr2009-029 ECM ECM ECM ECM ECM DESCRIPTION Injector 1 open circuit or shorted to ground Injector 1 shorted to battery Injector 2 open circuit or shorted to
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION Damaged injector, damaged circuit wires, damaged connector or damaged ECM output pins Check for 11.4 to 12.6 ohms between engine connector pin 3 and
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE P0352 P0353 P0354 P0355 P0356 P0357 smr2009-029 ECM ECM ECM ECM ECM ECM DESCRIPTION Ignition coil 2 open circuit or shorted to ground or to battery Ignition coil 3 open circuit or shorted to
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE P0358 P0359 ECM ECM DESCRIPTION POSSIBLE CAUSE SERVICE ACTION Damaged coil, damaged circuit wires, damaged connector or damaged ECM output pins Check for 0.85 to 1.15 ohms between engine
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE P0545 P0546 P0560 DESCRIPTION POSSIBLE CAUSE SERVICE ACTION Check for approximately 2280 to 2736 ohms at temperature of 19 to 21°C (66 to 70°F) between system circuits A-H4 and A-J4. Refer
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE DESCRIPTION P062F ECM ECM EEPROM fault exchange ECM P06B6 ECM SERVICE ACTION ECM Fast ADC fault (knock detection line) ECM POSSIBLE CAUSE P1120 P1264 P1502 P1503 P1504 P1505 ECM ECM ECM ECM
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE P160E P1610 P1611 P1612 P1613 P1614 P1615 P1616 P1619 P1620 smr2009-029 DESCRIPTION POSSIBLE CAUSE SERVICE ACTION Throttle Actuator - Controller Fault digital position control below limit
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE P1621 P1622 P1654 P1657 P1658 DESCRIPTION POSSIBLE CAUSE SERVICE ACTION ECM Throttle Actuator Abortion of adaptation Damaged throttle actuator, damaged circuit wires, damaged connector or
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION P16C5 ECM Safety fuel cut off activ - Monitoring level 1 P16C6 ECM Safety fuel cut off activ - Monitoring level 2 ECM Monitoring fault due to
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE P2428 P2620 P2621 ECM ECM ECM DESCRIPTION POSSIBLE CAUSE SERVICE ACTION High exhaust temperature detected Exhaust overheat, damaged sensor or damaged circuit wires. Check cooling system for
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    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE U16A1 U16A2 U16A3 U16A4 U16A5 U16A6 U16A7 U16A8 U16A9 smr2009-029 DESCRIPTION POSSIBLE CAUSE SERVICE ACTION ECM Cluster CAN Time out error-Missing CAN ID 514h Cluster fault detected by ECM
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    Section 04 FUEL SYSTEM Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC)) INTELLIGENT THROTTLE CONTROL (iTC) SERVICE TOOLS Description Part Number Page DIAGNOSTIC HARNESS ............................................................... 529 036 179 ......................................... 215 FLUKE
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    Section 04 FUEL SYSTEM Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC)) While the throttle lever might be fully depressed and held, the ECM could close the throttle plate, instead of opening it, if the iBR lever were depressed. Then, the ECM could open the throttle plate to accelerate the engine
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    Section 04 FUEL SYSTEM Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC)) smr2009-042-005_c smr2009-030-033_a 1. 8-pin connector 2. 12-pin connector Connect the DIAGNOSTIC HARNESS (P/N 529 036 179) to make an in-line connection between the disconnected connectors. Test on the 12-pin Connector of
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    Section 04 FUEL SYSTEM Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC)) smr2009-030-100_a Step 1: Pry out Step 2: Pull out sensor Revert removal procedure for installation. Pay attention to the following. Align sensor pins into their holes. smr2009-030-102_a 1. Route harness here When
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    Section 04 FUEL SYSTEM Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC)) smr2009-042-002_a smr2009-036-002_b 1. 2. 3. 4. Read Data Monitoring tab Cluster tab Cruise indicator light If the test succeeded, the switch and wiring are good and the problem may be related to the information center or
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    Section 04 FUEL SYSTEM Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC)) 10 12 1 12. Reconnect gauge connector. 13. Properly insert cruise switch wiring in slot in switch support before installing MODE/SET and UP/DOWN arrow switches. 11 smr2009-036-003_a GAUGE CONNECTOR PIN-OUT 3. Attach a string
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) ELECTRONIC FUEL INJECTION (EFI) SERVICE TOOLS Description Part Number Page DIGITAL INDUCTION TACHOMETER ........................................... 529 014 500 ......................................... 222 ECM ADAPTER
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) WARNING If any gasoline leak and/or odor are present, do not start the engine. Repair the leak. SYSTEM DESCRIPTION The electronic fuel injection system (EFI) on this engine is based on the open-loop Bosch ME-Motronic system. It
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Flame Arrester The flame arrester is a tube inside the intake manifold. It prevents flames leaving through the intake system if the engine backfires. EFI Sensors smr2009-030-019_a 1. 2. 3. 4. 5. 6. 7. 8. 9. Supercharger
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Use a DIGITAL INDUCTION TACHOMETER (P/N 529 014 500). Install the D.E.S.S. key on its post. Briefly press the START button to wake up the ECM. Engine must not crank. In B.U.D.S., click on the Reset button. 529014500 Wrap the
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) It is important to ensure that the mechanical integrity of the engine/propulsion system are intact. For diagnostics purposes, use B.U.D.S. software. See COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE subsection. After a problem has
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) ECM Power Supply Troubleshooting ECM Power Supply Diagram Battery A1 FB#2 Fuse F17 FB#2 Bus bar (Vdc) B2 B7 B8 FB#2 Relay B12 B5 D1 A12 FB#2 Fuse F21 D2 B10 A10 D6 FB#1 2 Start switch Bus bar (Vdc) D4 1 D3 Fuse F20 FB#2 A4 B-M4
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) – Relay and wiring. Refer to POWER DISTRIBU- TION – ECM power supply wires and ground wires. See below. ECM Power Supply Test Remove cover of fuse box #2 (FB). Refer to POWER DISTRIBUTION subsection. Install the D.E.S.S. key on
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) smr2009-030-010_a If measurement is out of specification, check ground bus bar in fuse box #2 and continuity of its wires and connections with the engine grounds. Also check battery ground and engine grounds. smr2009-016-026_b
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) NOTICE Always replace ECM by the same part number or by an approved equivalent. Reconnect ECM connectors to ECM. Reconnect battery cables. If a new ECM is installed, refer to ECM REPLACEMENT in this subsection. Briefly press the
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Click on the Open button. mmr2009-023-080 Click once on the Folder Up button in the Open box. smr2009-030-006 IMPORTANT: Ensure to use the file that specifically matches the vehicle you are servicing. NOTE: The file name
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Entering the Collected Information Into the ECM Remove the faulty ECM. Install and connect the new ECM. Use the B.U.D.S. software. Refer to COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE subsection. Install the D.E.S.S. key on its
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) 3. Customer name 4. Enter the old ECM serial number in the Part Replacement under History tab. Click on Add Part in History. Perform the Closed throttle reset. Refer to Closed Throttle Reset (TPS) in ADJUSTMENTS in this
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Fuel Rail Removal Cut locking ties retaining engine harness to fuel rail. smr2009-030-027_a 1. Fuel rail Unplug all injector connectors. Pull fuel rail out with fuel injectors. Fuel Rail Installation smr2009-030-011_b 1. Cut
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) FUEL INJECTOR Fuel Injector Operation Test with B.U.D.S. (Dynamic) 1. Connect B.U.D.S. Refer to COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE. 2. Start engine. 3. Using the B.U.D.S. software, shut down each engine cylinder, one at a
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) 5. Fuel pressure must be within specification. Refer to FUEL TANK AND FUEL PUMP subsection. Re-activate fuel pump as necessary. 6. In B.U.D.S., energize the fuel injector no. 1. smr2009-030-013_a ACTIVATION AND ECM TABS 1.
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Fuel Injector Input Voltage Test Open seat. Remove rear ventilation box. Refer to AIR INTAKE SYSTEM. Disconnect fuel injector connectors. NOTE: Push against tab underneath connector as shown to unlock it. smr2009-030-029_a If
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Disconnect the ECM A connector. Install ECM ADAPTER TOOL (P/N 529 036 166) on ECM connector. Remove the long bus bar from fuse box #1. smr2009-030-015_j If continuity is good, wiring and connectors are functional. If continuity
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) INJECTOR PIN 1 RESISTANCE @ 20°C (68°F) 2 See above Insert the fuel injector in place on fuel rail. Secure injector to fuel rail with its clip. Install fuel rail. Refer to FUEL RAIL in this subsection. THROTTLE BODY
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Throttle-Body Faults and Effects NOTE: Among other things, a weak or broken spring and a sticky throttle plate (carbon build-up, dried salt water etc) are validated by the throttle body diagnostic mode. FAULT smr2009-030-032_a
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) NOTICE Only use an appropriate throttle body cleaner that will not damage O-rings and EFI sensors. WARNING Use the product in well ventilated area. Refer to product manufacturer's warnings. Wipe off any product leakage in bilge.
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Throttle plate must fully open and when released, must return freely to the rest position (slightly opened). Push throttle plate where shown. It must completely close and when released, freely return to the rest position
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Install the D.E.S.S. key on its post. Briefly press the START button to wake up the ECM. Do not start engine. Connect B.U.D.S. Refer to COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE. In B.U.D.S., select the Monitoring tab then the
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) vmr2008-022-005_a If any resistance value is incorrect, check wire continuity between ECM and throttle body. If continuity is good, replace throttle body. If resistance values are correct, try a new ECM. Refer to ENGINE CONTROL
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Remove deck extension. Refer to BODY. Remove air intake silencer. Refer to AIR INTAKE SYSTEM. Drain oil from PTO housing. Refer to PTO HOUSING AND MAGNETO. NOTE: It is not necessary to drain oil from engine. Disconnect CPS
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Trigger Wheel Inspection Refer to PTO HOUSING AND MAGNETO in the ENGINE section. CAPS CONNECTOR MEASUREMENT PIN VOLTAGE 1 3 Battery voltage CAMSHAFT POSITION SENSOR (CAPS) smr2009-030-035_a smr2006-020-057_a TYPICAL 1. CAPS CAPS
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) vmr2007-050-004 They can be inserted at the end of the standard probes of the FLUKE 115 MULTIMETER (P/N 529 035 868). smr2009-027-011_f 1. Pull out Use the FLUKE 115 MULTIMETER (P/N 529 035 868) and select . Read resistance of
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) smr2009-030-034_a 1. CAPS connector smr2007-021-009_c 1. Metallic object If voltage is appropriate, check/repair wiring/connector between sensor and ECM. If it is good, check ECM. Refer to ENGINE CONTROL MODULE (ECM). If voltage
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) TEMPERATURE °C - 30 - 20 °F - 22 - 4 RESISTANCE (OHMS) NOMINAL 12600 11400 LOW 11800 11000 HIGH 13400 11800 - 10 14 9500 8000 11,000 0 32 5900 4900 6900 10 50 3800 3100 4500 20 68 2500 2200 2800 30 86 1700 1500 1900 40 104 1200
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) COOLANT TEMPERATURE SENSOR (CTS) If resistance tests good, reconnect the CTS connector and disconnect the ECM connector A on the ECM. Using a multimeter and the ECM ADAPTER TOOL (P/N 529 036 166), check the circuit resistance as
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Remove rear ventilation box. Refer to AIR INTAKE SYSTEM. Remove deck extension. Refer to BODY. Disconnect CTS connector and remove CTS. Install the new CTS and torque to 18 N•m (159 lbf•in). Reinstall remaining removed parts.
