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  www.SeaDooManuals.net…
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  2000 Shop Manual VOLUME 2 RX DI GTX DI www.SeaDooManuals.net…
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  Legal deposit: National Library of Quebec trimester 2000 National Library of Canada All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. © Bombardier Inc. 2000 Technical Publications Bombardier Inc.

• Page 4: Table Of Contents

  TABLE OF CONTENTS PAGE SECTION SUBSECTION SAFETY NOTICE ……………………….INTRODUCTION ……………………….SERVICE TOOLS 01 — Table of contents …………….01-01-1 AND PRODUCTS 02 — Mandatory service tools …………..01-02-1 03 — Optional service tools…………..01-03-1 04 — Service products …………….01-04-1 MAINTENANCE 01 — Table of contents …………….

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  01 — Table of contents …………….12-01-1 02 — Adjustment and repair …………..12-02-1 TECHNICAL DATA 01 — RX ………………..13-01-1 02 — RX DI and GTX DI …………….. 13-02-1 WIRING DIAGRAMS 01 — Wiring diagrams …………….14-01-1 SMR2000_036_00A2.FM www.SeaDooManuals.net…

• Page 6: Safety Notice

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

• Page 7: Introduction

  It is located on floorboard at the rear of the water- craft. MODEL MODELS NUMBER RX …………5513 RX International ……..5514 RX DI ………… 5646 RX DI International ……5656 GTX DI ……….5649 GTX DI International ……5659 HULL IDENTIFICATION NUMBER (H.I.N.) F08L0QA RX Models TYPICAL It is located on footboard at the rear of watercraft.

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  INTRODUCTION ENGINE IDENTIFICATION NUMBER (E.I.N.) The Engine Identification Number is located on the upper crankcase on MAGNETO side. 1. Engine Identification Number (E.I.N.) ARRANGEMENT OF THIS MANUAL The manual is divided into 14 major sections: 01 SERVICE TOOLS AND PRODUCTS 02 MAINTENANCE 03 TROUBLESHOOTING 04 ENGINE…
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  INTRODUCTION Page heading indicates section and subsection detailed. Subsection title indicates beginning of the subsection. Italic sub-title above exploded view indicate pertaining models. Drop represents a liquid product to be applied to a surface. In this case Loctite 243 to screw threads.
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  INTRODUCTION Sub-title with part name(s) from exploded view. Section 06 FUEL SYSTEM Title indicates main procedure to be carried-out. To remove carburetors from engine, proceed as fol- Inspect parts for corrosion dammage (shaft, butterfly, lows: spring screw, check valve housing, etc.). Sub-sub-title in Remove air vent tube support.

• Page 11: General Information

  INTRODUCTION LIST OF ABBREVIATIONS USED IN THIS MANUAL DESCRIPTION Alternate Current Air Pressure Sensor Air Temperature Sensor Bombardier Utility and Diagnostic B.U.D.S. Software Capacitor Discharge Ignition Crankshaft Position Sensor F01L45B Cooling System Indicator 1. Left (port) Direct Current 2. Right (starboard) DESS Digitally Encoded Security System The information and component/system descrip-…

• Page 12: Engine Emissions Information

  INTRODUCTION A number of procedures throughout the book re- EPA Emission Regulations quire the use of special tools. Before undertaking All new 1998 and later watercrafts manufactured any procedure, be sure that you have on hand all by Bombardier are certified to the United States the tools required, or approved equivalents.

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  INTRODUCTION LOCTITE APPLICATION Blind Holes PROCEDURE The following describes the most common appli- cation procedures when working with Loctite products. NOTE: Always use proper strength Loctite prod- uct as recommended in this Shop Manual. Threadlocker Uncovered Holes (bolts and nuts) 1.
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  INTRODUCTION 1. Clean threads (stud and hole) with solvent. Adjusting Screw 2. Apply Loctite Primer N (P/N 293 800 041) on threads and allow to dry. 3. Put several drops of proper strength Loctite threadlocker on female threads and in hole. 4.
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  INTRODUCTION Standard Thread Repair 1. Remove old gasket and other contaminants with Loctite Chisel remover (P/N 413 708 500). 1. Follow instructions on Loctite FORM-A-THREAD Use a mechanical mean if necessary. (P/N 413 708 600) package. NOTE: Avoid grinding. 2. If a plate is used to align bolt: 2.
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  INTRODUCTION Standard 1. Clean inner housing diameter and outer gasket diameter. 1. Clean shaft external part and element internal part. 2. Spray housing and gasket with Loctite Primer N (P/N 293 800 041). 2. Apply a strip of proper strength Loctite on shaft circumference at insert or engagement point.

• Page 17: Tightening Torques

  INTRODUCTION TIGHTENING TORQUES N•m FASTENER SIZE (8.8) Lbf•ft Tighten fasteners to torque mentioned in explod- ed views and text. When they are not specified refer to following table.The table also gives the metric conversion. N•m FASTENER SIZE (8.8) Lbf•in N•m FASTENER SIZE (8.8) Lbf•ft SMR2000_036_00A2.FM…

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  INTRODUCTION N•m FASTENER SIZE (8.8) Lbf•ft N•m FASTENER SIZE (8.8) Lbf•ft TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTS Technical Publications Bombardier Inc. Valcourt (Quebec), Canada SMR2000_036_00A2.FM www.SeaDooManuals.net…
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  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS MANDATORY SERVICE TOOLS ………………. 01-02-1 ENGINE ……………………..01-02-1 COOLING/FUEL/OIL SYSTEMS ………………01-02-4 PROPULSION SYSTEM………………… 01-02-5 WORKSHOP ……………………01-02-6 OPTIONAL SERVICE TOOLS ………………..01-03-1 ENGINE ……………………..01-03-1 COOLING/FUEL/OIL SYSTEMS ………………

• Page 20: Service Tools

  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) MANDATORY SERVICE TOOLS ENGINE Degree wheel Carbon dam compressor Piston pin puller P/N 529 035 607 P/N 529 035 716 P/N 529 035 503 Expansion sleeve P/N 295 000 117 (787 engine) APPLICATION 947 DI engine.

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  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) Puller Alignment support plate kit VCK (Vehicle Communication Kit) P/N 529 035 547 P/N 529 035 506 P/N 529 035 676 1) Alignment plates A) P/N 529 035 507 B) P/N 529 035 508 2) Support P/N 529 035 511…
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  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) Engine leak tester kit Intake plug Ring gear blocking tool P/N 295 500 352 P/N 529 035 708 P/N 295 000 155 Pump only P/N 529 021 800 APPLICATION 947 DI engine.

• Page 23: Cooling/Fuel/Oil Systems

  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) COOLING/FUEL/OIL SYSTEMS Gear holder Coupler hose 1. Fuel pressure gauge P/N 420 277 905 P/N 295 500 258 P/N 529 035 709 41 cm (16 in) 2. Fuel pressure gauge T-fitting P/N 529 035 710 3.

• Page 24: Propulsion System

  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) PROPULSION SYSTEM Impeller remover/installer Bearing/seal installer Pliers P/N 295 000 001 P/N 295 000 107 P/N 295 000 054 Caillau F01J0T4 APPLICATION F01B1T4 All models. APPLICATION NOTE: This tool is also used for All models.

• Page 25: Workshop

  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) WORKSHOP Tool board P/N 295 500 608 ® F00A0S4 APPLICATION All models. 01-02-6 SMR2000-038_01_02A.FM www.SeaDooManuals.net…

• Page 26: Optional Service Tools

  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (OPTIONAL SERVICE TOOLS) OPTIONAL SERVICE TOOLS ENGINE Coil centering tool Stroboscopic timing light Digital/induction type tachometer P/N 420 876 922 P/N 529 031 900 P/N 529 014 500 A01B1V4 APPLICATION 717 engine. A00B4F4 APPLICATION F01B1G4…

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  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (OPTIONAL SERVICE TOOLS) Crimping tool Protective mat Engine lifting device P/N 295 100 164 P/N 295 000 128 Not sold by Bombardier Do it yourself Refer to REMOVAL AND INSTAL- LATION section of engine. F00B0E4 F02B0A4 APPLICATION…
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  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (OPTIONAL SERVICE TOOLS) Rubber pad Digital multimeter P/N 290 877 032 P/N 529 022 000 F06B064 APPLICATION 947 engine. MPEM programmer P/N 529 035 718 F01B1O4 F01D885 APPLICATION 1) Puller ass’y All models. P/N 420 877 635 2) Protective cap P/N 420 876 557…

• Page 29: Cooling/Fuel/Oil Systems

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

• Page 30: Propulsion System

  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (OPTIONAL SERVICE TOOLS) PROPULSION SYSTEM Fitting Machinist’s square Impeller housing remover P/N 295 000 086 Not sold by Bombardier P/N 295 000 113 Snap-on PMF 122 F01B0Z4 F02B064 APPLICATION APPLICATION All models. F01L2O4 GTS model.

• Page 31: Watercraft Handling

  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (OPTIONAL SERVICE TOOLS) WATERCRAFT HANDLING Dolly (with wheels) Tie-down with ratchet Tie-down P/N 295 000 126 3.60 m (12 ft) long 1.50 m (5 ft) long P/N 295 100 104 P/N 295 100 103 APPLICATION All models.

• Page 32: Service Products

  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 04 (SERVICE PRODUCTS) SERVICE PRODUCTS Loctite ® is a trademark of Loctite™ Corporation. Permatex ® is a trademark of Loctite™ Corporation. Dow Corning ® is a trademark of Dow Corning Corporation. Medium strength threadlocker High temperature threadlocker Retaining compound P/N 293 800 060…

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  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 04 (SERVICE PRODUCTS) Chisel gasket remover Molykote 111 Sealant P/N 413 708 500 P/N 413 707 000 P/N 293 530 011 (510 mL) Sikaflex 221 (black) (350 mL) A00B3W4 F01B1D4 Primer for gasket eliminator Ultra Copper High temp sealant P/N 293 800 041 P/N 413 710 300…
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  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 04 (SERVICE PRODUCTS) Deoxit contact lubricant Anti-seize lubricant Sea-Doo fuel stabilizer P/N 293 550 015 P/N 293 800 023 P/N 413 408 600 (200 mL) Loctite 767 236 mL (8 oz) 454 g (16 oz) F01B174 BOMBARDIER LUBE P/N 293 600 016…
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  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 04 (SERVICE PRODUCTS) BOMBARDIER injection oil BOMBARDIER Formula XP-S DI Jet pump oil synthetic injection oil P/N 413 803 000 (3 x 4 L) P/N 293 600 011 (12 x 6 oz) P/N 293 600 032 (12 x 1 L) P/N 413 803 200 (205 L) Sea-Doo synthetic jet pump oil…

• Page 36: Table Of Contents

  Section 02 MAINTENANCE Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS PERIODIC INSPECTION CHART ………………. 02-02-1 FLUSHING AND LUBRICATION ………………. 02-03-1 GENERAL ……………………… 02-03-1 PROCEDURE ……………………02-03-1 WATER-FLOODED ENGINE ………………..02-04-1 GENERAL ……………………… 02-04-1 PROCEDURE ……………………02-04-1 STORAGE……………………..02-05-1 ENGINE DRAINING ………………….02-05-1 FUEL SYSTEM ……………………

• Page 37: Periodic Inspection Chart

  Section 02 MAINTENANCE Subsection 02 (PERIODIC INSPECTION CHART) PERIODIC INSPECTION CHART Maintenance, replacement, or repair of the emission control devices and systems may be per- formed by any marine SI (spark ignition) engine repair establishments or individual. FREQUENCY DESCRIPTION ➀ ✔…

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  Section 02 MAINTENANCE Subsection 02 (PERIODIC INSPECTION CHART) FREQUENCY DESCRIPTION Electrical connections condition and fastening (ignition system, electrical ✔ ✔ box(es), starting system, fuel injectors (DI models), etc.) ✔ MPEM mounting brackets/fasteners ✔ ✔ Digitally Encoded Security System ✔ ✔ Monitoring beeper ✔…

• Page 39: Flushing And Lubrication

  Section 02 MAINTENANCE Subsection 03 (FLUSHING AND LUBRICATION) FLUSHING AND LUBRICATION GENERAL Install flushing adapter (P/N 295 500 473) to the water outlet located at the rear of the watercraft. Flushing Flushing the cooling system with fresh water is essential to neutralize corroding effects of salt or other chemical products present in water.