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Using a multimeter and the ECM ADAPTER TOOL (P/N 529 036 166), check the resistance of circuit A-B4, A-G4 and A-H2. If wiring harness is good, check ECM. Refer to ENGINE CONTROL MODULE (ECM) in this section. Otherwise, repair
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) KNOCK SENSOR (KS) vmr2008-022-005_a If resistance value is correct, check ECM. Refer to ENGINE CONTROL MODULE (ECM) in this section. If resistance value is incorrect, repair the connector or replace the wiring harness between
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    Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) vmr2008-022-005_a smr2009-030-038_a 1. KS connector Using a multimeter, check the resistance between both terminals on the knock sensor. If wiring harness is good, check ECM. Refer to ENGINE CONTROL MODULE (ECM) in this section.
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    252
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    Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) FUEL TANK AND FUEL PUMP SERVICE TOOLS Description Part Number DIAGNOSTIC HARNESS ............................................................... ECM ADAPTER TOOL................................................................... FLUKE
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    Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) FUEL TANK AND FUEL PUMP 4.5 N•m (39 lbf•in) NEW NEW NEW NEW NEW 60 N•m (44 lbf•ft) NEW NEW NEW NEW 3.5 N•m (31 lbf•in) smr2009-031-001_a 254 smr2009-031
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    Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) FUEL SYSTEM DIAGNOSTIC FLOW CHART Fuel pump does not run Fuel pump runs for 2 sec. then stops Press Start button Install fuel pressure gauge on fuel pressure line Check fuses. Check fuel pump operation. Repair or replace if necessary.
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    Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) GENERAL WARNING Fuel lines remain under pressure at all times. Always proceed with care and use appropriate safety equipment when working on a pressurized fuel system. Wear safety glasses. WARNING Always disconnect battery prior to
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    Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) When the START button is pressed, the electrical system is powered. The fuel pump will come on for approximately 2 seconds to pressurize the fuel rail in preparation for the engine start. The ECM supplies the ground signal to turn on
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    Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) smr2009-031-002_c 1. Outlet valve If pressure in fuel tank build up and exceed 2.8 kPa - 7.6 kPa (.4 PSI - 1.1 PSI), the outlet valve opens and let excess pressure evacuate outside fuel tank. smr2009-031-008_a 1. Ventilation box
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    Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) smr2009-031-101_a TEST SETUP mmr2009-121-004_a 1. Y-fitting P/N 293 710 059 2. Check valve P/N 275 500 505 3. Apply compressed air here Install the vacuum/pressure gauge on inlet valve end. Slowly apply pressurized air. NOTE: If
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    Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) WARNING If a leak is found, do not start the engine. Wipe off any fuel that leaked and ventilate the hull thoroughly to remove any accumulated fuel vapors. Do not use electric powered tools on watercraft unless system has passed the
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    Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) Set the vacuum/pressure pump to vacuum. smr2009-031-012_a 1. Pressure selected smr2009-031-013_a 1. Vacuum selected Squeeze the vacuum/pressure pump handle several times to pressurize air to the inlet valve. Install a SMALL HOSE PINCHER
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    Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) FUEL SYSTEM HIGH PRESSURE LEAK TEST WARNING A high pressure leak test must be carried out before starting the engine anytime a fuel system component has been disconnected for maintenance, or replacement. Visually inspect fuel system to
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    Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) MODELS FUEL PRESSURE (when pressing the START button) 1503 4-TEC supercharged intercooled 386 - 414 kPa (56 - 60 PSI) Test when Cranking or Starting Engine 529035709 smr2009-031-018_a 1. Connect to fuel pump 2. Connect to outlet hose
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    Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) “B1” type hose approved by BRP for ventilation hoses. These hoses available from BRP meet our system requirements and will ensure continued proper and safe operation. WARNING Use of fuel lines other than those recommended by BRP may
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    Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) smr2009-030-024_a 1. Throttle body 2. Inlet hose 3. Connector Remove D.E.S.S. key from its post to prevent engine starting. Press START button. The fuel pump should run for 2 seconds to build up fuel system pressure. If fuel pump runs,
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    Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) 529036166 Set multimeter to following table. and test pump circuit as per PUMP CIRCUIT TEST THROUGH FUEL PUMP TEST PROBES Fuse box #1 terminal C1 ECM connector B pin B-M1 smr2009-031-021_a RESISTANCE @ 20°C (68°F) Approx. 12
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    Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) smr2009-031-008_a 1. Ventilation box Disconnect the negative battery terminal, refer to CHARGING SYSTEM subsection. Disconnect fuel pump electrical connector. Disconnect the vent tube from the fuel pump. Wrap shop rags around the high
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    Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) WARNING Always wipe off any fuel spillage from the watercraft. When working with fuel or fuel system and its components, always work in a well ventilated area. Fuel Pump Installation Reverse the removal procedure however, pay attention
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    Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) Press new filter on by hand. Ensure it is fully seated and locked onto the pump reservoir housing. Reinstall fuel pump as per procedure in this subsection. Carry out a FUEL SYSTEM HIGH PRESSURE LEAK TEST as described in this subsection.
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    Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) Place fuel tank retaining strap ends in anchoring clips. Temporarily use tape to hold straps on the top of fuel tank. smr2009-031-017_b 1. Quick connect fitting (high pressure fuel hose) 2. Vent hose 3. Harness connector Disconnect
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    Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) Fuel Level Troubleshooting FUEL LEVEL TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE Fuel gauge always display EMPTY – Wiring/connectors – Fuel level sensor – Float stuck in low position Fuel gauge always display FULL – Water in fuel pump
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    Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) Remove diagnostic harness and reconnect connector. Fuel Level Sensor Resistance Test at Information Center 529036179 NOTE: Plug only the connector that has been disconnected. Briefly press the START button to wake up the ECM. Install
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    Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) Fuel Level Sensor Removal smr2008-022-018_f TYPICAL — FUEL PUMP MODULE 1. Fuel pump module connector Alternately drain then fill fuel tank and measure the sensor resistance between pins C and D of the fuel pump connector. See table in
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    Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) Once the pressure regulator is rotate over the locking tab, pull up on it to remove it from the pump reservoir cover. smr2008-022-022_a 1. Pressure regulator 2. Ground wire contact on pressure regulator 3. Ground wire disconnected Using
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    Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) Align the fuel pressure regulator tabs into the pump reservoir cover and turn it counterclockwise until it locks properly. smr2008-022-026_a 1. Fuel level sensor release tabs 2. Locking pins smr2008-022-025_b PRESSURE REGULATOR
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    Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) Ensure fuel level sensor connector is locked into the module flange connector. smr2008-022-021_a 1. Fuel level sensor connector Carry out a FUEL LEVEL SENSOR RESISTANCE TEST as described in this subsection. Reinstall the fuel pump
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    Section 05 ELECTRICAL SYSTEM Subsection 01 (CONTROLLER AREA NETWORK (CAN)) CONTROLLER AREA NETWORK (CAN) SERVICE TOOLS Description Part Number Page ECM ADAPTER TOOL................................................................... 529 036 166 ......................................... 279 FLUKE 115
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    Section 05 ELECTRICAL SYSTEM Subsection 01 (CONTROLLER AREA NETWORK (CAN)) TROUBLESHOOTING DIAGNOSTIC TIPS Check the fault codes using B.U.D.S. software as a first troubleshooting step. Refer to MONITORING SYSTEM/FAULT CODES section. CAN Communication Problems The following chart gives some
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    Section 05 ELECTRICAL SYSTEM Subsection 01 (CONTROLLER AREA NETWORK (CAN)) CAN Continuity Tests If a communication problem is present, perform the appropriate continuity test relating to the component reported by B.U.D.S. Test wire continuity between the corresponding terminal of the CAN bus bar in
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    280
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    Section 05 ELECTRICAL SYSTEM Subsection 02 (POWER DISTRIBUTION) POWER DISTRIBUTION SERVICE TOOLS Description Part Number Page FLUKE 115 MULTIMETER ............................................................ 529 035 868 ......................................... 287 SERVICE PRODUCTS Description Part
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    Section 05 ELECTRICAL SYSTEM Subsection 02 (POWER DISTRIBUTION) SIMPLIFIED ELECTRICAL SYSTEM SCHEMATIC B-M4 D4 A1 A3 ECM (power) F17 (30 A) A5 FUSE BOX NO. 2 BAT A2 B2 E3 E1 Voltage regulator/rectifier 1 iBR (power) E2 A10 D3 D6 D4 5 Multifunction gauge (GPS) E4 Power relay 2 Diagnostic connector
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    Section 05 ELECTRICAL SYSTEM Subsection 02 (POWER DISTRIBUTION) GENERAL It is highly recommended to disconnect the battery when replacing any electric or electronic component. WARNING Always disconnect battery exactly in the specified order, BLACK (-) cable first, RED (+) cable last. Always
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    Section 05 ELECTRICAL SYSTEM Subsection 02 (POWER DISTRIBUTION) Fuse box Cover Installation When installing a fuse box cover, ensure the seal is properly seated. If the seal has been removed, ensure to reinstall it as illustrated. smr2009-016-011_a FRONT OF ENGINE 1. Engine grounds A cable
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    Section 05 ELECTRICAL SYSTEM Subsection 02 (POWER DISTRIBUTION) smr2009-027-010_b FUSE BOX 2 — BUS BAR IDENTIFICATION 1. 12 Vdc from battery 2. 12 Vdc from battery 3. CAN LO 4. CAN HI 5. Ground bus-bar The power relay in FB2 is connected directly to one of two 12 Vdc bus bars in FB2. When the
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    Section 05 ELECTRICAL SYSTEM Subsection 02 (POWER DISTRIBUTION) If B.U.D.S. is being used for communicating with the electronic modules, or if the information center must be ON for testing, selecting modes of operation, changing key settings, or for other functions accessed through the information
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    Section 05 ELECTRICAL SYSTEM Subsection 02 (POWER DISTRIBUTION) – Check the ECM fuse in FB2. – Check the GAUGE fuse in FB1. If you cannot feel the power relay activating when pressing the START button, or if you suspect that it does not function correctly, refer to POWER RELAY in this subsection.