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  Section 02 MAINTENANCE Subsection 03 (FLUSHING AND LUBRICATION) Carburetor-Equipped Models 1. Garden hose installed 2. Quick connector adaptor Start the engine then immediately open the water 1. Air intake silencer 2. Spray BOMBARDIER LUBE here tap. DI Models WARNING Spray, through hole of air intake silencer. Do not touch any electrical parts or jet pump NOTE: An increase of engine RPM may be noticed area when engine is running.
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  Section 02 MAINTENANCE Subsection 03 (FLUSHING AND LUBRICATION) All Models Carburetor-Equipped Models Fully depress the throttle lever then press the Close the water tap then stop the engine. start/stop button to crank the engine a few turns CAUTION: Always close the water tap before to distribute the oil onto cylinder wall.

• Page 42: Water-Flooded Engine

  Section 02 MAINTENANCE Subsection 04 (WATER-FLOODED ENGINE) WATER-FLOODED ENGINE GENERAL Carburetor-Equipped Models Fully depress the throttle lever then crank the en- If engine is water-flooded, it must be serviced gine to drain crankcase and ignition will be cut. within a few hours after the event. Otherwise en- gine will have to be overhauled.

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  Section 02 MAINTENANCE Subsection 04 (WATER-FLOODED ENGINE) All Models DI Models CAUTION: To avoid starting motor overheat- Spray through hole of air intake silencer. ing, the cranking period should not exceed 5- NOTE: An increase of engine RPM may be no- 10 seconds and a rest period of 30 seconds ticed while spraying the lubricant in the air intake should be observed between cranking cycles.

• Page 44: Storage

  Section 02 MAINTENANCE Subsection 05 (STORAGE) STORAGE ENGINE DRAINING Check engine drain hose (lowest hose of engine). Make sure there is no sand or other particles in it and that it is not obstructed so that water can leave the engine. Clean hose and fitting as neces- sary.

• Page 45: Cooling System Flushing And Engine Internal Lubrication

  Section 02 MAINTENANCE Subsection 05 (STORAGE) NOTE: Fuel stabilizer should be added prior en- gine lubrication to ensure that the carburetors, if so equipped, are protected against varnish de- posits. WARNING Fuel is flammable and explosive under cer- tain conditions. Always work in a well venti- lated area.

• Page 46: Anticorrosion Treatment

  Section 02 MAINTENANCE Subsection 05 (STORAGE) ANTICORROSION TREATMENT Carburetor-Equipped Models Install hose pinchers at the following location: Wipe off any residual water in the engine compart- ment. Spray BOMBARDIER LUBE lubricant over all me- tallic components in engine compartment. Lubricate the throttle cable with BOMBARDIER LUBE lubricant.

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  Section 02 MAINTENANCE Subsection 05 (STORAGE) Disconnect water INLET hose where shown. DI Models Install hose pinchers at the following location: 1. Disconnect hose this side of T-fitting 1. Water outlet hose Antifreeze Insert a funnel into hose and pour antifreeze mix in engine until the colored solution appears at cool- ing system bleed outlet (LH side of hull).
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  Section 02 MAINTENANCE Subsection 05 (STORAGE) Disconnect water INLET hose at engine. Continue to pour until antifreeze flows in air com- pressor water outlet hose. Temporarily install a short piece of hose to replace the one removed. Antifreeze Insert a funnel into the temporary hose and pour antifreeze mix in engine until the colored solution appears at cooling system bleed outlet.

• Page 49: Troubleshooting

  Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) TROUBLESHOOTING CHART The following is provided to help in diagnosing the probable source of troubles. It is a guideline and should not be assumed to have all causes for all problems. NOTE: On DI models, always check for fault codes recorded in the MPEM first using the VCK (vehicle .

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  Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE WILL NOT START (cont’d) OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Faulty component in the fuel injection • Check for fault codes with the VCK system (DI models) (vehicle communication kit). Refer to Diagnostic Procedures in ENGINE MANAGEMENT •…
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  Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE HARD TO START OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Water in fuel reservoir • Flush reservoir and refill with fresh gas • Mechanical engine failure • Check cylinder compression • Check for crankcase leaks •…
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  Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE MISFIRES, RUNS IRREGULARLY (cont’d) OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Low fuel level • Check/refill • Stale or water fouled fuel • Check/siphon and refill • Fuel filter dirty or restricted • Check/clean/replace •…
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  Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE CONTINUALLY BACKFIRES OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Fouled, defective spark plugs • Clean/replace (carburetor models) Weak spark • Malfunction of rev limiter in MPEM • Clean/replace, refer to section ELEC- (carburetor models) TRICAL SYSTEM Spark plugs •…
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  Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE LACKS ACCELERATION OR POWER OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Weak spark • Check/replace, refer to section ELEC- TRICAL SYSTEM • Carburetion, jetting too rich/lean • Check/adjust, refer to section FUEL (carburetor models) SYSTEM •…
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  Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE CANNOT REACH MAXIMUM RPM OTHER OBSERVATION POSSIBLE CAUSE REMEDY • RAVE valve does not open • Check, refer to section ENGINE and COOLING SYSTEM • Faulty water regulator valve • Check, refer to COOLING SYSTEM •…
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  Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ABNORMAL NOISE FROM PROPULSION SYSTEM OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Weeds/debris caught in intake grate • Check/clean or impeller • Low oil level in jet pump • Check/troubleshoot source of leak/re- fill supply, refer to section PROPUL- SION SYSTEM •…

• Page 57: Table Of Contents

  Section 04 ENGINE Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS LEAK TEST……………………..04-02-1 GENERAL ……………………… 04-02-1 PREPARATION ……………………04-02-1 TESTING PROCEDURE ………………… 04-02-1 ENGINE LEAKAGE DIAGNOSTIC FLOW CHART …………04-02-5 REMOVAL AND INSTALLATION………………04-03-1 GENERAL ……………………… 04-03-1 ENGINE REMOVAL………………….04-03-1 CLEANING …………………….

• Page 58: Leak Test

  Section 04 ENGINE Subsection 02 (LEAK TEST) LEAK TEST GENERAL PREPARATION A Sea-Doo Engine Leak Test Kit (P/N 295 500 352) Verify fuel system for leaks. and Supplementary Engine Leak Test Kit (P/N 295 WARNING 500 780) are available to help diagnose engine problems such as engine seizure, poor perfor- If any fuel leak is found, do not start the en- mance, oil leakage, etc.

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  Section 04 ENGINE Subsection 02 (LEAK TEST) 947 CARBURETOR-EQUIPPED ENGINE — REAR VIEW 947 DI ENGINE — SIDE VIEW 1. Block engine drain hose with a hose pincher 1. Block engine drain hose with a hose pincher 2. Install pump to inlet drain 2.
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  Section 04 ENGINE Subsection 02 (LEAK TEST) Activate pump and pressurize engine cooling sys- tem to 34 kPa (5 PSI). Wait 3 minutes and check if pressure drops; if so, verify all testing components. – If kit components are not leaking and pressure drops, verify all external jointed surfaces and temperature sensors.
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  Section 04 ENGINE Subsection 02 (LEAK TEST) Check small oil injection pump lines and fittings; check for air bubbles or oil column going toward pump, which indicate a defective check valve. Check for leak through cournterbalancing shaft seal toward air compressor (DI engines). Air bub- bles in lowest fitting (oil return line) underneath compressor indicates a seal leakage.

• Page 62: Engine Leakage Diagnostic Flow Chart

  Section 04 ENGINE Subsection 02 (LEAK TEST) ENGINE LEAKAGE DIAGNOSTIC FLOW CHART 947 Engine 04-02-5 SMR2000-043_04_02A.FM www.SeaDooManuals.net…

• Page 63: Removal And Installation

  Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) REMOVAL AND INSTALLATION GENERAL DI Models Disconnect throttle position sensors (TPS), mani- On DI models, it is not necessary to remove en- fold air pressure sensor (MAPS) and manifold air gine from watercraft to service TOP END, PTO FLY- temperature sensor (MATS).

• Page 64
  Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) NOTE: Engine will have to be raised inside bilge to disconnect drain hose before removing from bilge. Refer to COOLING SYSTEM for proper water hose location. Tuned Pipe To remove tuned pipe, refer to EXHAUST SYSTEM. Air Intake Silencer To remove air intake silencer, refer to AIR INTAKE.

• Page 65: Cleaning

  Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) Remove rear engine support. Disconnect BLACK negative cable from engine crankcase. TYPICAL 1. Rear support 1. Positive starter cable 2. Ground cable Removal of Remaining Components Carry on engine lifting then tilt engine so that it can Lift up engine slowly until oil injection hoses can be removed from the body opening.

• Page 66: Installation

  Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) INSTALLATION Installation of engine in watercraft is essentially the reverse of removal procedures. However pay particular attention to the following. Rubber Mount, Shim and Screw Check tightness and condition of rubber mounts. If they have been removed, apply Loctite 243 (blue) on screw threads.

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  Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) Engine Support Screws Apply Loctite 243 (blue) on screw threads. Torque engine support screws to 25 N•m (18 lbf•ft) when procedure is completed. F07D05A TYPICAL 1. Alignment shaft 2. PTO flywheel If the alignment is incorrect loosen engine support screws to enable to align PTO flywheel with shaft FRONT ENGINE SUPPORT end.
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  Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) Final Inspection Check throttle cable condition and lubricate cable with BOMBARDIER LUBE lubricant. After its installation, properly adjust and bleed oil in- jection pump as specified in OIL INJECTION PUMP and adjust throttle cable as specified in ENGINE MANAGEMENT.