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    Section 05 ELECTRICAL SYSTEM Subsection 02 (POWER DISTRIBUTION) smr2007-027-060_a TERMINAL 30 288 87 RESISTANCE max. 0.5 (continuity) smr2009-049
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    Section 05 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) IGNITION SYSTEM SERVICE TOOLS Description Part Number Page ECM ADAPTER TOOL................................................................... 529 036 166 ......................................... 292 FLUKE 115 MULTIMETER
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    Section 05 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) ENGINE WILL NOT START (ENGINE TURNS OVER) 1. Fouled or defective spark plug - Replace. 2. Defective CPS - Check operation of CPS and replace if necessary. Refer to ELECTRONIC FUEL INJECTION section. 3. Defective trigger wheel - Check.
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    Section 05 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) smr2008-024-005_b smr2009-032-001_a IGNITION COIL INPUT VOLTAGE TEST IGNITION COIL ACTIVATION 1. Activation tab 2. ECM tab 3. Click on the desired ignition coil You should hear the spark occurring. If in doubt, use a sealed vapor proof
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    Section 05 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) smr2009-030-015_h If test succeeded, wiring and connectors are functional. If test failed, repair/replace wiring from fuse box terminal to ignition coil. Reinstall bus bar and cover. Ignition Coil Control Circuit Test Disconnect ECM
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    Section 05 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) smr05-015-002_b SECONDARY WINDING CIRCUIT TERMINAL Secondary winding 1 and spark plug terminal RESISTANCE @ 20°C (68°F) 9.5 - 13.5 k If any test failed, replace ignition coil. Ignition Coil Removal Open seat. Remove rear ventilation box.
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    Section 05 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) Unscrew spark plug then use the ignition coil to take spark plug out of spark plug hole. smr2009-032-004_a 1. Seal properly seated SPARK PLUGS Spark Plug Removal smr2009-032-003_a Open seat. Remove rear ventilation box. Refer to AIR
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    Section 05 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) the spark plug at prescribed intervals, examining the plug face (i.e. the part of the plug projecting into the combustion chamber). Spark Plug Installation Prior to installation, ensure the contact surfaces of the cylinder head and spark
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    Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) CHARGING SYSTEM SERVICE TOOLS Description Part Number Page ENGINE LEAK TEST KIT................................................................ 295 500 352 ......................................... 302 SERVICE TOOLS – OTHER SUPPLIER
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    Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) INSPECTION CHARGING SYSTEM OUTPUT First ensure that battery is in good condition prior to performing the following tests. NOTE: It is good practice to check for fault codes using the B.U.D.S. software as a first troubleshooting step.
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    Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) TEST ENGINE SPEED 5500 RPM smr2009-034-002_c 1. Fuse box #2 Locate the RED/BLUE wire on terminal A9 of fuse box and clamp the ammeter over it. CURRENT Approx. 10 A (while suspension does not move) NOTE: Initial current reading will be
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    Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) OUTPUT CURRENT TEST TEST ENGINE SPEED CURRENT (DC) 5500 RPM Approx. 10 A (while suspension does not move) NOTE: Initial current reading will be higher than specified due to the battery drain from the engine start. This proves the charging
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    Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) Voltage Regulator/Rectifier Installation Installation is the reverse of removal procedure. However, pay attention to the following. Lock voltage regulator/rectifier in position. Wiggle it to make sure it is safely locked. NOTE: “Key Off”
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    Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) Use the vacuum/pressure pump in the ENGINE Set vacuum/pressure pump to VACUUM. LEAK TEST KIT (P/N 295 500 352). 295500352 Set vacuum/pressure pump to PRESSURE. smr2009-031-013_a 1. Vacuum selected Squeeze the vacuum/pressure pump handle
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    Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) ssi2009-002-003_a 1. Storage bin 3. Disconnect the diagnostic connector from its holder. smr2006-023-003_a Battery Removal WARNING The BLACK negative battery cable must always be disconnected first and reconnected last. Never charge or
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    Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) 6. Remove the electrical component support from the battery holder. 6.1 Lift and push the top of electrical component support forward to unlock it from battery holder. smr2009-033-009_a 1. Disconnect here ssi2009-002-008_a 1. Electrical
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    Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) NOTICE Should any electrolyte spillage occur, immediately wash off area with a solution of baking soda and water, then rinse thoroughly. Remove retaining screws from battery holder if applicable. smr2009-005-006 Remove battery holder from
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    Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) WARNING Battery electrolyte is caustic. To prevent spillage, ensure battery cell caps are sufficiently tight to properly seal each cell. Battery Electrolyte Level Check electrolyte level in each cell, add distilled water up to the upper
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    Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) ELECTROLYTE TEMPERATURE °C °F 38 OPERATION TO PERFORM 100 32 90 27 80 21 70 16 60 10 50 4 40 - 1 .012 Add to the reading: .008 30 .004 CORRECT READING .004 Subtract from the reading: .008 .012 .016 EXAMPLE NO. 1 EXAMPLE NO. 2 TEMPERATURE
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    Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) WARNING Failure to remove the sealing tube could result in an explosion. 1 1. Remove caps and fill battery to UPPER LEVEL line with electrolyte (specific gravity: 1.265 at 21°C (70°F)). NOTE: This battery may fill slower than others due
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    Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) 1 2 - + 3 For best results, battery should be charged when it is at room temperature. A battery that is cold may not accept current for several hours after charging has begun. Do not charge a frozen battery. If the battery charge is very
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    Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) NOTE: Some chargers have a polarity protection feature which prevents charging unless the charger leads are connected to the correct battery terminals. A completely discharged battery may not have enough voltage to activate this
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    Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) ssi2009-002-005_a 1. BLACK (-) cable 2. RED (+) cable 10. Apply dielectric grease on battery posts. 11. Verify cable routing and attachments. 12. Insert diagnostic connector in its holder. 13. Install remaining removed components.
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    312
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    Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) STARTING SYSTEM SERVICE TOOLS Description Part Number Page DIAGNOSTIC HARNESS ............................................................... 529 036 179 ......................................... 315 ECM ADAPTER
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    Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) 3. Discharged battery - Check/recharge. Refer to CHARGING SYSTEM. STARTER TURNS, BUT STARTER DRIVE DOES NOT MESH WITH RING GEAR 4. Defective START/STOP switch - Check. 1. Worn starter drive gear - Replace starter drive. Refer to PTO
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    Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) NOTE: The solenoid may be the cause of a burnt fuse (F4). If fuse is good, proceed with the STARTER QUICK TEST. ENGINE START/STOP SWITCH Measure resistance through switch as per following table. START/STOP SWITCH OPERATION TEST SWITCH
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    Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) START/STOP SWITCH INPUT VOLTAGE TEST 8-PIN CONNECTOR OF DIAGNOSTIC HARNESS SWITCH POSITION Released Pressed and held Pins 1 and 2 VOLTAGE Battery voltage Close to 0 Vdc If test succeeded, problem is in the control circuit going to ECM.
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    Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) CONTROL CIRCUIT TEST POWER CIRCUIT TEST 8-PIN CONNECTOR OF DIAGNOSTIC HARNESS FUSE BOX 2 Pin 2 Terminal B2 RESISTANCE 8-PIN CONNECTOR OF DIAGNOSTIC HARNESS ECM CONNECTOR B RESISTANCE Close to 0 (continuity) Pin 1 B-D1 Close to 0
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    Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) smr2009-034-006_a If test succeeded, carry out a SOLENOID CON- TROL CIRCUIT TEST. smr2009-034-002_c 1. Fuse box 2 If test failed, carry out a POWER CIRCUIT TEST as follows. Solenoid Input Voltage Test (at Solenoid Connector) Solenoid
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    Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) SOLENOID CONTROL CIRCUIT TEST SOLENOID CONNECTOR ECM CONNECTOR B RESISTANCE Pin B B-L4 Close to 0 (continuity) smr2009-034-008_a If test failed, replace solenoid. If test succeeded, perform the following test. Disconnect battery negative
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    Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) Solenoid Dynamic Test SOLENOID DYNAMIC TEST (ENGINE CRANKING) Ensure battery and starter solenoid are properly connected. Set ECM in engine drowned mode: Depress throttle lever and install a rubber band to hold lever in full throttle
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    Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) smr2009-034-005_a smr2009-034-002_d 1. 2. 3. 4. 5. Fuse box 2 Diagnostic connector Electrical component support Voltage regulator/rectifier connectors Starter solenoid connector 7. Push locking tab and HOLD it. 1. Cables Solenoid
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    Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) NOTE: It may be necessary to pull retaining tab to ensure proper locking. Wiggle solenoid to ensure it is securely locked. Reinstall remaining components. Reconnect battery and test starter solenoid operation. BLACK booster cable: Connect
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    Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) Disconnect starter power cable. Remove starter retaining screws. Starter Gear Installation Installation is the reverse of removal procedure. However, pay particular attention to the following. Use a new circlip. Starter Installation
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    Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) WARNING To prevent electric shock whenever connecting the RED power cable to the starter motor, ensure the BLACK (-) battery cable is disconnected. Apply DIELECTRIC GREASE (P/N 293 550 004) on terminal and nut. Ensure to install rubber
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    Section 05 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.) SERVICE TOOLS Description Part Number Page DIAGNOSTIC HARNESS ............................................................... 529 036 179
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    Section 05 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) BEEPER SIGNIFICATION 2 short beeps Indicate a working D.E.S.S. key. Engine starting can take place. 1 long beep Indicates a wrong D.E.S.S. key is being used or something is defective. Engine starting is not