• Page 69: Magneto System

  Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) MAGNETO SYSTEM 947 Carburetor-Equipped Engine PARTS 04-04-1 SMR2000-045_04_04A.FM www.SeaDooManuals.net…

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  Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) 947 DI Engine PARTS 04-04-2 SMR2000-045_04_04A.FM www.SeaDooManuals.net…

• Page 71: Disassembly

  Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) DISASSEMBLY Cover Loosen screws no. 11. Remove engine magneto cover no. 1. TYPICAL 1. Screw To remove the flywheel/rotor assembly, unscrew nut no. 13 counterclockwise when facing it. TYPICAL 1. Cover 2. Screw Remove oil pump shaft from flywheel nut.

• Page 72: Cleaning

  Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) CLEANING Clean all metal components in a solvent. CAUTION: Clean coils and magnets using only a clean cloth. Clean crankshaft taper and threads using acetone. Apply the acetone on a rag first then clean the crankshaft.

• Page 73
  Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) Rotor and Flywheel Apply Loctite 243 (blue) on nut no. 13. Install nut with lock washer and torque to 115 N•m (85 lbf•ft). Apply Loctite 648 (green) on mating surface of the CAUTION: Never use any type of impact wrench. rotor no.

• Page 74: Top End

  Section 04 ENGINE Subsection 05 (TOP END) TOP END 947 Carburetor-Equipped Engines 17 18 20 21 24 23 22 04-05-1 SMR2000-046_04_05A.FM PARTS www.SeaDooManuals.net…

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  Section 04 ENGINE Subsection 05 (TOP END) 947 DI Engines 04-05-2 PARTS SMR2000-046_04_05A.FM www.SeaDooManuals.net…

• Page 76: General

  Section 04 ENGINE Subsection 05 (TOP END) GENERAL To close the RAVE valves, the MPEM deactivates the solenoid which blocks the crankcase positive The 2-stroke ROTAX engine rotates counterclock- pressure. The RAVE valves are opened to the at- wise seen from the rear (PTO flywheel). mosphere.

• Page 77
  Section 04 ENGINE Subsection 05 (TOP END) 947 DI Engines To open the RAVE valves, the MPEM activates a solenoid which directs the pressure from air com- pressor to the valves. RAVE VALVE OPENED 1. Pressure from solenoid 1. Pressure from air compressor 2.

• Page 78: Disassembly

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

• Page 79
  Section 04 ENGINE Subsection 05 (TOP END) Remove spring no. 30 retaining bellows no. 21 to NOTE: Hold the sliding valve to prevent it from valve piston no. 20. turning. F06D0TB 1. Unscrew piston 1. Spring 2. Hold sliding valve Free bellows no.
• Page 80
  Section 04 ENGINE Subsection 05 (TOP END) Remove supporting ring no. 28. Remove sliding valve no. 22. F06D27A 1. Remove sliding valve 1. Remove supporting ring Remove bellows no. 21. Remove O-ring no. 23. F06D0VA 1. Remove O-ring 1. Remove bellows 04-05-7 SMR2000-046_04_05A.FM www.SeaDooManuals.net…
• Page 81
  Section 04 ENGINE Subsection 05 (TOP END) Cylinder Head Cover and Cylinder Head Disconnect temperature sensor wire and spark plug cables. Connect spark plug cables on grounding device. Disconnect hose of RAVE valves. On DI engines, remove air/fuel rail. Refer to EN- GINE MANAGEMENT.
• Page 82
  Section 04 ENGINE Subsection 05 (TOP END) 947 DI Engines Use Snap-On Torx socket E12 and unscrew cylin- der head screws no. 14 following the sequence shown in the next illustration. F06D0ZA 1. Remove cylinder block NOTE: To ease removal, a plastic tip hammer can be used.
• Page 83
  Section 04 ENGINE Subsection 05 (TOP END) To remove circlip no. 5, insert a pointed tool in pis- – Fully thread on puller handle. ton notch then pry it out and discard. – Insert extractor spindle into the piston pin. –…

• Page 84: Cleaning

  Section 04 ENGINE Subsection 05 (TOP END) 1. Needles and thrust washer 2. Sleeve 1. Shoulder sleeve flush with piston recess CLEANING – Loosen the extracting nut and remove puller. Discard all gaskets and O-rings. – Remove the shoulder sleeve from piston. Clean all metal components in a solvent.

• Page 85
  Section 04 ENGINE Subsection 05 (TOP END) Inspect plane surfaces for warpage. Small defor- mation can be corrected by grinding surface with a fine sand paper. Install sand paper on a surface plate and rub part against oiled sand paper. The inspection of engine top end should include the following measurements.
• Page 86
  Section 04 ENGINE Subsection 05 (TOP END) Piston/Cylinder Wall Clearance To determine the piston dimension, take the mea- surement on the piston dome. F00B09A 1. Use the micrometer to set the cylinder bore gauge 2. Dial bore gauge 1. Piston dome 2.

• Page 87: Assembly

  Section 04 ENGINE Subsection 05 (TOP END) Read the measurement on the cylinder bore gauge. Different thicknesses of cylinder base gaskets are The result is the exact piston/cylinder wall clearance. used for a precise adjustment of the combustion chamber volume. NOTE: Make sure the cylinder bore gauge indica- tor is set exactly at the same position as with the To identify gasket thickness, refer to the identifi-…

• Page 88
  Section 04 ENGINE Subsection 05 (TOP END) RAVE Valve Piston At assembly, place the pistons no. 3 with the let- Carburetor-Equipped Engines ters “AUS” (over an arrow on the piston dome) Install the supporting ring no. 28 with the bevel facing in direction of the exhaust port.
• Page 89
  Section 04 ENGINE Subsection 05 (TOP END) – Install the shoulder sleeve tool on the opposite side of the piston pin. F01D0Q A 1. Outer ring removal after inner sleeve insertion into bore – Make sure thrust washers are present each side of rollers.
• Page 90
  Section 04 ENGINE Subsection 05 (TOP END) – Place piston over connecting rod and align ENGINE TOOL P/N bores, then gently tap piston pin with a fiber 290 877 517 hammer to push out inner plastic ring on oppo- site side. Support piston from opposite side. 1.
• Page 91
  Section 04 ENGINE Subsection 05 (TOP END) Cylinder Base Gasket To easily slide cylinder block over pistons, use ring compressor (P/N 290 876 965). Install new base gasket. NOTE: The general procedure is to install a new gasket of the same thickness. However, if you do not know the gasket thickness that was installed or if a crankshaft and/or crankcase repair or re- placement was involved, refer to the COMBUS-…

• Page 92: Adjustment

  Section 04 ENGINE Subsection 05 (TOP END) All Engines Cylinder Head Install cylinder head gasket. 947 Carburetor-Equipped Engines Apply Loctite 243 (blue) on the threads of the cyl- inder block studs no. 32. Apply Loctite 243 (blue) below head of cylinder head bolts no.

• Page 93: Combustion Chamber Volume Measurement

  Section 04 ENGINE Subsection 05 (TOP END) Combustion Chamber Volume 947 DI Engines Measurement 1. Remove both direct injectors and bring one pis- ton to Top Dead Center using a TDC gauge. All Engines Keep spark plugs in their holes. NOTE: This procedure is required to determine gasket thickness if you do not know the gasket All 947 Engines…

• Page 94
  Section 04 ENGINE Subsection 05 (TOP END) NOTE: The liquid level in cylinder must not drop for a few seconds after filling. If so, there is a leak between piston and cylinder. The recorded vol- ume would be false. 5. Let burette stand upward for about 10 minutes, until liquid level is stabilized.

• Page 95: Bottom End

  Section 04 ENGINE Subsection 06 (BOTTOM END) BOTTOM END 947 Carburetor-Equipped Engines 04-06-1 SMR2000-047_04_06A.FM PARTS www.SeaDooManuals.net…

• Page 96
  Section 04 ENGINE Subsection 06 (BOTTOM END) 947 DI Engines PARTS 04-06-2 SMR2000-047_04_06A.FM www.SeaDooManuals.net…

• Page 97: Disassembly

  Section 04 ENGINE Subsection 06 (BOTTOM END) DISASSEMBLY Starter Drive Assembly Loosen 2 Allen screws no. 24 retaining starter Engine has to be removed from watercraft and top drive cover no. 25. end has to be disassembled to open bottom end. Refer to REMOVAL AND INSTALLATION and TOP END.

• Page 98
  Section 04 ENGINE Subsection 06 (BOTTOM END) Reed Valve Remove both carburetor flanges. 1. Carburetor flange 1. M8 x 45 flanged screws 2. M10 x 73.5 flanged screws Remove reed valves no. 28 from crankcase. Put engine back on a support. Insert a pry bar be- Crankcase tween crankcase lugs to separate halves.
• Page 99
  Section 04 ENGINE Subsection 06 (BOTTOM END) 1. Puller (P/N 420 877 635) 2. Protective cap (P/N 290 877 414) 3. Distance ring (P/N 420 876 569) 4. Ring (P/N 420 977 480) 5. Ring halves (P/N 420 876 330) 6.

• Page 100: Cleaning

  Section 04 ENGINE Subsection 06 (BOTTOM END) Counterbalance Shaft All Models CAUTION: Be careful not to spray cleaner on Use a press to remove counterweights no. 16 and the painted surface of the engine. bearings no. 15. CAUTION: Never use a sharp object to scrape CAUTION: There is no woodruff key to position away old sealant as score marks incurred are the counterweights.

• Page 101
  Section 04 ENGINE Subsection 06 (BOTTOM END) Such misalignment may cause a crankshaft hard to be manually turned. Verification can be done by measuring deflection each end of crankshaft. If deflection is found greater than specified toler- ance, this indicates worn bearing(s), bent and/or disaligned crankshaft.
• Page 102
  Section 04 ENGINE Subsection 06 (BOTTOM END) Crankshaft Deflection Remove crankshaft bearings and check deflection again on V-shaped blocks as illustrated. All Models MEASUREMENT MAG SIDE PTO SIDE Crankshaft 0.050 mm 0.030 mm deflection (max.) (.002 in) (.001 in) Crankshaft deflection is measured each end with a dial indicator.
• Page 103
  Section 04 ENGINE Subsection 06 (BOTTOM END) Using a feeler gauge, measure distance between thrust washer and crankshaft counterweight. Close puller claws so that they can be inserted in end bearing. Holding claws, turn puller shaft clock- wise so that claws open and become firmly tight against bearing.

• Page 104: Assembly

  Section 04 ENGINE Subsection 06 (BOTTOM END) Check stopper distance from center of reed valve To properly position the outer bearing(s), a dis- block. tance gauge must be temporarily installed against the inner bearing. Slide the outer bearing until stopped by the distance gauge, then remove it. ENGINE DISTANCE GAUGE P/N 529 035 100 (MAG)

• Page 105
  Section 04 ENGINE Subsection 06 (BOTTOM END) Crankshaft and Counterbalance Shaft Install crankshaft no. 3 first in crankcase. After crankshaft installation, install counterbal- ance shaft no. 13. Make sure to properly index crankshaft and counterbalance shaft by aligning marks of gears. CAUTION: Marks on the crankshaft and coun- terbalance shaft must be aligned, otherwise engine will vibrate and premature wear will oc-…
• Page 106
  Section 04 ENGINE Subsection 06 (BOTTOM END) Place seals no. 17 in their respective positions. Use the silicone-based Loctite 5910 (P/N 293 800 081) on mating surfaces. Use a plexyglass plate and apply some sealant on it. Use a soft rubber roller (50 — 75 mm (2 — 3 in)) (available in arts products suppliers for printmak- ing) and roll the sealant to get a thin uniform coat on the plate (spread as necessary).
• Page 107
  Section 04 ENGINE Subsection 06 (BOTTOM END) Make sure all locating dowels are in place. F06D1PA 1. Dowel F07D09C All Engines Crankcase Screws Starter Drive Bearing Apply Molykote 111 below head of screws and To install bearing no. 23 of starter drive assembly, Loctite 518 on threads.
• Page 108
  Section 04 ENGINE Subsection 06 (BOTTOM END) Final Assembly 947 Carburetor-Equipped Engines When engine assembly is completed, add 40 mL (1.35 oz) of motor oil SAE 30 to the counterbalance shaft gear through the crankcase filler plug. F06D2CA 1. Remove plug and add SAE 30 motor oil 04-06-14 SMR2000-047_04_06A.FM www.SeaDooManuals.net…

• Page 109: Exhaust System

  Section 04 ENGINE Subsection 07 (EXHAUST SYSTEM) EXHAUST SYSTEM 12-13 04-07-1 SMR2000-049_04_07A.FM PARTS www.SeaDooManuals.net…

• Page 110: Removal

  Section 04 ENGINE Subsection 07 (EXHAUST SYSTEM) REMOVAL RX Models Remove seat. GTX DI Models Remove seat support. 1. Disconnect hose from outlet fitting Disconnect the water injection hose at tuned pipe head no. 10. 1. Seat support 2. Remove screws…

• Page 111
  Section 04 ENGINE Subsection 07 (EXHAUST SYSTEM) Loosen clamp no. 1 retaining exhaust hose no. 3 Loosen Allen screw retaining carburetor/throttle to tuned pipe cone no. 5. body bracket to tuned pipe head. F06D2DA F06D14A 1. Loosen clamp 1. Loosen Allen screw Loosen and remove clamp no.

• Page 112: Exhaust Manifold

  Resonators RX Models F06D1UA Remove vent tube support. 1. Remove bolt RX DI Models Remove tuned pipe head no. 10. Upper Type Resonators Loosen bolt no. 6 of tuned pipe cone beside the Detach resonator from body. engine water supply hose.

• Page 113: Tuned Pipe Repair

  1. Water supply hose 2. To injection fitting on tuned pipe Disconnect retaining strap no. 2 of muffler. Pull muffler no. 11 out of bilge. NOTE: On RX models, remove the VTS motor. Refer to VARIABLE TRIM SYSTEM. TYPICAL 1. Footwell type resonator All Models 2.

• Page 114: Installation

  Section 04 ENGINE Subsection 07 (EXHAUST SYSTEM) Test – Use compressed air at 124 kPa (18 PSI) to pres- surize tuned pipe. NOTE: Prior to verifying leaks, plug all holes and pressurize tuned pipe while immerging it in water. CAUTION: Always ensure water passages are not blocked partially or completely while weld- ing tuned pipe.

• Page 115
  Section 04 ENGINE Subsection 07 (EXHAUST SYSTEM) CAUTION: Torque the tuned pipe in accor- Torque bolt of tuned pipe cone beside the engine dance with the following sequence, otherwise water return hose to 40 N•m (29 lbf•ft). serious engine damage will occur. Torquing sequence: Torque all screws by hand.
• Page 116
  Section 04 ENGINE Subsection 07 (EXHAUST SYSTEM) F06D14A 1. Torque clamp to 4 N•m (35 lbf•in) 04-07-8 SMR2000-049_04_07A.FM www.SeaDooManuals.net…

• Page 117: Table Of Contents

  Section 05 ENGINE MANAGEMENT (DI) Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS OVERVIEW……………………..05-02-1 OPERATING PRINCIPLE ………………..05-02-2 AIR INDUCTION……………………. 05-02-2 AIR COMPRESSOR SYSTEM……………….. 05-02-2 FUEL DELIVERY SYSTEM………………..05-02-2 BASIC OPERATION ………………….05-02-2 AIR/FUEL RAIL ASSEMBLY ………………..05-02-2 FUEL PUMP MODULE………………….. 05-02-3 ELECTRONIC MANAGEMENT………………

• Page 118
  Section 05 ENGINE MANAGEMENT (DI) Subsection 01 (TABLE OF CONTENTS) DIAGNOSTIC PROCEDURES………………..05-04-1 GENERAL……………………..05-04-1 DESS SYSTEM ……………………05-04-2 FAULT DETECTION AND COMPENSATORY ACTIONS ……….05-04-4 COMPONENT FAILURE WARNING SYSTEM …………..05-04-4 VCK (VEHICLE COMMUNICATION KIT) …………….05-04-6 DI SYSTEM FAULT CODES ………………..05-04-7 05-01-2 SMR2000-037-05-01ATOC.FM www.SeaDooManuals.net…

• Page 119: Overview

  Section 05 ENGINE MANAGEMENT (DI) Subsection 02 (OVERVIEW) OVERVIEW 05-02-1 SMR2000-050-05-02A.FM www.SeaDooManuals.net…

• Page 120: Operating Principle

  Section 05 ENGINE MANAGEMENT (DI) Subsection 02 (OVERVIEW) OPERATING PRINCIPLE The Orbital Combustion Process (OCP) provides a stratified combustion process resulting from the direct injection of a finely atomized fuel spray (less than 10 microns). This is achieved by using a pneu- matically assisted direct injection system, a unique combustion chamber geometry and a pre- cise control of the combustion process by the…

• Page 121: Fuel Pump Module

  Section 05 ENGINE MANAGEMENT (DI) Subsection 02 (OVERVIEW) The air/fuel rail assembly is mounted on top of the FUEL PUMP MODULE cylinder head. It provides support for the air/fuel injectors and both air and fuel regulators. It also contains passages for the air and the fuel. The rail is a small reservoir for the injectors that keeps enough fluid at the proper pressure to supply the injectors demand.

• Page 122: Electronic Management

  Section 05 ENGINE MANAGEMENT (DI) Subsection 02 (OVERVIEW) ELECTRONIC MANAGEMENT – interpreting information – distributing information MPEM (multi-purpose electronic – start/stop function module) – timer The electronic fuel injection is equipped with a – DESS (Digitally Encoded Security System) MPEM. It is also called ECU (Electronic Control –…

• Page 123
  Section 05 ENGINE MANAGEMENT (DI) Subsection 02 (OVERVIEW) NOTE: Actually, it is the memory of the MPEM Gauges are supplied with current for 33 seconds which is programmed to recognize the digital code when connecting the safety lanyard cap on its post of the safety lanyard cap.
• Page 124
  Section 05 ENGINE MANAGEMENT (DI) Subsection 02 (OVERVIEW) When the oil level is low in the reservoir, the IMPORTANT: The sensors and injectors are con- MPEM sends out a signal to the information center tinuously powered with the supply from the bat- gauge and the pilot lamp on the gauge will turn on.
• Page 125
  Section 05 ENGINE MANAGEMENT (DI) Subsection 02 (OVERVIEW) This engine management system controls both Flooded Engine (drowned mode) the fuel injection and the ignition timing. If the engine does not start and it is flooded, pro- As shown in the DI CONTROL SYSTEM illustra- ceed as follows: tion, the MPEM is the central point of the fuel in- Remove spark plug cables and connect them on…

• Page 126: Ignition System

  Section 05 ENGINE MANAGEMENT (DI) Subsection 02 (OVERVIEW) These performance-reduced modes allow the rid- Ignition Coil er to go back home which would not be possible Ignition coil induces voltage to a high level in the without this advanced system. Refer to the DIAG- secondary windings to produce a spark at the NOSTIC PROCEDURES for a complete chart.

• Page 127: Component Inspection And Adjustment

  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) COMPONENT INSPECTION AND ADJUSTMENT GENERAL Engine problems are not necessarily related to the WARNING electronic fuel injection system. Fuel lines remain under pressure at all times. It is important to ensure that the mechanical integ- Always proceed with care and use appropri- rity of the engine/propulsion system is present: ate safety equipment when working on pres-…

• Page 128: Electrical System

  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) ELECTRICAL SYSTEM Before replacing a MPEM, always check electrical connections. Make sure that they are very tight and It is important to check that the electrical system they make good contact and that they are corrosion- is functioning properly: free.

• Page 129: Amp Connector Pin-Out

  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) The resistance value of a temperature sensor may test good at a certain temperature but it might be defective at other temperatures. If in doubt, try a new sensor. Also remember this validates the operation of the sensor at ambient temperature.

• Page 130: Air Induction System

  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) AIR INDUCTION SYSTEM THROTTLE BODY Installation Reinstall removed parts on the new throttle body. Mechanical Inspection For TPS replacement procedures, refer to Throt- Check that the throttle plates moves freely and tle Position Sensor (TPS) in Electronic Manage- smoothly when depressing throttle lever.

• Page 131
  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) NOTE: In the following illustrations, the lower link plate has been removed for clarity purposes only. It does not have to be removed to perform the adjustment. Loosen lock nut of idle set screw. Unscrew idle set screw so that master throttle plate completely closes in the throttle body.
• Page 132
  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Apply Loctite Ultra Grey ® Silicone Gasket Maker Throttle Cable Adjustment on idle set screw head. Mecanically adjust the throttle cable using the ad- justing device underneath body, below steering. Free-play on lever should be between 2 and 3.5 mm (1/16 and 1/8 in).

• Page 133: Air Compressor

  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) AIR COMPRESSOR PRESSURE TEST CAUTION: Ensure to install the pressure relief valve to allow excess pressure to go out. Note The pressure test will show the available pressure the arrow on the valve. Otherwise, air compres- from the air compressor.

• Page 134
  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) If reed valve is found defective, it is suggested to Ensure to position screw from the bottom up as replace it then to temporarily reassemble the com- show. Torque nut to 2.7 N•m (24 lbf•in). pressor to then make a pressure test.
• Page 135
  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) TOLERANCES ENGINE MEASUREMENT NEW PARTS WEAR (min.) (max.) LIMIT Piston/cylinder wall 0.12 mm 0.2 mm N.A. clearance (.005 in) (.008 in) 0.1 mm 0.25 mm 0.5 mm Ring end gap (.004 in) (.010 in) (.020 in)
• Page 136
  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Assembly When attaching connecting rod to “crankpin”, strictly follow this procedure: Apply injection oil in cylinder and on rings prior to installing. 1. Block counterbalance shaft to prevent any rota- tion.

• Page 137: Fuel Delivery

  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) FUEL DELIVERY AIR/FUEL RAIL Pressure Test The pressure test will show the available pressure at the air/fuel rail. It validates the pressure regula- tor and leaks in the system. IMPORTANT: Before checking air/fuel rail pres- sure, make sure the fuel pressure from the fuel pump and the air pressure from the air compres-…

• Page 138
  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Fuel Injector If resistance value is incorrect, repair the wiring harness/connectors between AMP plug connec- When one fuel injector is defective, both have to tor and fuel injector. be replaced as an assembly with the air/fuel rail. Replacement Testing the fuel injector operation can be per- formed with the air/fuel rail installed.
• Page 139
  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) NOTE: When lifting/removing air/fuel rail, we rec- ommend replacing carbon dams on direct injec- tors that have been running for 50 hours or more. Installation For installation, reverse the removal process but pay attention to the following.