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    Section 05 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) smr2009-035-003_c After approximately 10 seconds, the following window will pop up confirming the new key has been saved in the PC computer. smr2009-035-005_a 1. Key to be erased Click on Erase Key button at
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    Section 05 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) If programming is complete, write the changes to the ECM. Refer to WRITING CHANGES TO ECM in this subsection. After the write operation, remove key from D.E.S.S. post. Try the key(s) on the watercraft. Erasing
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    Section 05 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) sdd2009-001-024_e 1. MODE button smo2009-002-114_c NOTE: Pressing the SET button twice will enable the Rental key setting function. 6. Press the UP or DOWN arrow button to toggle the key setting between 1 and
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    Section 05 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) MAXIMUM WATERCRAFT SET SPEED TABLE D.E.S.S. KEY TYPE KEY SETTING APPROX. MAX. SPEED 5 58 km/h (36 MPH) 4 55 km/h (34 MPH) 3 50 km/h (31 MPH) 2 47 km/h (29 MPH) 1 42 km/h (26 MPH) 5 74 km/h (46 MPH) 4 69 km/h
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    Section 05 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) smr2009-035-001_b D.E.S.S. Key on Post Probe D.E.S.S. post terminals to check continuity as follows. smr2009-042-005_b 8-PIN CONNECTOR D.E.S.S. POST HARNESS 1. 8-pin connector here Set multimeter to . Probe
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    Section 05 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) 8-PIN CONNECTOR ECM ADAPTER RESISTANCE D.E.S.S. POST VEHICLE TOOL @ 20°C (68°F) HARNESS 5 B-E4 4 B-B2 3 B-F2 Close to 0 smr2009-035-009_a Reinstall removed components. If any continuity test failed, check
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    Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) GAUGE SERVICE TOOLS Description Part Number Page FLUKE 115 MULTIMETER ............................................................ 529 035 868 ................................. 344, 353 SERVICE PRODUCTS Description Part Number Page DIELECTRIC
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    Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) PROCEDURES INFORMATION CENTER Information Center Overview The information center (cluster) is a multifunction gauge that supplies several real time useful informations to the driver. The information can be displayed in three languages (English,
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    Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) Gauge Description 9 3 7 8 2 1 4 4 6 10 11 13 12 14 5 smo2009-002-119_a 1. Speedometer 2. Tachometer 3. Digital screen 4. Indicator lights 5. Fuel level 6. VTS position 7. iS position 8. Numerical display 9. Multifunction display 10. Depth sounder
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    Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) The numerical and multifunction displays in the digital screen can be used to display various indications, or for selecting modes of operation and changing settings as explained in their respective subsections. PILOT LAMPS (ON) MESSAGE DISPLAY
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    Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) A single segment of a bar gauge type indicator is turned on to indicate the relative position of the watercraft bow. pears and a single segment of the bar gauge is turned on to indicate the position of the suspension. Refer to SUSPENSION (iS) for
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    Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) 9) Multifunction Display When the watercraft is being operated, the multifunction displays provides and indication of compass direction, scrolling messages from the fault monitoring system, or a scrolling DOCK MODE ON message when the function is
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    Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) – KEY MODE – SETTINGS. Press the SET button (or the UP or DOWN arrow button) to enter the desired function. NOTE: The fault codes function is available only when there is an active fault. The settings function is only available when the engine is
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    Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) MESSAGE DISPLAY INFORMATION CALIBRATION CHECKSUM ERROR Cluster programming corrupted MAINTENANCE REQUIRED Watercraft maintenance required SUPERCHARGER MAINTENANCE REQUIRED Maintenance on supercharger required 10) Depth Sounder Indicator GTX Limited
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    Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) Setting Language and Units of Measurement smo2009-002-114_u IBR POSITION - FORWARD ILLUSTRATED (F) 14) Compass A GPS incorporated in the information center provides the indication in the multifunction display. The cardinal points, intermediate
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    Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) Clearing the Maintenance Reminder Indicators When the watercraft, engine or supercharger is due for maintenance, the maintenance reminder indicator light in the speedometer will come on, and a scrolling MAINTENANCE REQUIRED or SUPERCHARGER
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    Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) Double click the iS button to move the suspension to the up position. If the suspension does not move to the up position, the problem is related to the electrical power system. Refer to POWER DISTRIBUTION subsection. If the suspension moves to the
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    Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) NO Speed or Compass Indication If there is no speed or compass indication, look for the GPS indicator icon. If the GPS indicator is off, either the GPS cannot uplink with the satellites, or the GPS system in the information center is at fault. If
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    Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) 4. Carry out an input voltage test at the steering connector (vehicle harness side) as per following table. V 12 INFORMATION CENTER INPUT VOLTAGE TEST (STEERING CONNECTOR) INFORMATION CENTER VOLTAGE STEERING CONNECTOR Pin 7 (Violet) Pin 6 (Black)
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    Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) smr2009-027-011_g VOLTAGE TEST AT FUSE CONTACTS smr2009-036-006_a BATTERY VOLTAGE TEST 7. Remove the cover from fuse box 2 (FB2). smr2009-027-011_d TYPICAL - CONTACT COORDINATES (FRONT VIEW FB1) If battery voltage is measured at A12 but not at A11
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    Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) Continuity Test of Gauge Power Wire 1. Remove lanyard. 2. Disconnect gauge connector. NOTICE Pull connector lock out sideways. Do not twist the screwdriver. 5. Set multimeter to setting. 6. Test the information center power wire continuity as per
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    Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) Remove the RH rear storage bin, refer to BODY subsection. Remove the cover from fuse box 2. smr2009-036-005_a 12 PIN STEERING CONNECTOR PIN-OUT (VEHICLE SIDE) A. Connector alignment keys 2009-027-009_a 1. Fuse box #1 2. Fuse box #2 Remove the
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    Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) 10 12 1 11 smr2009-036-003_a GAUGE CONNECTOR PIN-OUT smr2009-027-010_f TYPICAL - CONTACT COORDINATES (FRONT VIEW FB2) Repair wiring and connectors as required. Information Center Removal smr2009-036-005_b 1. Open the front cover. 2. Move the
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    Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) Information Center Installation smr2009-042-067_a 1. LH side tab 2. Upper retaining tabs 5. Disconnect the gauge connector. NOTICE Pull connector lock out sideways. Do not twist the screwdriver. Installation of the information center is the reverse
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    Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) smr2009-036-011_b 1. 2. 3. 4. Read Data button Vehicle page tab Total Hours Supercharger maintenance hours (approximate time left) 4. Add the approximate time left to supercharger maintenance hours to the total hours to calculate the hours at which
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    Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) If the MODE switch is pressed, 2 diodes are bypassed. The remaining two diodes in the circuit drop 1.2 Vdc (at pin B). If the SET switch is pressed, 1 diode is bypassed. The remaining three diodes in the circuit drop 1.8 Vdc (at pin B). The gauge
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    Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) If one or all of the indicator lights does not come on, refer to MODE/SET AND UP/DOWN ARROW SWITCH TEST USING A MULTIMETER. MODE/SET and UP/DOWN Switch Test Using a Multimeter 1. Remove the gauge support cover, refer to INFORMATION CENTER REMOVAL
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    Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) If voltages measured on every switch are as specified (or very close to it), the switches and the wiring harness are good. The fault may be within the gauge. Replace the gauge and carry out a new MODE/SET AND UP/DOWN TEST USING B.U.D.S. to ensure
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    Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) DEPTH SOUNDER Depth Sounder Removal GTX Limited iS Models 1. Open the boarding platform. Depth Sounder Troubleshooting DEPTH SOUNDER TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE Depth sounder not connected. Depth sounder not properly installed. Nothing
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    Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) 5. Remove the battery (with holder) from the watercraft, refer to CHARGING SYSTEM. WARNING Always disconnect the battery cables exactly in the specified order, BLACK (-) battery cable first then the RED (+) cable last. 6. Unlock the depth sounder
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    Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) 6. Install the diagnostic connector in its holder. 7. Carry out the following procedure: TESTING DEPTH SOUNDER OPERATION. Testing Depth Sounder Operation 1. Press START/STOP button. 2. Install the D.E.S.S. key on the D.E.S.S. post. 3. Check
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    358
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    Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) STEERING AND O.T.A.S. SERVICE TOOLS Description Part Number D.E.S.S. POST REMOVER ............................................................ ECM ADAPTER TOOL...................................................................
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    Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) 6 N•m (53 lbf•in) 2.5 N•m (22 lbf•in) 16 N•m (142 lbf•in) 7 N•m (62 lbf•in) 10 N•m (89 lbf•in) 5 N•m (44 lbf•in) 7 N•m (62 lbf•in) 7 N•m (62 lbf•in) 0.7 N•m (6 lbf•in) 7 N•m (62 lbf•in) 0.7 N•m (6 lbf•in) 6 N•m (53 lbf•in) 7
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    Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) GENERAL ADJUSTMENT During assembly/installation, use torque values and service products as in the exploded view. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the
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    Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) smr2009-042-007_a 1. 2. 3. 4. Steering Steering Steering Steering column column clamp bolts column clamp cable adjusting nut smr2009-037-034_a After adjustment, torque steering column clamp bolts to 6 N•m (53 lbf•in).
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    Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) smr2009-037-007_a smr2009-037-041_a 1. 2. 3. 4. 5. 6. Nozzle Nozzle arm Hexagonal screw Nozzle link rod Socket screw VTS trim ring Remove nozzle from watercraft. 1. Grip insert NOTE: Verify grip insert for damage. Handlebar
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    Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) smr2009-037-009_a 1. 2. 3. 4. 5. Grip insert Grip Flat washer Screw Cap HANDLEBAR SWITCH COVER (LH OR RH) Handlebar Switch Cover Removal (LH or RH) 1. Insert the end of a small screwdriver in one of cover slots.