• Page 140: Fuel Pump

  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Using a multimeter, check resistance value be- NOTE: A thin film of injection oil may be applyed tween terminals as follows. to carbon dam if necessary to ease insertion in cyl- inder head.

• Page 141
  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Ensure there is enough gas in fuel tank. Use the VCK (Vehicle Communication Kit) to re- lease the fuel pressure in the system. Look in the Activation section of the software B.U.D.S. Disconnect inlet and outlet hoses from fuel pump using tool (P/N 529 035 714).
• Page 142
  Removal Open front storage compartment cover. Remove the storage basket. Remove glove box (see HULL/BODY section). Remove front vent tubes. RX DI Remove tube Y-connector. 1. Fuel pump 2. Retaining screw Remove tube bracket by unscrewing nuts from Disconnect electrical connector.
• Page 143
  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) RX DI Compress springs of pump module to reduce its height to allow pulling pump out. All Models Pull fuel pump toward front of vehicle. Wipe off any fuel spillage in the bilge.
• Page 144
  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) FUEL DELIVERY SYSTEM DIAGNOSTIC FLOW CHART Fuel pump runs Fuel pump does not run Connect safety lanyard for 2 sec. then stops Check fuses Check lanyard connection Install fuel pressure gauge on Check pump module operation fuel pressure line Repair or replace if necessary…

• Page 145: Electronic Management

  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) ELECTRONIC MANAGEMENT MPEM REPLACEMENT General Prior to replacing a suspected MPEM, ensure that all the recommendations in the general introduc- tion of this section have been followed. When MPEM is replaced, the safety lanyard(s), the TPS closed position and the TDC setting must be reprogrammed/reset.

• Page 146
  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Voltage Test — Both TPS If resistance values are incorrect, repair the wiring harness/connectors between AMP plug connec- Check the voltage output from MPEM to the desired tor and the TPS. throttle position sensor.

• Page 147: Crankshaft Position Sensor (Cps)

  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) NOTE: Reset must be done each time the throttle Check for RPM display at the information center position sensor (TPS) is loosened or removed or while cranking engine. If it displays approximate- throttle body(ies) is(are) replaced or MPEM is re- ly 300 RPM, the CPS circuitry is properly working.

• Page 148: Manifold Air Temperature Sensor (Mats)

  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Voltage Test Remove CPS. Unplug magneto connector. Check connector pins for corrosion or damage. Remove and reinstall the safety lanyard to activate the MPEM. Check the voltage readings on the harness side as follows: CONNECTION VOLTAGE…

• Page 149: Water Temperature Sensor (Wts)

  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Resistance Test Resistance Test Disconnect the plug connector from the MATS Disconnect the plug connector from the WTS and and check the resistance of the sensor itself. check the resistance of the sensor itself. The resistance should be between 2280 Ω…

• Page 150: Manifold Air Pressure Sensor (Maps)

  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) MANIFOLD AIR PRESSURE Resistance Test SENSOR (MAPS) Disconnect the AMP plug connector number 3 on the MPEM. Using a multimeter, check continuity of circuits 3-3, 3-6 and 3-7. If wiring harness is good, try a new MPEM. Refer to MPEM replacement procedures elsewhere in this section.

• Page 151: Knock Sensor (Ks)

  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Resistance Test Dynamic Test Disconnect the plug connector from the EGT and Using the vehicle communication kit (VCK) with check the resistance of the sensor itself. the B.U.D.S. software, monitor the knock sensor using the Faults section.

• Page 152
  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Leakage/Voltage Test Unplug the outlet hose from RAVE solenoid. NOTE: The solenoid activates both RAVE valves at the same time. Unplug the RAVE solenoid supply hose from air compressor. 1.

• Page 153: Ignition Coil

  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) WARNING Never make a spark test with spark plug re- moved. Flammable vapors may be present in the bilge and ignited which could cause an explosion. Primary Winding Disconnect the plug connector from the ignition coil and check the resistance of the primary circuit.

• Page 154
  Always reconnect spark plug cables at the same spark plugs where they come from. The 5700 cable coming out the edge of the electrical RX DI box must be connected to the MAG side spark 4300 plug. Otherwise, sever backfire may occur…

• Page 155: Tdc Setting

  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) NOTE: If PTO ignition coil is replaced, ensure to reinstall the white tape on the new coil on if it is not present. TDC SETTING General Before checking TDC setting with a stroboscopic timing light (dynamic test), it is mandatory to scribe a timing mark on the PTO flywheel (static test) corresponding to the specific engine.

• Page 156
  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) – Loosen adaptor lock nut then holding gauge 10. Connect timing light pick-up to MAG side with dial face directed toward you when you spark plug wire. are in line with the crankshaft, screw adaptor in spark plug hole.
• Page 157
  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) CAUTION: If engine is to be run more than a 1. Choose the Setting tab and look under Ignition few seconds, engine must be cooled using the Offset. flush kit. 2.

• Page 158: Spark Plugs

  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) If wiring harness tests good, it could be the The “hot” type plug has a longer insulator nose MPEM. Try a new MPEM referring to MPEM re- and transfers heat more slowly away from its firing placement procedures elsewhere in this section.

• Page 159: Cranking System

  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) 3. Hand screw spark plug into cylinder head. Then, tighten the spark plug clockwise an additional 1/4 turn with a proper socket. 1. Proper socket 2. Improper socket SPARK ENGINE TORQUE PLUG…

• Page 160: Di System Test Summary

  Section 05 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) DI SYSTEM TEST SUMMARY Pressure Tests VALUE COMPONENT kPa (PSI) 621 ± 14 (90 ± 2) Air compressor at cranking 185 ± 14 (27 ± 2) Fuel pressure regulator when installing safety lanyard 721 (105) minimum…

• Page 161
  — secondary winding w/o and coil post high tension leads — — 5700 ohms lead alone High tension leads RX DI models — White tape 4300 ohms lead alone — — 5700 ohms lead alone High tension leads GTX DI models —…

• Page 162: Diagnostic Procedures

  Section 05 ENGINE MANAGEMENT (DI) Subsection 04 (DIAGNOSTIC PROCEDURES) DIAGNOSTIC PROCEDURES GENERAL Here is the basic order suggested to diagnose a suspected fuel injection related problem: – Check the chart in TROUBLESHOOTING sec- tion to have an overview of problems and sug- gested solutions.

• Page 163: Dess System

  Section 05 ENGINE MANAGEMENT (DI) Subsection 04 (DIAGNOSTIC PROCEDURES) DESS SYSTEM Basic Self-Diagnostic Mode It is self-activated when the safety lanyard cap is being installed on the watercraft post. It gives immediate monitoring. Some codes may occur only when pressing the start/stop button. Refer to the following chart. SIGNAL CAUSE REMEDY…

• Page 164
  Section 05 ENGINE MANAGEMENT (DI) Subsection 04 (DIAGNOSTIC PROCEDURES) Advanced Self-Diagnostic Mode It needs to be enabled manually. Proceed as follows: 1. Remove safety lanyard cap from watercraft post. 2. Press 5 times on the watercraft start/stop button. NOTE: 1 short beep and 1 long beep must be heard. They validate beginning of diagnostic mode. 3.

• Page 165: Fault Detection And Compensatory Actions

  Section 05 ENGINE MANAGEMENT (DI) Subsection 04 (DIAGNOSTIC PROCEDURES) FAULT DETECTION AND COMPENSATORY ACTIONS For a basic overview of the monitoring system and the limp home modes, see OVERVIEW section. COMPONENT FAILURE WARNING SYSTEM Sensor Failures Refers to open or short circuit failures on sensors, drivers, injectors or ignition. BUZZER LIMP HOME MODE PROBLEM…

• Page 166
  Section 05 ENGINE MANAGEMENT (DI) Subsection 04 (DIAGNOSTIC PROCEDURES) System Failures Refers to operating conditions outside normal and/or safe ranges such as demand system failures, ex- treme voltages, over temperature conditions or low fuel/oil levels. BUZZER LIMP HOME MODE PROBLEM INFO CENTER RED LED BUZZER…

• Page 167: Vck (Vehicle Communication Kit)

  Section 05 ENGINE MANAGEMENT (DI) Subsection 04 (DIAGNOSTIC PROCEDURES) Buzzer Code VCK (vehicle communication WARNING kit) If the computer you are using is connected to the 110 Vac power outlet, there is a potential The VCK (Vehicle Communication Kit) (P/N 529 risk of electrocution when working in contact 035 676) is the primary tool to diagnose fuel injec- with water.

• Page 168: Di System Fault Codes

  Section 05 ENGINE MANAGEMENT (DI) Subsection 04 (DIAGNOSTIC PROCEDURES) DI SYSTEM FAULT CODES – Electrical noise might also lead engine to occa- sional cutout without generating a fault code when engine is restarted. When looking at the General fault code, pay attention to the “count” value in The faults registered in the MPEM are kept when the software B.U.D.S.

• Page 169
  Section 05 ENGINE MANAGEMENT (DI) Subsection 04 (DIAGNOSTIC PROCEDURES) TPS “OUT OF RANGE” Fault It is caused by the sensor reading going out of its allowable range. This fault can occur during the whole range of movement of the throttle. To diagnose this fully, it is recommended to operate the throttle through its full range.
• Page 170
  Section 05 ENGINE MANAGEMENT (DI) Subsection 04 (DIAGNOSTIC PROCEDURES) DI System Fault Code Chart SERVICE ACTION POSSIBLE CAUSES Service action: Check for 2.0 ohm resistance between system circuits 4-15 and 4-5. Direct Check for + 12 volts on pin A of injector connector (color). Open or Return to P1100…
• Page 171
  Section 05 ENGINE MANAGEMENT (DI) Subsection 04 (DIAGNOSTIC PROCEDURES) SERVICE ACTION POSSIBLE CAUSES Service action: Check for 5 volts on pin 1 and 0-0.5 volts on pin 3 and 0 volts on pin 2. Check system circuits 4-1, 4-2, 4-18. Check with throttle closed the resistance between 1 and 2 is 2000 ohms and between 2 and 3 is 1000 ohms and between 1 and 3 2500 ohms.
• Page 172
  Section 05 ENGINE MANAGEMENT (DI) Subsection 04 (DIAGNOSTIC PROCEDURES) SERVICE ACTION POSSIBLE CAUSES Service action: Check system circuits 3-3, 3-6, 3-7. Check sensor connector for 5 volts on pin 1 and 0 volts on pin 3 and 0 volts on pin 2. Check Sensor housing is correctly inserted into manifold.
• Page 173
  Section 05 ENGINE MANAGEMENT (DI) Subsection 04 (DIAGNOSTIC PROCEDURES) SERVICE ACTION POSSIBLE CAUSES Battery Full reset. Battery Possible causes: P1500 BV_HI_RED voltage Key off and voltage Battery failure, rectifier failure, battery terminal connection. very high Service action: Check fuse. Check system circuits 3-25 to battery + terminal, 2-26 to regulator 2 pin connector pin A, 2-25 to regulator 2 pin connector As soon as Battery…

• Page 174: Table Of Contents

  Section 06 COOLING SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS CIRCUIT, COMPONENTS AND CARE………………. 06-02-1 CIRCUIT ……………………..06-02-3 COMPONENTS ……………………06-02-6 CARE ……………………..06-02-9 06-01-1 SMR2000-037_06_01ATOC.FM www.SeaDooManuals.net…

• Page 175: Circuit, Components And Care

  Section 06 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) CIRCUIT, COMPONENTS AND CARE 947 ENGINE — CARBURETOR-EQUIPPED MODELS 06-02-1 SMR2000-054_06_02A.FM www.SeaDooManuals.net…

• Page 176
  Section 06 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) 947 ENGINE — DI MODELS 06-02-2 SMR2000-054_06_02A.FM www.SeaDooManuals.net…

• Page 177: Circuit

  Section 06 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) CIRCUIT All Models Water continues to circulates from inlet hose CAUTION: All hoses and fittings of the cooling through the one piece cylinder head which fea- system have calibrated inside diameters to as- tures improved combustion chamber and better sure proper cooling of the engine.