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    Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) 3. Unlock steering cover from steering. 3.1 Insert a small tool, such as an Allen key, into a steering cover hole. Press the tool against the retaining tab to unlock it. Repeat for the other side. NOTICE The tool must be
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    Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) smr2009-037-019_a 1. Harness slots 5.2 Clip the top of the cover. 5.3 Stretch the bottom of the steering cover until the cover edge passes over the inner ribs. smr2009-037-031_a 1. 2. 3. 4. Retaining screw Washer Bushings
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    Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) 2. Remove the adjusting nut from steering cable end. 3. At the rear of the vehicle, disconnect ball joint from jet pump nozzle arm. smr2009-037-022_a 1. Steering cable 2. Steering cable nut 6. Remove steering cable nut, half
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    Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) A 2. Remove the gauge support. Refer to GAUGE subsection. 3. Disconnect the four connectors under moving deck. smr2006-031-006_a A. 9 mm ± 1 mm (.354 in ± .039 in) 11.2 Tighten jam nut to 2.5 N•m (22 lbf•in). 11.3 Position the
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    Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) 3. On both side of vehicle, remove both pivot bushings (steering column support and steering adjustment handle). smr2009-037-028_a 1. Upper bushing 2. Steering column support 3. Lower bushing Check wear sleeve behind the
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    Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) O.T.A.S. SWITCH O.T.A.S. Switch Dynamic Test Connect B.U.D.S. software. Refer to COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE subsection. Briefly press the START/STOP button to wake up the ECM. Install the D.E.S.S. key on its
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    Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) STEERING POSITION Center position Fully turned MULTIMETER LEAD POSITION Pin "C" and vehicle ground O.T.A.S. MAGNETS RESISTANCE 1935 - 2365 324 - 396 If continuity test is out of specification, try any good magnet and bring it
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    372
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) iBR AND VTS SERVICE TOOLS Description Part Number Page DIAGNOSTIC HARNESS ............................................................... 529 036 179 ................................. 384, 386 FLUKE 115 MULTIMETER
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) 12 N•m Loctite 243 (106 lbf•in) NEW 12 N•m (106 lbf•in) 12 N•m (106 lbf•in) 24 N•m (18 lbf•ft) NEW 24 N•m (18 lbf•ft) NEW 18 N•m (24 lbf•ft) NEW 12 N•m (106 lbf•in) NEW 6 N•m (53 lbf•in) Silicone sealant 5150 10 N•m (88 lbf•in) NEW 8
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) GENERAL During assembly/installation, use torque values and service products as indicated in the exploded view. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) NOTE: The iBR lever must be pulled in at least 25% of its travel (approximately) before the iBR gate starts to move. The first 25% of iBR lever travel has no effect on the iBR gate. Every time the iBR gate moves when commanded by the
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) NOTICE An object or tool caught in the iBR gate, nozzle or linkages when using the iBR override function may cause damage to these components. Remove any foreign object that may obstruct the iBR gate travel. Activating iBR Override
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) WARNING When moving the iBR gate using the iBR override function, ensure nobody stands near the rear of the watercraft. Movement of the gate may squeeze fingers. SYSTEM DESCRIPTION (VTS) smo2009-002-114_hh 7. Press the UP/DOWN arrow
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) smr2009-038-026_a PULL DOWN SLIGHTLY ON iBR GATE sdd2009-001-042_a INFORMATION CENTER — VTS POSITION INDICATOR 1. Bow up 2. Bow down NOTE: Only the segment indicating the relative position of the VTS will be on. The illustration shows
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) 7. Check iBR gate backlash and gate operation after parts replacement and reassembly. FRICTION SLEEVE REPLACEMENT The 4 friction sleeves on the VTS trim ring should be replaced if they show signs of advanced wear (flat spots), or every
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) IBR GATE LOCKING SLEEVE REPLACEMENT 4. Install new screw(s) with Scotch Grip threadlocker and torque as specified in exploded view. NOTE: The iBR locking sleeve (iBR key) should be replaced if it is cracked, broken, show signs of
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) Test With Watercraft on a Waterway 1. Start watercraft and allow engine to run at idle RPM. NOTE: If iBR gate is not in the neutral position before the engine start, it will move to the neutral position on engine start up. 2. Depress
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) – Check the 30 A iBR power fuse in FB2 and the 5 A iBR control fuse in FB1 if the gate did not move using the iBR OVERRIDE function. – Connect the watercraft to B.U.D.S. to check for iBR system or CAN bus related fault codes. Carry out
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) NOTE: Connect only the test harness 12 and 6 pin connectors to both sides of same steering harness connectors. smo2009-002-124_a Step 1: Push storage bin latches backwards (one each side) Step 2: Lift and tilt forward to remove storage
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) 6-PIN CONNECTOR OF DIAGNOSTIC HARNESS PIN iBR LEVER RELEASED iBR LEVER PULLED IN VOLTAGE (Vdc) 4 5 5 6 4.9 - 5.1 0.15 - 0.35 1.4 - 1.6 Continuity Test of BRLS Wiring Harness 1. Ensure the steering connector (C01-12 POS and C03-6 POS)
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) smr2009-036-004_c 1. Forward ventilation box 2. 12 pin steering connector to disconnect 3. 6 pin steering connector to disconnect smr2009-038-003_b Step 1: Disconnect the 12 pin connector 6. Measure for continuity from the BRLS
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) CONTINUITY TEST STEERING CONNECTORS TO iBR CONNECTOR 12 PIN 6 PIN STEERING STEERING 12 PIN iBR Pin 5 (VI/YL) - Pin 7 (VI/YL) Pin 4 (BK) - Pin 9 (BK) Pin 3 (YL/WH) - Pin 5 (YL/WH) - Pin 4 (VI/YL) Pin 4 (VI/YL) - Pin 5 (BK) Pin 6 (BK) -
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) smr2009-038-029_a 1. iBR position indication smr2009-038-028_a 1. Read Data 2. Activation page tab 3. iBR tab 6. Select the iBR UP and iBR DOWN s alternately and look for a change in iBR Position (Deg). 2. Press and hold the VTS UP
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) smr2009-038-030_a 1. iBR motor harness connector 2. iBR motor module connector smr2009-038-033_b Step 1: Note iBR current draw Step 2: Note iBR position indication change iBR ACTUATOR CURRENT DRAW DOWN SELECTION -5 to -15 A UP SELECTION
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) iBR Actuator Input Voltage Test 1. Disconnect the 3 pin and 12 pin connectors from the iBR actuator. sdd2009-001-019_c 1. VTS UP 2. VTS DOWN NOTE: Electrical power will shut off after approximately 3 minutes. Briefly press the
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) If battery voltage is not measured, check the following: – 30 A iBR fuse in FB2 – Battery voltage at fuse contact D11 of FB2 – Wire continuity pin 2 iBR 3 pin connector to D12 of FB2 – Jumper continuity fuse contact FB2-D11 to FB2-A6 of
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) 2. Open the boarding platform and remove the LH storage bin. 3. Disconnect the two aft electrical connectors from the iBR actuator. The forward electrical connector (iBR motor power) does not need to be removed. smr2009-038-002_a 1.
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) iBR GATE iBR Gate Removal (with VTS Trim Ring and Steering Nozzle) 1. Move the iBR gate to the forward position (full up) using the iBR OVERRIDE function. Refer to SYSTEM DESCRIPTION (iBR) in this subsection. NOTICE Do not try to move
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) iBR Gate and VTS Trim Ring Disassembly VTS Trim Ring Removal Remove the two hexagonal screws securing the iBR gate to the VTS trim ring. smr2009-038-008_a 1. Trim ring hexagonal screw (LH side) smr2009-038-011_a 1. iBR gate retaining
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) smr2009-038-022_a TYPICAL - WORN AND DEFORMED PLASTIC BUSHING smr2009-038-025_a TYPICAL - WEAR MARK ON VTS RING AND iBR GATE CONTACT POINTS 1. Wear mark on VTS ring 2. Wear mark on iBR gate NOTE: Wear marks on VTS ring and iBR gate
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) 2. Replace as required. Steering Nozzle Lever Inspection 1. Inspect steering nozzle lever, steering arms, and spacers for cracks, elongated holes, evidence of wear, deformation and other damages. 2. Replace as required.
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) smr2009-038-011_b 1. Small end of nozzle 2. Steering lever 3. Warning label iBR Gate Installation (with VTS Trim Ring and Steering Nozzle) Installation is the reverse of the removal procedure however, pay attention to the following: –
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) iBR GATE SUPPORT PLATES iBR Gate Support Plate Removal NOTE: The following steps must be carried out when removing the LH or RH support plates. 1. Open the boarding platform. 2. Remove the following listed items, see procedures in this
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) smr2009-043-006_a smr2009-039-002_a 1. Bailer hoses 3. Loosen the gear clamp and disconnect the water pressure hose from the jet pump. smr2009-039-003_a 1. Water pressure hose 4. Remove the LH storage bin, refer to the BODY subsection.
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) 4. Install 5 new hexagonal screws to secure iBR support plates and torque as per exploded view. 5. Install the fitting plate, refer to FITTING PLATE in this subsection. 6. Install remaining parts in reverse order of removal. Refer to
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) smr2009-043-005_a TYPICAL 1. Hexagonal screw 2. Metal fitting plate retainer smr2009-039-003_a 4. Cut the locking ties and disconnect the 2 bailer hoses from the jet pump venturi. 1. Water pressure hose 6. Pull the fitting plate out of
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) Fitting Plate Installation Models With a Metal Retainer on Fitting Plate 1. Ensure the "O" ring seal is properly installed on the fitting plate and in good condition. 2. Insert the fitting plate through the outer iBR support plate. 3.
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) 7. Install remaining parts in the reverse order of removal, refer to appropriate procedure in this subsection. Models With Plastic Retaining Tabs on Fitting Plate NOTE: Installation is the same as the model with metal retainer except
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) 5. Depress and hold the VTS UP arrow button and ensure the iBR gate moves up to the forward position. NOTE: If the VTS button is released before full travel of the iBR gate, movement of the iBR gate will cease. If the iBR does not
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) fault may be within the gauge. Replace the gauge and carry out a new VTS BUTTON TEST USING B.U.D.S. to ensure the problem is solved. VTS Control Button Removal NOTE: The VTS and iS control s come as a switch assembly which must be
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    Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) smr2009-038-035_b 1. START/STOP switch 2. Wiring routed in slot provided in support 3. VTS/iS switch connector 4. Insert switch assembly in switch support. 5. Install steering cover, refer to STEERING AND O.T.A.S. 6. Carry out an
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    Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) JET PUMP SERVICE TOOLS Description Part Number IMPELLER REMOVER/INSTALLER ............................................... IMPELLER REMOVER/INSTALLER ............................................... IMPELLER SHAFT BEARING TOOL
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    Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) XPS synthetic grease 125 N•m (92 lbf•ft) Loctite 577 (thread sealant) NEW Jet pump bearing grease Loctite 767 (antiseize lubricant) Jet pump bearing grease (24 ml (.81 U.S. oz)) NEW 125 N•m (92 lbf•ft) Jet pump bearing grease (4 ml (.14
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    Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) GENERAL During assembly/installation, use torque values and service products as in the exploded views. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENER and LOCTITE APPLICATION at the beginning of this manual for
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    Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 5290218002 smr2009-006-008_a TYPICAL — MEASURING IMPELLER SHAFT RADIAL PLAY 1. Dial gauge 2. Measure close to impeller hub end RADIAL PLAY 0 mm (0 in) Excessive play can come either from worn bearing or damaged jet pump housing bearing
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    Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) Sacrificial Anode Removal Unscrew sacrificial anode hexagonal screw and remove anode. smr2009-006-002_a TYPICAL 1. Small leak here is acceptable 6. Disconnect pump and remove pressure cap. 7. Reinstall impeller cover. Refer to IMPELLER
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    Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 3. Loosen gear clamp and remove the hose from the water pressure outlet fitting on the jet pump housing. Jet Pump Housing Inspection and Cleaning 1. Visually inspect jet pump housing. Pay attention to the stator. Ensure the assembly is
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    Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 2. Install the pump on a spare ride plate, the mounting screws should be tight, but it is not required to torque them. 3. Torque hexagonal screws retaining the adapters to the jet pump housing as specified in the exploded view. 4. Remove
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    Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) VENTURI Venturi Removal Jet Pump Housing installed 1. Remove the iBR gate and VTS trim ring as an assembly. Refer to iBR AND VTS subsection. 2. Cut locking ties and remove the 2 bailer hoses from the venturi. 3. Refer to JET PUMP HOUSING
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    Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 5. Remove both O-rings. Check impeller boot and O-rings condition on impeller. Replace as required. smr2009-006-004_a smr2009-006-003_a TYPICAL 1. O-rings 1. Impeller boot 2. Impeller O-ring 3. Pump housing O-ring Impeller Cover Inspection
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    Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 3. Install impeller cover by aligning the cover index mark with the pump top fin as shown. 1 sdd2009-001-114_c 1. Align mark with top fin NOTE: Cover can only be installed in one position as screw holes are not located symmetrically. 4.