• Page 178
  Section 06 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) Water exits tuned pipe water jackets through an All Models outlet fitting. Draining of the cooling system is accomplished by the drain hose connected to a fitting at the bottom of the cylinder-block, on tuned pipe side.
• Page 179
  Section 06 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) The water supply of the water flow regulator is Regulated water is injected in the tuned pipe by a provided by the water supply hose coming from calibrated fitting. the pump. F06E0AA 1.

• Page 180: Components

  Section 06 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) COMPONENTS CAUTION: The elbow fittings are calibrated and can not be interchanged with one of a dif- ferent size as severe engine damage could re- Clamp sult. To cut or secure non-reusable Oetiker clamps of The elbow fitting can be identified by using the cooling system hoses, use pliers (P/N 295 000 number stamped onto the fitting or by measuring…

• Page 181
  Section 06 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) The water flow regulator valve is mounted directly onto the muffler. F01E1FA TYPICAL 1. Water supply hose of regulator valve 2. Regulated water to injection fitting 3. Water injected into the muffler LOW SPEED OPERATION 1.
• Page 182
  Section 06 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) Adjustment Remove fitting from valve housing. The water flow regulator valve has been calibrated at the factory and should not be modified. NOTE: Water flow regulator valves ordered from the parts channel are also calibrated. The valve cap on the DI models is sealed and it is not adjustable.

• Page 183: Care

  Section 06 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) Remove the tapered needle from valve housing. Inspection Inspect parts for damage. Verify especially bel- lows for cracks. Assembly Assembly is essentially the reverse of disassem- bly procedures. CARE For flushing purposes, the cooling system is equipped with either a fitting spigot or a hose adapter depending upon the model.

• Page 184: Towing The Watercraft In Water

  Section 06 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) Towing the Watercraft in Water CAUTION: Failure to do this may result in dam- age to the engine. If you must tow a stranded Special precautions should be taken when towing watercraft in water and do not have a hose a Sea-Doo watercraft in water.

• Page 185: Table Of Contents

  Section 07 FUEL SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS FUEL CIRCUIT……………………07-02-1 GENERAL ……………………… 07-02-3 REMOVAL……………………… 07-02-3 INSPECTION ……………………07-02-5 ASSEMBLY……………………. 07-02-6 FUEL SYSTEM PRESSURIZATION ………………. 07-02-6 AIR INTAKE ……………………..07-03-1 REMOVAL……………………… 07-03-3 ASSEMBLY……………………. 07-03-3 CARBURETOR ……………………07-04-1 GENERAL ………………………

• Page 186: Fuel Circuit

  Section 07 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) FUEL CIRCUIT RX (carburetor-equipped models) PARTS 07-02-1 SMR2000-055_07_02A.FM www.SeaDooManuals.net…

• Page 187
  Section 07 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) GTX DI Models PARTS 07-02-2 SMR2000-055_07_02A.FM www.SeaDooManuals.net…

• Page 188: General

  Section 07 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) GENERAL WARNING DI Models: The fuel system of a fuel injection system hold much more pressure than on a carbureted watercraft. Prior to disconnecting a hose or to removing a component from the fuel system, follow the recommendation de- scribed in ENGINE MANAGEMENT (DI) under Fuel System.

• Page 189
  Section 07 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) Unscrew the fuel filter bowl no. 12 counterclock- Fuel Baffle Pick Up wise then pull toward the bottom. Carburetor-Equipped Models NOTE: The baffle pick up has an integrated fuel sender for the fuel gauge. F01F01A TYPICAL Step…

• Page 190: Inspection

  F01F02A Refer to ENGINE MANAGEMENT (DI) section. 1. Gasket in bowl Fuel Tank WARNING RX/RX DI Models Ensure that there is no leakage from the fuel NOTE: It is necessary to remove the engine. Re- filter. fer to ENGINE section.

• Page 191: Assembly

  Section 07 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) Pressure Relief Valve NOTE: A fuel tank is comprised of 3 components: the tank, the fuel pick up neck and the filler neck. All Models The necks are injection molded and the tank is This valve will eliminate fuel spillage when the wa- then blow molded over the necks.

• Page 192
  Section 07 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) NOTE: The system must maintain a pressure of 34 kPa (5 PSI) during 10 minutes. Never pressurize over 34 kPa (5 PSI). Reconnect air inlet hose of fuel tank to body. WARNING If any leak is found, do not start the engine and wipe off any fuel leakage.

• Page 193: Air Intake

  Section 07 FUEL SYSTEM Subsection 03 (AIR INTAKE) AIR INTAKE Carburetor-Equipped Models PARTS 07-03-1 SMR2000-056_07_03A.FM www.SeaDooManuals.net…

• Page 194
  Section 07 FUEL SYSTEM Subsection 03 (AIR INTAKE) DI Models PARTS 07-03-2 SMR2000-056_07_03A.FM www.SeaDooManuals.net…

• Page 195: Removal

  Section 07 FUEL SYSTEM Subsection 03 (AIR INTAKE) REMOVAL Pull air ducts out. Air Intake Silencer Remove seat support (GTX DI models). Unlock the clip no. 2 on top of air intake silencer. F06D34A 1. Air duct 1. Clip NOTE: Do not disconnect oil lines. Remove bolts retaining both air ducts to engine Push the air intake silencer out of the carburetor (both sides).

• Page 196
  Section 07 FUEL SYSTEM Subsection 03 (AIR INTAKE) Air Intake Silencer Make sure that gaskets no. 5 are installed into car- buretor holes of air intake silencer or throttle bod- ies on DI models. Check O-rings no. 6 on carburetor intake adaptors or throttle bodies on DI models and change them if necessary.

• Page 197: Carburetor

  Section 07 FUEL SYSTEM Subsection 04 (CARBURETOR) CARBURETOR Mikuni BN-46i PTO/MAG PARTS 07-04-1 SMR2000-057_07_04A.FM www.SeaDooManuals.net…

• Page 198: General

  Section 07 FUEL SYSTEM Subsection 04 (CARBURETOR) GENERAL The following illustration shows which part of the carburetor begins to function at different throttle plate openings. F06F0LA TYPICAL 1. Pulse line 2. Loosen gear clamp Disconnect fuel supply line from fuel pump. F01F13A Disconnect fuel return line.

• Page 199: Cleaning

  Section 07 FUEL SYSTEM Subsection 04 (CARBURETOR) CLEANING The carburetor exterior surfaces should be cleaned with a general solvent and dried with com- pressed air before disassembly. CAUTION: Be careful at carburetor cleaning not to remove paint. Paint removal will cause carbu- retor to rust very rapidly.

• Page 200
  Section 07 FUEL SYSTEM Subsection 04 (CARBURETOR) Internal Fuel Filter – Obstruct outlet nipple with a finger and hold while pumping. To verify condition of filter no. 5, proceed as follows: – Pump tester until it reaches 28 kPa (4 PSI). Remove pump cover no.

• Page 201: Assembly

  Section 07 FUEL SYSTEM Subsection 04 (CARBURETOR) To check the injector, install pump gauge tester to Needle Valve Lever the injector hose. Rounded end of needle valve lever no. 8 must be NOTE: Injectors are also equipped with check flush with surrounding metering chamber floor valves.

• Page 202
  Section 07 FUEL SYSTEM Subsection 04 (CARBURETOR) Refer to the following table for pop-off pressure specifications: POP OFF PRESSURE MODEL min./max. (PSI) 19/23 NOTE: Pressure test should be performed three F01F34A times to obtain a valid reading. LOW LEVER If pop-off pressure is not within specification, Step : Depress here check control lever adjustment.

• Page 203: Installation

  Section 07 FUEL SYSTEM Subsection 04 (CARBURETOR) O-Ring When installing O-rings no. 13 of low speed and high speed screws, apply some BOMBARDIER LUBE (P/N 293 600 016) to prevent sticking. Fuel Accelerator Pump Lubricate pump plunger, roller and cam with syn- thetic grease (P/N 293 550 010) and roller shaft with BOMBARDIER LUBE (P/N 293 600 016).

• Page 204: Adjustments

  Section 07 FUEL SYSTEM Subsection 04 (CARBURETOR) ADJUSTMENTS Tighten jam nuts and torque to 3 N•m (27 lbf•in). NOTE: Grease carburetor linkage at both ends Twin Carburetor Synchronization with synthetic grease (P/N 293 550 010). With idle speed screw not touching throttle lever Connect linkage between both carburetor levers.

• Page 205
  Section 07 FUEL SYSTEM Subsection 04 (CARBURETOR) Ensure throttle plates are completely closed on both carburetors. Loosen jam nut and turn adjustment nut to elimi- nate all the slack in the throttle cable between sen- sor and carburetor. Tighten jam nut. 1.
• Page 206
  Section 07 FUEL SYSTEM Subsection 04 (CARBURETOR) CAUTION: Do not attempt to set engine idle speed with low-speed screw. Tighten low speed screw until a slight resistance is felt. Then, back it off to the specification as per following chart. WATERCRAFT MODEL LOW SPEED SCREW 1.5 ±…
• Page 207
  Section 07 FUEL SYSTEM Subsection 04 (CARBURETOR) Idle Speed Screw Turning screw no. 15 clockwise increases engine idle speed and turning screw counterclockwise decreases engine idle speed. F02F1QA TYPICAL 1. Adjustment screw 2. Small gap 1. Idle speed screw NOTE: Turning the adjustment screw clockwise will increase the gap.

• Page 208: Table Of Contents

  Section 08 LUBRICATION SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS OIL INJECTION SYSTEM …………………. 08-02-1 GENERAL ……………………… 08-02-2 OIL SYSTEM PRESSURIZATION ………………08-02-2 OIL INJECTION PUMP ………………….08-03-1 REMOVAL……………………… 08-03-3 DISASSEMBLY ……………………08-03-3 CLEANING ……………………. 08-03-3 ASSEMBLY ……………………08-03-3 ADJUSTMENT ……………………

• Page 209: Oil Injection System

  Section 08 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM) OIL INJECTION SYSTEM GTX DI Models PARTS 08-02-1 SMR2000-058_08_02A.FM www.SeaDooManuals.net…

• Page 210: General

  Section 08 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM) GENERAL DI Models Connect pump gauge tester (P/N 529 021 800) to Whenever repairing the oil injection system, al- disconnected tube at throttle body. ways verify for water infiltration in reservoir. All Models Perform also a pressure test of the oil injection system.