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    Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 529035820 TOOL FOR 130 AND 155 ENGINES smr2009-006-005_a TYPICAL 1. Flat side 2. Apply LOCTITE 767 (ANTISEIZE LUBRICANT) (P/N 293 800 070) on threads of impeller shaft. 529035956 TOOL FOR 215 AND 255 ENGINES 6. Unscrew the impeller
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    Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) WEAR RING Wear Ring Inspection Check wear ring for: – Deep scratches – Irregular surface – Any apparent damage. Check IMPELLER/WEAR RING CLEARANCE, see procedure at the beginning of this subsection. Wear Ring Removal smr2009-006-007
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    Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 2. Mount in a vise the appropriate impeller remover/installer tool according to engine type. MODEL 130 and 155 engines 1 215 and 255 engines TOOL IMPELLER REMOVER/INSTALLER (P/N 529 035 820) IMPELLER REMOVER/INSTALLER (P/N 529 035 956) 1 2
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    Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 8. Use the IMPELLER SHAFT PUSHER (P/N 529 035 955) to press impeller shaft out of pump housing. NOTE: Bearing will come out with the impeller shaft. smr2009-006-009_a TYPICAL 5. Remove impeller shaft nut. 529035955_a smr2009-006-010_a
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    Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) smr2009-006-012_a smr2009-006-006_a TYPICAL 1. Impeller shaft and bearing 2. Bearing tool on INNER race TYPICAL Impeller Shaft Nut Removal if Impeller has Loosened 1. Turn pump upside down and mount the flat sides of impeller shaft in a
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    Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) smr2009-006-019_a TYPICAL 1. Threads 2. Seal lip contact surface 3. Threads Inspect ball bearing for corrosion. smr2009-006-014_a Impeller Shaft and Bearing Installation Bearing Installation The installation is essentially the reverse of
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    Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 1 F18J12A F18J14B TYPICAL 7. Press a NEW double lip seal using the SEAL/BEARING PUSHER (P/N 529 035 819) until seal bottoms. Make sure seal lip are facing upwards. TYPICAL 1. Seal/bearing pusher 8. Install spacer and then the other seal
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    Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) smr2009-006-017_a TYPICAL 1. O-rings F18J0QA 12. Before installing any other parts, pressurize jet pump to insure proper seal installation. Refer to LEAK TEST in this subsection. 13. Install impeller. Refer to IMPELLER in this subsection.
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    Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 19. Install the impeller cover. Refer to IMPELLER COVER in this subsection. smr2009-039 425
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    426
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    Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) DRIVE SHAFT SERVICE TOOLS Description Part Number Page DRIVE SHAFT ADAPTER............................................................... 529 035 985 ................................. 431, 433 DRIVE SHAFT WRENCH
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    Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) NEW Engine oil Loctite 577 (thread sealant) XPS synthetic grease 8 turns + 125 N•m (92 lbf•ft) LH threads smr2009-040-001_a 428 smr2009-040
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    Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) GENERAL The jet pump must be removed to replace any component of the drive system. Refer to JET PUMP for removal procedure. During assembly/installation, use torque values and service products as specified in the exploded view. Clean
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    Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) PROCEDURES DRIVE SHAFT Drive Shaft Removal To prevent oil spillage when pulling out drive shaft, carry out the following: – Start engine. – Bring engine to 4000 RPM for 10 seconds. – Stop engine at this RPM. NOTE: If engine cannot be
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    Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) smr2009-040-003_a 1. Sealing ring smr2009-007-002_a TYPICAL 1. Drive shaft wrench 12. From rear of watercraft, install the DRIVE SHAFT ADAPTER (P/N 529 035 985) on drive shaft end. smr2009-007-001_a TYPICAL 1. Rubber protector 10.
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    Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) smr2009-007-006_a smr2009-007-003_b TYPICAL - CLOCKWISE TO UNSCREW CAUTION Ensure to unscrew clockwise on LH threads (opposite of usual threads). 14. Place rags under PTO housing to prevent oil spillage. If spillage occurs, clean
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    Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) 2. Remove the damper at the end of drive shaft and replace it with a NEW one. smr2009-007-010_a LOCTITE 577 APPLICATION A. First 5 threads B. 3 mm (1/8 in) smr2006-028-004_a 1. Damper 3. Wipe clean the sealing ring and the carbon seal
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    Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) smr2009-007-002_a smr2009-007-003_a TYPICAL 1. Drive shaft adapter NOTE: Make sure all spark plugs are removed from engine. 12. Removing spark plugs helps to engage threads more easily thus preventing cross-threading the sealing ring.
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    Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) 23. Run watercraft then ensure there is no oil leak in PTO seal area. 24. Properly reinstall the deck extension, moving deck and ventilation box. Refer to BODY subsection. SEALING RING Sealing Ring Removal 1. Remove drive shaft. Refer
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    Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) smr2009-007-008_a WRONG 1. Sealing ring incompletely inserted into PTO seal 436 smr2009-040
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    Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) SUSPENSION (iS) SERVICE TOOLS Description Part Number Page FLUKE 115 MULTIMETER ............................................................ 529 035 868 ................. 447, 449–450, 452 MAGNETO HARNESS 6
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    Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) FRONT 48 N•m NEW (35 lbf•ft) 10 N•m NEW (89 lbf•in) NEW 12 N•m NEW (106 lbf•in) 25 N•m (18 lbf•ft) NEW 25 N•m NEW (18 lbf•ft) NEW 12 N•m (106 lbf•in) NEW 10 N•m NEW (89 lbf•in) 10 N•m (89 lbf•in) NEW NEW 25 N•m (18 lbf•ft) NEW 75 N•m (55
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    Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) REAR NEW 12 N•m (106 lbf•in) NEW 25 N•m (18 lbf•ft) NEW 25 N•m (18 lbf•ft) NEW 12 N•m (106 lbf•in) NEW 10 N•m (89 lbf•in) NEW 25 N•m (18 lbf•ft) 25 N•m (18 lbf•ft) 25 N•m NEW (18 lbf•ft) 10 N•m NEW (89 lbf•in) smr2009-041-002_a smr2009-041
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    Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) GENERAL NOTE: For a complete overview of the vehicle electrical system, refer to POWER DISTRIBUTION subsection. It is highly recommended to disconnect the battery when replacing any electric or electronic component. WARNING Always disconnect
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    Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) The suspension can be set to the AUTO or MANUAL mode. In AUTO mode, suspension height is factory preset and the iS module constantly monitors the stroke of the suspension and it automatically readjusts suspension height for changing water
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    Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) 5. Leak on hydraulic circuit. - Repair or replace defective part(s). 6. Faulty suspension position sensor. - Test sensor and replace as required. SUSPENSION BOTTOMS HARD. 1. Spring(s) out of specification or broken. - Replace the defective
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    Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) DIAGNOSTIC FLOW CHARTS iS Electrical Troubleshooting Suspension does not move NO Can you see iS display? Check CAN bus YES Check for hydraulic or mechanical problem, see is hydraulic/mechanical troubleshooting flow chart Can you hear the
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    Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) iS Hydraulic/Mechanical Troubleshooting Suspension does not move Can you hear the hydraulic pump running when pressing iS button(s) on steering? Check for an electrical problem, see iS electrical troubleshooting flow chart NO YES NO Level
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    Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) PROCEDURES SHOCK ABSORBER Shock Absorber Removal 1. Remove the moving deck. Refer to BODY subsection. 2. Remove tapes securing central bellows to mounting plate. 3. Move down central bellows to reach shock holder screws. 4. Remove and discard
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    Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) 2. The shock should extend unassisted. Rod must come out at a steady speed. If any problem is detected, replace the shock absorber. Shock Absorber Installation The installation is the reverse of the removal procedure. However, pay attention
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    Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) Suspension Position Sensor Input Voltage Test At Sensor Connector SUSPENSION POSITION SENSOR CONNECTOR Pin 1 Pin 2 VOLTAGE 5 Vdc 295000136 5. Using the FLUKE 115 MULTIMETER (P/N 529 035 868), check voltage as per the following table. Using
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    Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) 529035868 smr2009-041-011_a SUSPENSION POSITION (% in B.U.D.S.) iS MODULE (6-pin connector) RESISTANCE All positions 4 6 1803 - 2203 100% 5 6 4 5 1361 - 1663 88% 5 6 1904 - 2327 88% 4 5 1410 - 1724 75% 5 6 1871 - 2287 75% 4 5 1448 - 1770 53%
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    Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) NOTE: When reassembling parts, index sensor lever shaft with sensor inner slot. The sensor lever must be positioned to 180° with the sensor electrical connector. smr2009-041-055_a Repeat the test using a test light. TEST LIGHT POSITION Pin 1
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    Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) iS Module Input Voltage Test (Battery Power) Continuity Test of iS Module Battery Power Wire Using the FLUKE 115 MULTIMETER (P/N 529 035 868), perform the following test. iS MODULE 3-PIN CONNECTOR BATTERY VOLTAGE (VDC) Pin 1 Positive post
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    Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) smr2009-041-037_a smr2009-041-034_a 1. Suspension position sensor connector 3. Detach the retaining latch. 1. iS module input voltage connector NOTE: The locking tab of input voltage connector is located underneath. 6. Remove the iS module
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    Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) transmit it through the CAN bus. The module will react to the command, carry out the function, and transmit the result back through the CAN bus. The gauge will use the signals from the switches and the transmitted information from the other
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    Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) Hydraulic Pump Fluid Level Verification iS SWITCH TEST SWITCH POSITION Switch released UP depressed DOWN depressed MULTIMETER LEAD/GAUGE CONNECTOR VOLTAGE RED lead/Pin 14 BLACK lead/Pin 15 Approx. 2 Vdc BLACK lead/Pin 14 Red lead/Pin 15 OL
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    Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) Reinstall reservoir plug and tighten it to 1 N•m (9 lbf•in). If the current draw is excessive, replace the hydraulic pump. Hydraulic Pump Operation Test Hydraulic Pump Removal (as a Unit with Actuator) Connect a jumper from the positive (30 A
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    Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) smr2009-041-028_a 1. Actuator holder screws 7. Remove the suspension position sensor to avoid damaging it. 8. Remove screws securing both rear ends of front suspension arm to suspension base. smr2009-041-045_a VIEW FROM THE REAR OF VEHICLE 1.
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    Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) smr2009-041-016_a 1. Cut this locking tie 2. Hydraulic hose 6. Unscrew the retaining clamp completely and remove it. smr2009-041-019_a 1. Socket screw 2. Hydraulic hose lock 9. Remove hose from pump and plug hose to avoid oil spillage. 10.
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    Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) 4. Secure hydraulic pump to suspension base. 4.1 Install pump retaining screw and tighten it to 10 N•m (89 lbf•in). 4.2 Install retaining clamp and tighten it to 2 N•m (18 lbf•in). 5. Secure hose to reservoir with a new locking tie. 6. Route
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    Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) smr2009-041-052_a 1. Hose fully inserted in lock slot 2. Position hydraulic hose in lock hook Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on threads of lock screw. Tighten screw to 8 N•m (71 lbf•in). Install the hydraulic pump in vehicle. Make
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    Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) smr2009-041-026_a smr2009-041-024_a 1. Lateral support screw 2. Decouple lateral support from suspension shaft. 3. Using the SUPERTITANIUM DRILL BIT 3/16" (P/N 529 031 800), remove all rivets (12) securing the lateral bellows ring to body.
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    Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) 2. Using a marker, trace the shape of suspension base at the bottom of the hull to reposition it at the same place. 3. Remove and discard suspension base screws. smr2009-041-024_a RH SIDE SHOWN 1. Lateral support screw 4. Decouple lateral
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    Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) Suspension Base Installation The installation is the reverse of the removal procedure. However, pay attention to the following. 1. Install the suspension base. 1.1 Position the base in accordance with the reference marks previously drawn at
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    Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) NOTE: If the upper arm shaft or one of its arm shaft support has been removed or loosened, refer to SUSPENSION ARM SHAFTS for proper installation procedure. 2. Tighten screws to 25 N•m (18 lbf•ft). 3. Carefully lower and secure the rear
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    Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) 5.3 Reposition rear suspension arm brackets on fixed deck until positioning of moving deck is satisfactory. 6. Secure the rear suspension arm to the fixed deck. 6.1 Install NEW screws to secure rear suspension arm brackets. 6.2 Remove and
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    Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) smr2009-041-078_a 1. Support pin 2. Holder hole 4. Tighten the LH support screws to 25 N•m (18 lbf•ft). 5. Apply a force on the RH support to move it on the left side. NOTE: A bar clamp can be used to compress both supports together. NOTICE
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    Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) 5. Remove and discard socket screws securing rear brackets to arm shaft ends. smr2009-041-071_a 1. Bad installation 2. Good installation smr2009-041-069_a 1. Socket screw 2. LH rear bracket 6. Press one rear bracket against the suspension arm
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    466
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    Section 07 BODY AND HULL Subsection 02 (BODY) BODY SERVICE TOOLS Description Part Number Page SUPERTITANIUM DRILL BIT 3/16"................................................ 529 031 800 ......................................... 485 SERVICE PRODUCTS Description Part Number Page BRP PLASTIC & VINYL
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    Section 07 BODY AND HULL Subsection 02 (BODY) 2. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on threads of shock absorber body. 3. Tighten manually the attachment on gas shock. 4. Install the bellows and secure it using a locking tie. 5. Install the gas shock on cover. NOTE: The corrugated section
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    Section 07 BODY AND HULL Subsection 02 (BODY) Deck Extension Installation 1. Position the deck extension. 2. Install screws retaining deck extension and air inlet. 3. Tighten these screws to 1.5 N•m (13 lbf•in). NOTICE Do not tighten screws over this recommended torque. Otherwise, the rubber
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    Section 07 BODY AND HULL Subsection 02 (BODY) Tilting Moving Deck for Servicing Watercraft 5. Lift the rear suspension arm against seat handle and attach it with locking tie or strap. 1. Remove the BOARDING PLATFORM, see procedure in this subsection. smr2009-042-012_a ssi2009-002-002_a 1. Seat
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    Section 07 BODY AND HULL Subsection 02 (BODY) Removing the Moving Deck for Servicing Watercraft 1. Open the front storage cover and remove the front basket. 2. Remove the BOARDING PLATFORM, see procedure in this subsection. smr2009-042-066_a 1. Hoist 2. Lifting strap ssi2009-002-002_a 1. Boarding
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    Section 07 BODY AND HULL Subsection 02 (BODY) smr2009-042-011_a 1. Rear suspension arm 2. Reinstallation marks 3. Screws (discard) 6. Lift and attach the rear suspension arm against seat handle. smr2009-042-014_a RH SIDE SHOWN 1. Front carpet (discard) 2. Protective cap 8.2 Remove and discard
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    Section 07 BODY AND HULL Subsection 02 (BODY) 15. Install lifting straps. 15.1 Using both mooring cleats under steering, install two lifting straps. smr2009-042-005_a 1. Disconnect these connectors 14. Detach steering cable from steering column. 14.1 Remove bolt securing ball joint to steering
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    Section 07 BODY AND HULL Subsection 02 (BODY) smr2009-042-074_a 1. Steering cable 2. Steering column 3. Install steering cable clamp and its bolts. Do not tighten bolts yet. smr2009-042-015_a RH SIDE SHOWN 1. Retaining screws (new) 6. Remove pieces of wood located under lateral supports and
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    Section 07 BODY AND HULL Subsection 02 (BODY) 10. Install two homemade alignment pins on suspension mounting plate. 10.1 Take two M8 x 50 bolts and cut their heads. 10.2 Make into a round shape the cut ends. 16. Carefully lower and secure the rear suspension arm to the fixed deck. 16.1 Position the
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    Section 07 BODY AND HULL Subsection 02 (BODY) STORAGE COMPARTMENT COVER smr2009-042-029_a 1. Cover hinge key 2. Front body module slot smr2009-042-024_a 1. Storage compartment cover Storage Compartment Cover Removal 1. Open cover. 2. Cut locking tie retaining the bellows of gas shock. Storage
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    Section 07 BODY AND HULL Subsection 02 (BODY) 3. Install the new mirror and tighten wing nut. 3.1 The mirror adjustment is correct when the spring length is between 10 mm and 12 mm (13/32 in and 15/32 in). smr2009-042-031_a 1. Lower attachment in its cavity Close cover to lock the bottom of the gas
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    Section 07 BODY AND HULL Subsection 02 (BODY) GLOVE BOX COVER FRONT GRILLE smr2009-042-055_a 1. Glove box cover Glove Box Cover Removal 1. Move steering in its upper position. 2. Open glove box cover until cover hinges are aligned with front body module openings. smr2009-042-056_a LOCATED UNDER
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    Section 07 BODY AND HULL Subsection 02 (BODY) BODY COVER ssi2009-003-004_a LH SIDE SHOWN 1. Remove this plastic push-in clip smr2009-042-057_a 1. Body covers Body Cover Removal 6. Open seat and using a 3/16" drill bit, drill the rivets securing the seat trims. 1. Remove the STORAGE COMPARTMENT
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    Section 07 BODY AND HULL Subsection 02 (BODY) – Storage bin – Glove box cover – Body covers and front grille – Steering and steering lock – Speed-Tie unit (if equipped). 2. Remove both screws and washers located between seat and glove box. smr2009-042-059_a RH SIDE SHOWN 1. Center retaining tab 10.
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    Section 07 BODY AND HULL Subsection 02 (BODY) smr2009-042-064_a 1. Front body module retaining tabs 6. Remove front body module. Front Body Module Installation The installation is the reverse of the removal procedure. SEAT Seat Removal 1. Open seat. 2. Attach the seat to support it during removal.
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    Section 07 BODY AND HULL Subsection 02 (BODY) For dirt build-up, use BRP PLASTIC & VINYL CLEANER (P/N 413 711 200), Vinyl Finish Vinyl Cleaner or an equivalent. Let soak for approximately 10 minutes, then gently scrub with a soft bristle brush. For specific stain removal, refer to your cleaning and
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    Section 07 BODY AND HULL Subsection 02 (BODY) smr2009-042-045_a smr2009-042-048_a 1. Front bumper 2. Protective caps 1. Rear bumper 2. Protective cap 2. Remove side screws securing front bumper to body. 2. Remove side screws securing rear bumper to body. smr2009-042-046_a smr2009-042-049_a FROM RH
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    Section 07 BODY AND HULL Subsection 02 (BODY) smr2009-042-053_a smr2009-042-051_a 1. Protective skin 1. Trace a line here 3. Pull the top of bumper to unclip it from body. NOTE: A heat gun can be used to soften side bumper. 4. Insert bumper over body lip. 4.1 Insert lower section first. 4.2 Insert
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    Section 07 BODY AND HULL Subsection 02 (BODY) ssi2009-003-003_a 1. Upper trim smr2009-042-034_a 4. Remove the plastic push-in clip retaining the LH trim. 1. Retaining tabs 7. Using a small screwdriver, release both retaining hooks securing the cam trim on locking mechanism. ssi2009-003-004_a 1.
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    Section 07 BODY AND HULL Subsection 02 (BODY) smr2009-042-036_a 1. Retaining screws 4. Remove the Speed-Tie unit from vehicle. ssi2009-003-010_a 1. Rear locking tab Front Speed-Tie Unit Installation 13. Lightly pull the top of LH trim and remove the reel of the Speed-Tie unit from its location as
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    Section 07 BODY AND HULL Subsection 02 (BODY) 5. Lift the lever and insert the locking mechanism so that the lever is pointing toward the front of vehicle. ssi2009-003-010_a 1. Rear locking tab 2.3 Lightly pull the top of LH trim and insert the reel of the Speed-Tie unit in its location as shown.
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    Section 07 BODY AND HULL Subsection 02 (BODY) 9. Install the front trim. 9.1 Insert top tabs and align lower tabs with openings. ssi2009-003-102_a 1. Locking lever 2. Boarding platform slot 4. Position a double cage nut on the locking mechanism. ssi2009-003-016_a 1. Tabs 9.2 Press trim in place.
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    Section 07 BODY AND HULL Subsection 02 (BODY) ssi2009-003-109_a 1. Tabs 2. Alignment pin ssi2009-003-105_a 1. Speed-Tie unit 9. Close boarding platform. 10. Tighten tapered screws securing the locking mechanism to 2.5 N•m ± 0.5 N•m (22 lbf•in ± 4 lbf•in). 12.2 Press trim in place. 13. Test
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    Section 07 BODY AND HULL Subsection 02 (BODY) ssi2009-003-018_a 1. Untie this knot 2. Remove the locking mechanism and let the 4. rope retracts into housing. 5. Remove the back cover. ssi2009-003-021_a 1. Retaining screw 8. Split the rewind unit and remove damaged rope. ssi2009-003-019_a 1. Back
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    Section 07 BODY AND HULL Subsection 02 (BODY) ssi2009-003-025_a 1. Inner stopper A. 106 mm ± 6 mm (4-1/8 in ± 15/64 in) 11. On rewind unit base, identify the short tongue. ssi2009-003-028_a 1. Cover notch 13.2 Press in the cover until both parts are completely pressed together. ssi2009-003-026_a 1.