• Page 211: Oil Injection Pump

  Section 08 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) OIL INJECTION PUMP Carburetor-Equipped Models 27 N•m (20 lbf•ft) 3.5 N•m (31 lbf•in) Dielectric grease 3.5 N•m (31 lbf•in) F07G03S PARTS 08-03-1 SMR2000-059_08_03A.FM www.SeaDooManuals.net…

• Page 212
  Section 08 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) DI Models PARTS 08-03-2 SMR2000-059_08_03A.FM www.SeaDooManuals.net…

• Page 213: Removal

  Section 08 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) NOTE: The following procedures can be done with- out removing the engine from hull. REMOVAL Pump Cable The cable end has a slight press fit in the lever. Using a small screwdriver, pry cable end out. Oil Injection Pump Remove tuned pipe head.

• Page 214
  Section 08 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) Refer to CARBURETOR or THROTTLE BODY for If necessary, turn cable adjustment nut to obtain throttle cable adjustment procedure. pump mark alignment. Refer to above illustrations. NOTE: On Carburetor-Equipped Models, make Tighten jam nut and recheck alignment marks.

• Page 215: Checking Operation

  Section 08 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) DI Models – Use the VCK (Vehicle Communication Kit) P/N 529 035 676. Look in the Monitoring section of the software B.U.D.S. – Use the “Oil lines bleeding” function that al- lows to “lock”…

• Page 216: Table Of Contents

  Section 09 ELECTRICAL SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS IGNITION SYSTEM…………………… 09-02-1 GENERAL ……………………… 09-02-1 MULTI-PURPOSE ELECTRONIC MODULE (MPEM)…………09-02-2 IGNITION TIMING ………………….09-02-4 IGNITION SYSTEM TESTING PROCEDURE …………..09-02-8 SPARK PLUGS ……………………09-02-10 CHARGING SYSTEM………………….09-03-1 GENERAL ………………………

• Page 217: Ignition System

  Section 09 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) IGNITION SYSTEM Carburetor-Equipped Models NOTE: For DI models, refer to ENGINE MANAGE- MENT section. GENERAL The ignition system consist of different sub-systems where some are interrelated. Unregulated AC current is produced by the mag- neto.

• Page 218: Multi-Purpose Electronic Module (Mpem)

  Section 09 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Ignition Coil Some fuses are directly mounted onto the MPEM. All the electrical system is controlled by the MPEM. Ignition coil induces voltage to a high level in sec- It has internal micro-processor and is directly pow- ondary windings to produce a spark at spark plug.

• Page 219
  Section 09 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Gauges are supplied with current for 33 seconds Power Distribution when connecting the safety lanyard cap on the The MPEM distributes power from battery to all switch or when pressing the start/stop switch accessories.

• Page 220: Ignition Timing

  Section 09 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Electrical Box With this DC-CDI system, the ignition timing can be checked with either the engine hot or cold. Al- The high amperage/voltage components are locat- so, the ignition timing is to be checked at 3500 ed into the electrical box.

• Page 221
  Section 09 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) 4. Install and adjust a TDC gauge (P/N 295 000 IGNITION TIMING ENGINE 143) in MAG side spark plug hole. (BTDC) 2.99 mm (.118 in) 7. Scribe a thin mark on PTO flywheel aligned with timing mark pointer tool.
• Page 222
  Section 09 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) 2. Connect timing light pick-up to MAG side spark MPEM Programmer plug wire. NOTE: For more information on the programmer, refer to the MPEM programmer guide (P/N 219 700 090). Through the MPEM programmer, the ignition tim- ing can be advanced up to 3°…
• Page 223
  Section 09 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) – You estimate the correction should be set to Proceed as Follows to Adjust the 1° (advanced) to align flywheel mark. Back in Ignition Timing with the MPEM the chart, look to find 1° (advanced). This Programmer: gives number 4.

• Page 224: Ignition System Testing Procedure

  Section 09 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) CAUTION: If the ignition timing is adjusted too Connect one test probe to the WHITE/GRAY wire advanced, this will cause serious damage to and the other test probe to the switch terminal. the engine.

• Page 225
  Section 09 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Trigger Coil Verification 5. Crank engine and note result. The obtained val- ue should be between 0.2 and 0.5 Vac. STATIC TEST: CONTINUITY 6. If the trigger coil is out of specification, replace it. 1.

• Page 226: Spark Plugs

  Section 09 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Heat Range DYNAMIC TEST Use an ignition coil tester, available from after- The proper heat range of the spark plugs is deter- market tool/equipment suppliers. mined by the spark plugs ability to dissipate the heat generated by combustion.

• Page 227
  Section 09 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Fouling Spark Plug Installation Fouling of the spark plug is indicated by irregular Prior to installation make sure that contact surfac- running of the engine, decreased engine speed es of the cylinder head and spark plug are free of due to misfiring, reduced performance, and in- grime.
• Page 228
  Section 09 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) NGK Spark Plug Symbol Explanation WIDE GAP PREFIX SUFFIX 10: 1.0 mm (.040″) B R 8 E S 11: 1.1 mm (.044″) 13: 1.3 mm (.050″) 14: 1.4 mm (.055″) 15: 1.5 mm (.060″) 20: 2.0 mm (.080″) Thread Heat rating…

• Page 229: Charging System

  Section 09 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) CHARGING SYSTEM GENERAL CAUTION: Do not use a higher rated fuse as this cause severe damage. Magneto Carburetor-Equipped Models The purpose of the charging system is to keep the Two 15 A fuses protect the charging system. The battery at a full state of charge.

• Page 230
  Section 09 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) If multimeter reads over 15 volts, regulator is de- 2. Install the 6-pin magneto harness adapter (P/N fective. Replace it. 295 000 136). NOTE: If it is continually necessary to add distilled 3.

• Page 231: Battery

  If casing is damaged, replace battery and thoroughly clean battery tray and close RX Models area with water and baking soda. Remove LH side bilge vent tube at rear. Inspect battery posts for security of mounting.

• Page 232
  Section 09 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) Battery Testing ELECTROLYTE OPERATION TO TEMPERATURE There are 2 types of battery tests: electrolyte read- PERFORM °C °F ing and load test. An electrolyte reading is made on a battery without discharging current. It is the .012 .008 to the…
• Page 233
  Section 09 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) Disconnect and remove battery from watercraft Perform the following operations anytime a new as explained in Removal. battery is to be installed. Check electrolyte level in each cell, add distilled 1. Remove the sealing tube from the vent elbow. water up to upper level line.
• Page 234
  Section 09 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) 4. Readjust the electrolyte level to the UPPER 6. Disconnect battery charger. LEVEL line. Step : Unplug battery charger Step : Disconnect — lead Step : Disconnect + lead A17E0RB 7. Test battery state of charge. Use a hydrometer. 1.
• Page 235
  Section 09 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) Charging a Used Battery Charging a Very Flat or Completely Discharged Battery WARNING The battery charger should have an adjustable charging rate. Variable adjustment is preferred, Never charge battery while installed in water- but a unit which can be adjusted in small incre- craft.

• Page 236: Battery Installation

  Vent line must be free and open. Avoid skin contact with electrolyte. 3. First connect RED positive cable. 4. Connect BLACK negative cable last. 5. Apply dielectric grease on battery posts. 6. Verify cable routing and attachment. RX Models Reinstall bilge vent tube. 09-03-8 SMR2000-061_09_03A.FM www.SeaDooManuals.net…

• Page 237: Starting System

  Section 09 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) STARTING SYSTEM PARTS 09-04-1 SMR2000-062_09_04A.FM www.SeaDooManuals.net…

• Page 238: General

  Section 09 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) GENERAL Engine Start/Stop Switch and Safety Lanyard Switch Causes of troubles are not necessarily related to Refer to IGNITION SYSTEM or ENGINE MANAGE- starter but may be due to a burnt fuse, faulty bat- MENT.

• Page 239: Starting System Troubleshooting

  Section 09 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) STARTING SYSTEM TROUBLESHOOTING SYMPTOM CAUSE REMEDY STARTER DOES NOT TURN. Check wiring condition and replace Burnt fuse on MPEM. fuse. Poor contact of battery terminal(s). Clean and tighten terminal(s). Poor battery ground cable connection. Clean and tighten.

• Page 240: Starter Removal

  Section 09 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) STARTER REMOVAL STARTER DISASSEMBLY Disconnect BLACK cable ground connection from Locate index marks on yoke no. 1 and end covers battery. no. 3 and no. 10. WARNING Always disconnect BLACK ground cable first and reconnect last.

• Page 241
  Section 09 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) Remove end cover no. 3 and gasket on armature Release brush wires of yoke from brush holder shaft side. no. 2. Remove thrust washers no. 19 from armature Remove brush holder no. 2. shaft.

• Page 242: Cleaning

  Section 09 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) Remove brushes. Check commutator for roughness, burnt or scored surface. If necessary, turn commutator on a lathe, To remove bearing and seal in end cover, release enough to resurface only. tabs of retainer. Check commutator for mica depth.

• Page 243: Starter Assembly

  Section 09 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) Brush Measure brush length. If less than 8.5 mm (.335 in), replace them. NOTE: New brush length is 12 mm (.472 in). 1. Non metallic surface on the side Install the 3 washers no. 8 onto armature shaft. When installing end covers no.

• Page 244: Starter Specification

  Section 09 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) STARTER SPECIFICATION Connect the RED positive cable to the starter and Nominal output 0.8 kW torque nut no. 17 to 6 N•m (53 lbf•in). Apply di- electric grease on terminal and nut. Voltage 12 V Rated time…

• Page 245: Instruments And Accessories

  Section 09 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) INSTRUMENTS AND ACCESSORIES GENERAL Water Temperature Sensor (L TEMP) The water temperature sensor is integrated with It is possible to activate the instruments when the the speed sensor located on the ride plate. engine is not running.

• Page 246
  Section 09 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) All Models Speedometer (90 mm) Speed Sensor The speedometer gives a reading through a speed sensor. Speed sensor is installed on riding plate. It works with the water flow which turns a magnetic paddle wheel that triggers an electronic pick-up that in turn sends a speed signal to the speedom- eter.
• Page 247
  Section 09 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) The information center includes the following dis- Clock/Compass (if so equipped): Displays the play areas. cardinal points to indicate the orientation of the watercraft. WARNING Use the compass as a guide only. Not to be used for navigation purposes.

• Page 248: Other Functions

  Section 09 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) Warning Light When another display mode is chosen, the default display will be displayed back after 4 seconds. The red warning LED (Light-Emitting Diode) blinks As a self test, all LCD segments and the LED will along with the message display to catch your at- turn on for 3 seconds each time the information tention.