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    Section 07 BODY AND HULL Subsection 02 (BODY) ssi2009-003-030 15. Lock the end of rope as shown. ssi2009-003-033_a 18. Unlock the end of the rope and pull it out by the housing opening. NOTE: Be careful not to release the rope and the spring. Otherwise you will need to remove drum and repeat the
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    Section 07 BODY AND HULL Subsection 02 (BODY) 21. Check Speed-Tie operation. 22. Reinstall the Speed-Tie unit on vehicle. DECALS Decal Removal Using a heat gun warm up one end of decal for a few seconds until decal can roll off when rubbing with your finger. NOTE: When heating near light surfaces,
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    Section 07 BODY AND HULL Subsection 02 (BODY) WARNING Protect skin, wear gloves when in contact with resin, hardeners and gelcoat. A barrier skin cream may also be used. Do not expose area to open flame or lit cigarette. Some of the materials are flammable. Protect eyes, wear safety glasses when
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    Section 07 BODY AND HULL Subsection 02 (BODY) then additional reinforcement may be necessary. This subject will be covered in COMPOUND FRACTURES. buffing with a white medium compound. Finish off using a fine compound. While buffing, pay close attention to avoid overheating the surface. Preparing
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    Section 07 BODY AND HULL Subsection 02 (BODY) pieces evenly. Try to work quickly, you may only have 15 or 20 minutes. You may clean the brush with acetone. Wait until the repair has hardened before moving on to the interior repair. If the size of the opening is too large for the pieces to maintain
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    Section 07 BODY AND HULL Subsection 03 (HULL) HULL SERVICE PRODUCTS Description Part Number BRP HEAVY DUTY CLEANER ....................................................... LOCTITE 5150 (SILICONE SEALANT) ........................................... LOCTITE 577 (THREAD SEALANT)
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    Section 07 BODY AND HULL Subsection 03 (HULL) Hull NEW 14.5 N•m (128 lbf•in) Hull Loctite 5150 (silicone sealant) NEW 14.5 N•m (128 lbf•in) Loctite 5150 (silicone sealant) 50 N•m (37 lbf•ft) 25 N•m (18 lbf•ft) 25 N•m DEVCON (18 lbf•ft) HP250Q DEVCON HP250Q DEVCON HP250Q 25 N•m (18 lbf•ft) Loctite
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    Section 07 BODY AND HULL Subsection 03 (HULL) All Models 5 N•m (44 lbf•in) 5 N•m (44 lbf•in) Loctite 5900 (300 ml) 7 N•m (62 lbf•in) NEW 35 N•m (25 lbf•ft) NEW 35 N•m (25 lbf•ft) Loctite 5900 (300 ml) NEW 35 N•m (25 lbf•ft) Loctite 567 pipe sealant (250 ml) 8 N•m (71 lbf•in) smr2009-043-100_a
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    Section 07 BODY AND HULL Subsection 03 (HULL) GENERAL Verify condition and operation of hinges and latching mechanisms. Replace any damaged components. During assembly/installation, use torque values and service products as specified in the exploded views. Clean threads before applying a
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    Section 07 BODY AND HULL Subsection 03 (HULL) RIDE PLATE Ride Plate Removal NOTE: The jet pump support and ride plate must be removed as an assembly. The pump support is fastened to the ride plate and the forward pump support mounting screws cannot be accessed when the ride plate is installed.
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    Section 07 BODY AND HULL Subsection 03 (HULL) Ride Plate Installation 1. Install the jet pump support on the ride plate, see procedure in this section. NOTE: The jet pump support must be installed on the ride plate before installation of the ride plate on the watercraft. 2. Reinstall hose fittings
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    Section 07 BODY AND HULL Subsection 03 (HULL) 9. Reinstall coolant hoses on ride plate fittings, pay attention to gear clamp positioning. See following illustration. 3. Sealant is applied between the jet pump support and the ride plate. Using a heat gun, heat the base of the pump support to soften
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    Section 07 BODY AND HULL Subsection 03 (HULL) Thru-Hull Fitting Removal Inner Fitting Removal 1. Remove drive shaft, refer to DRIVE SHAFT subsection. 2. Using a heat gun, heat the glue at the joint between the hull and the inner thru-hull fitting to soften the glue applied. smr2009-043-020_a 1.
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    Section 07 BODY AND HULL Subsection 03 (HULL) 2. Insert the outer fitting into the hull from the jet pump side of the hull towards the inside. Ensure fitting is pushed in against the hull. 3. Continue with INNER FITTING INSTALLATION procedure. Inner Fitting Installation 1. Apply DEVCON HP 250 Q
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    Section 07 BODY AND HULL Subsection 03 (HULL) The bailer pick ups are connected through a hose system to two syphon tubes mounted in the jet pump venturi that draw the water out of the bilge through the bailer pick ups. The bailers are also connected to the bilge drain plugs in the stern. Bailer
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    Section 07 BODY AND HULL Subsection 03 (HULL) smr2009-043-032_a smr05-005-001_A 1. Elbow fitting holes DRAIN PLUGS NOTE: The two drain plugs on the stern are each connected to a bailer. When watercraft is on dry land, the drain plugs can be removed to manually drain the bilge. DRAIN PLUG REMOVAL 1.
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    Section 07 BODY AND HULL Subsection 03 (HULL) der the splash deflector indicates the exact location of the piece to cut out. Carry out the following steps. 1. Remove splash deflector, refer to BODY subsection. 2. Using a drill bit 6 mm (1/4 in) in size MINIMUM, drill a hole at each of the five
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    Section 07 BODY AND HULL Subsection 03 (HULL) 4. Clean any residue of silicone sealant from the hull. Stern Eyelet Installation smr2007-034-110_a 1. 2. 3. 4. 5. 6. 7. 1. Install small washers and nylon washers to stern eyelet and insert it through the hull. 2. Inside hull, apply LOCTITE 5150
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    Section 07 BODY AND HULL Subsection 03 (HULL) smr2009-043-025_a 1. Passe thru insert smr2009-043-026_b BLIND HOLE INSERT 1. Excess glue on head 3. Use a six pan socket of appropriate size and a ratchet wrench to unscrew the insert from the hull. NOTE: An impact tool may be used to facilitate
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    Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (RXT iS 255/GTX LIMITED iS 255) RXT iS 255/GTX LIMITED iS 255 MODEL RXT iS 255 GTX LIMITED iS 255 ENGINE Engine type ROTAX 1503 4-TEC, 4-stroke, Single Over Head Camshaft (SOHC) Induction Supercharged intercooled 3 Number of cylinders Number of
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    Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (RXT iS 255/GTX LIMITED iS 255) MODEL RXT iS 255 GTX LIMITED iS 255 ENGINE (cont'd) 1st Lower compression ring, tapered face 3rd Piston ring type Upper compression ring, rectangular 2nd Oil scraper ring Rectangular New 0.30 mm to 0.50 mm (.012 in to
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    Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (RXT iS 255/GTX LIMITED iS 255) MODEL RXT iS 255 GTX LIMITED iS 255 ENGINE (cont'd) Connecting rod small end radial play Wear limit 0.080 mm (.0031 in) New Piston pin diameter 22.996 mm to 23.000 mm (.9054 in to .9055 in) Wear limit Balance shaft
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    Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (RXT iS 255/GTX LIMITED iS 255) MODEL RXT iS 255 GTX LIMITED iS 255 ELECTRICAL SYSTEM #1: Gauge #2: CAPS 5 A #5: iBR control 5 A #6: Fuel pump 6 A #7: Inj/Ign cyl 1 10 A #8: Inj/Ign cyl 2 10 A #9: Inj/Ign cyl 3 10 A #10: OTAS switch 3 A #11: iS
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    Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (RXT iS 255/GTX LIMITED iS 255) MODEL RXT iS 255 GTX LIMITED iS 255 STEERING AND PROPULSION Steering Adjustable tilt 26° Steering nozzle pivoting angle O.T.A.S. (Off-Throttle Assisted Steering) Jet pump Type Grease type Rotation (seen from rear)
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    Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (RXT iS 255/GTX LIMITED iS 255) MODEL RXT iS 255 GTX LIMITED iS 255 iS SUSPENSION (cont'd) Type Oil type Hydraulic pump Oil quantity Motor Radial piston Automatic transmission fluid (ATF) Dexron III Reservoir is full when oil level reaches 130 mm ±
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    Section 09 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM INFORMATION) WIRING DIAGRAM INFORMATION GENERAL WIRING DIAGRAM LOCATION The wiring diagram is in the back cover pocket. WIRING DIAGRAM CODES 1 1 Wire Color Codes YL - BK 1 2 F04H6LA smr05-026-002_a 1. Wire main color 2. Tracer (thin colored
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    Section 09 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM INFORMATION) smr2009-045-007_a 1. CAN wire 2. Wire destination FB2: Fuse box #2 C7: Terminal C7 in fuse box #2 On the wiring diagram, corresponding CAN links are identified in fuse box #2 using the following coding. smr2009-045-008_a 1. CAN
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    Section 09 WIRING DIAGRAM Subsection 02 (CONNECTOR INFORMATION) CONNECTOR INFORMATION SERVICE TOOLS Description Part Number CRIMPING TOOL (HEAVY GAUGE WIRE) .................................... ECM ADAPTER TOOL................................................................... ECM TERMINAL REMOVER
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    Section 09 WIRING DIAGRAM Subsection 02 (CONNECTOR INFORMATION) Connector Disassembly 1 3 3 2 F18Z0NA 2 1 TYPICAL 1. Deutsch connectors 2. Press release button Engine Connector Insert a small flat screwdriver between the support and the Deutsch connectors. Pry while sliding out connectors in the
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    Section 09 WIRING DIAGRAM Subsection 02 (CONNECTOR INFORMATION) 6. After all required terminals have been inserted, the lock must be installed. 1 1 V01G0PA MALE CONNECTOR 1. Male lock 1 F04H6LA 1. Wire identification numbers NOTE: Before extraction, push wire forward to relieve pressure on
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    Section 09 WIRING DIAGRAM Subsection 02 (CONNECTOR INFORMATION) smr2009-045-013_b smr2009-045-011_a Rotate connector lock until it stops. Install connector to ECM. Rotate connector lock until it snaps locked. smr2009-045-012_a Pull out connector. smr2009-045-011_b 1. Locked here ECM Connector
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    Section 09 WIRING DIAGRAM Subsection 02 (CONNECTOR INFORMATION) ECM Connector Probing The most recommended and safest method to probe ECM connector terminals is to use the ECM ADAPTER TOOL (P/N 529 036 166). This tool will prevent deforming or enlarging terminals which would lead to bad ECM
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    Section 09 WIRING DIAGRAM Subsection 02 (CONNECTOR INFORMATION) smr2009-045-015_a WARNING smr2009-045-027_a WARNING Before terminal installation, ensure all terminals are properly crimped on wires. After plugging connectors, ensure they are properly fastened. BRLS, TAS AND STARTER SOLENOID
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    Section 09 WIRING DIAGRAM Subsection 02 (CONNECTOR INFORMATION) WARNING Before terminal installation, ensure all terminals are properly crimped on wires. After plugging connectors, ensure they are properly fastened. SPS CONNECTORS (BOSCH) To remove a terminal from connector, use a special tool such
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    Section 09 WIRING DIAGRAM Subsection 02 (CONNECTOR INFORMATION) A A32E2QA smr2009-045-023_a A. 10 mm (3/8 in) 1. Pry out locking cap NOTE: Make sure not to cut wire strands while stripping the wire. Install the appropriate terminal on the wire according to the requirement. Refer to appropriate
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    Section 09 WIRING DIAGRAM Subsection 02 (CONNECTOR INFORMATION) 1 Install the protective heat shrink rubber tube on the terminal. Heat the heat shrink rubber tube using the heat gun so that it grasps the wire and the terminal. NOTICE Make sure that the protective heat shrink rubber tube has been
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    NOTES
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    NOTES
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    2009 Sea-Doo 4-TEC iTC iS Series RXT iS 255 GTX Limited iS 255 smr2009-045-001
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    STARTING SYSTEM IGNITION SYSTEM CHARGING SYSTEM smr2009-045-002
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