• Page 249
  Section 09 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) English/Metric System Allows to display the units in the metric system or in the SAE English system. 1. Press TOGETHER to end NOTE: If MODE and SET buttons are not pressed at the end, the default display will come back after 10 seconds and the time entered will remain.
• Page 250
  Section 09 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) NOTE: If maintenance message (MAINT) con- RX and RX DI tinues to blink, it indicates a fault with the fuel in- jection system on Di models. Refer to DIAGNOS- TIC PROCEDURES section.
• Page 251
  Section 09 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) RESISTANCE DISPLAY RESISTANCE DISPLAY (Ω) TEMPERATURE (°C) (Ω) TEMPERATURE (°F) 12495.0 20 ± 2 22919.8 45 ± 4 10000.0 25 ± 2 17491.7 55 ± 4 8054.9 30 ± 2 13487.5 65 ±…
• Page 252
  Section 09 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) FUEL LEVEL AND RESISTANCE FUEL LEVEL RESISTANCE (mm) (Ω) From 248.9 ± 5 and more 0 + 2.2 From 234.4 to 248.8 ± 5 17.8 ± 2.2 From 200.9 to 234.3 ± 5 27.8 ±…
• Page 253
  WHITE wire of VTS control module. there is enough oil in tank. Connect test probes of a multimeter to BROWN/ BLACK wire and BROWN/WHITE wire of VTS con- RX Models trol module. VTS Switch NOTE: To permit VTS actuation when engine is not…

• Page 254: Digitally Encoded Security System (Dess)

  Section 09 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM) DIGITALLY ENCODED SECURITY SYSTEM Carburetor-Equipped Models NOTE: For DI models, refer to ENGINE MANAGE- MENT section. GENERAL The Digitally Encoded Security System (DESS) features an anti-start protection against unautho- rized use of the watercraft. The following components are specially designed for this system: Multi-Purpose Electronic Module (MPEM), safety lanyard cap and safety lanyard…

• Page 255
  Section 09 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM) Basic Self-Diagnostic Mode It is self-activated when the safety lanyard cap is being installed on the watercraft switch. It gives imme- diate monitoring. Some codes may occur only when pressing the start/stop button. Refer to the following chart.
• Page 256
  Section 09 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM) Advanced Self-Diagnostic Mode It needs to be enabled manually. Proceed as follows: 1. Remove safety lanyard cap from watercraft switch. 2. Press 5 times on the watercraft start/stop button. NOTE: 1 short beep and 1 long beep must be heard. They validate beginning of diagnostic mode. 3.

• Page 257: Table Of Contents

  Section 10 PROPULSION SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS JET PUMP ……………………..10-02-1 GENERAL ……………………… 10-02-3 JET PUMP INSPECTION ON WATERCRAFT …………..10-02-3 REMOVAL……………………… 10-02-5 DISASSEMBLY……………………10-02-8 CLEANING ……………………. 10-02-10 PARTS INSPECTION ………………….10-02-10 ASSEMBLY……………………. 10-02-13 PUMP PRESSURIZATION ………………..10-02-18 INSTALLATION ……………………

• Page 258: Jet Pump

  Section 10 PROPULSION SYSTEM Subsection 02 (JET PUMP) JET PUMP RX and RX DI Models 27 26 PARTS 10-02-1 SMR2000_065_10_02A.FM www.SeaDooManuals.net…

• Page 259
  Section 10 PROPULSION SYSTEM Subsection 02 (JET PUMP) GTX DI Model 10-02-2 PARTS SMR2000_065_10_02A.FM www.SeaDooManuals.net…

• Page 260: General

  1. Stamped part number 1. Inspect impeller and boot WATERCRAFT IMPELLER MATERIAL PITCH MODEL Progressive Stainless 271 000 920 pitch steel 15° — 21° Progressive RX DI and Stainless 271 000 128 pitch GTX DI steel 15° — 21° 10-02-3 SMR2000_065_10_02A.FM www.SeaDooManuals.net…

• Page 261
  Section 10 PROPULSION SYSTEM Subsection 02 (JET PUMP) Impeller/Wear Ring Clearance This clearance is critical for jet pump performance. Clearance can be checked from water inlet open- ing or from venturi side. However, the last method requires more work. To check clearance from water inlet side, remove inlet grate.

• Page 262: Removal

  (P/N 293 800 018) on plug threads and reinstall it on cover. Properly reinstall removed parts. Reverse Gate Oil Replacement RX and RX DI Models Remove: To remove reverse gate no. 29, put shift lever in – reverse gate cable reverse position.

• Page 263
  Section 10 PROPULSION SYSTEM Subsection 02 (JET PUMP) Connecting Rod Remove: – reverse gate – pivot bolt no. 89. Withdraw connecting rod. Pivot Triangle Remove: – reverse gate – connecting rod – pivot bolts no. 40. Withdraw pivot triangle no. 41. Pivot Arm 1.
• Page 264
  Section 10 PROPULSION SYSTEM Subsection 02 (JET PUMP) Nozzle RX and RX DI Models Disconnect steering cable from jet pump nozzle no. 1. Remove: – reverse gate – spring – pivot bolts no. 42 retaining pivot arm and VTS ring to nozzle.

• Page 265: Disassembly

  Section 10 PROPULSION SYSTEM Subsection 02 (JET PUMP) DISASSEMBLY NOTE: Whenever removing a part, visually check for damage such as: corrosion, crack, split, break, porosity, cavitation, deformation, distortion, heat- ing discoloration, wear pattern, missing plating, missing or broken needles in needle bearing, wa- ter damage diagnosed by black-colored spots on metal parts, etc.

• Page 266
  Section 10 PROPULSION SYSTEM Subsection 02 (JET PUMP) To remove impeller, apply a rotating movement Impeller Shaft and pull at same time. Slide impeller out of hous- Remove shaft holder tool. ing. Remove tool from impeller. Remove impeller shaft no. 21 with thrust washer and thrust bearing.

• Page 267: Cleaning

  Section 10 PROPULSION SYSTEM Subsection 02 (JET PUMP) CLEANING PARTS INSPECTION Thoroughly clean jet pump housing by applying Loc- Impeller tite Stripper (P/N 293 110 004). Allow it some time Visually inspect impeller splines. Check for wear or to dissolve the old dried Loctite (10 to 15 minutes). deformation.

• Page 268
  Section 10 PROPULSION SYSTEM Subsection 02 (JET PUMP) Wear Ring To check both bearings, proceed the same way with other shaft end. Position gauge tip on diam- Check wear ring no. 18 for deep scratches, irreg- eter, close to flats on shaft. ular surface or any apparent damage.
• Page 269
  Section 10 PROPULSION SYSTEM Subsection 02 (JET PUMP) Thrust Washer and Thrust Bearing Visually inspect thrust washer no. 22, thrust bear- ing no. 23 and their contact surface. Check for scoring, pitting, flaking, discoloration or other evi- dence of wear. For best inspection, use a 7X mag- nifying glass to check wear pattern.

• Page 270: Assembly

  Section 10 PROPULSION SYSTEM Subsection 02 (JET PUMP) Anti-Rattle Pusher Check for melted plastic around metal pad. If so, replace it. BEARING/SEAL INSTALLER TOOL 1. Seal side 2. Bearing side For outlet end of housing use inner bearing installer tool P/N 529 035 609. Check for excessive wear of pad.

• Page 271
  Section 10 PROPULSION SYSTEM Subsection 02 (JET PUMP) CAUTION: Never hammer the bearing into its Thrust Washer housing. Position jet pump housing no. 7 with the stator vanes on top. Insert thrust washer no. 22 in the stator seat. F00J0BA F00J0DA 1.
• Page 272
  Section 10 PROPULSION SYSTEM Subsection 02 (JET PUMP) Impeller Shaft Apply Loctite 243 (blue) to shaft threads. To prevent seal lip damage when inserting impeller shaft, use impeller shaft guide (P/N 295 000 002). F01J1OA Insert tool onto shaft end then carefully install shaft in jet pump housing.
• Page 273
  Section 10 PROPULSION SYSTEM Subsection 02 (JET PUMP) Install impeller remover/installer tool into impeller Anti-Rattle System splines and tighten. Install spring no. 27 on slider no. 26. F00J08A 1. Impeller remover/installer tool CAUTION: Make sure thrust washer and bearing 1. Spring are not wedged in shaft groove.
• Page 274
  Section 10 PROPULSION SYSTEM Subsection 02 (JET PUMP) CAUTION: This is a synthetic oil. Do not mix with mineral based oil. Do not mix oil brands. NOTE: When filling reservoir, oil must be poured into cover quite slowly to allow complete housing fill.

• Page 275: Pump Pressurization

  Section 10 PROPULSION SYSTEM Subsection 02 (JET PUMP) Apply Loctite 518 (Gasket Eliminator) on mating surface. Position venturi no. 9 with bailer passages on top. Apply Loctite 243 (blue) on threads of screws no. 10. NOTE: On the GTX DI model, install the reverse support with the venturi.

• Page 276: Steering Cable

  NOTE: Make sure the pivot triangle turn freely. (24 lbf•ft). NOTE: Slightly lubricate wear ring with BOMBAR- Reverse Gate DIER LUBE lubricant to minimize friction during RX and RX DI initial start. Install reverse gate with spacer and washer. Nozzle Torque to 20 N•m (15 lbf•ft).

• Page 277: Drive System

  Section 10 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) DRIVE SYSTEM 10-03-1 PARTS SMR2000-066_10_03A.FM www.SeaDooManuals.net…

• Page 278: General

  Section 10 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) GENERAL – Squeeze pliers to draw hooks together and dis- engage windows from locking hooks. Jet pump must be removed to replace any com- ponents of the drive system. Refer to JET PUMP for removal procedure.

• Page 279
  Section 10 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) Circlip and Floating Ring Hold floating ring no. 6 and compress boot no. 10; then, pull out circlip no. 5 from drive shaft groove. 1. Use ball end mill for radius. This section of the slot should be 38 mm (1-15/32 in) deep 2.

• Page 280: Inspection

  Section 10 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) Boot Loosen gear clamp no. 11 holding boot, then care- fully pull boot and carbon ring no. 8 from hull in- sert. Carbon Ring Loosen gear clamp no. 9 then pull carbon ring from boot no.

• Page 281: Installation

  Section 10 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) Boot Subtract the installed length measurement from the free length measurement. A difference of 4 mm To verify the preload of the boot no. 10, proceed to 12 mm (5/32 in to 15/32 in) should be obtained. as follows: If the length is less than 4 mm (5/32 in), install a NOTE: To verify the boot preload and free length,…

• Page 282
  Section 10 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) Circlip – Insert pointed tips of pliers first in closing hooks. Push the floating ring to compress the boot. Insert the circlip no. 5 in the drive shaft groove. F06I06A 1. Push floating ring TYPICAL 2.

• Page 283: Lubrication

  Section 10 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) Small Clamp To secure small clamp no. 4, place notch side of plier on clamp embossment and squeeze plier. 1. Squeeze plier LUBRICATION PTO Flywheel Using a grease gun, carefully lubricate PTO fly- wheel with synthetic grease (P/N 293 550 010), until boot is just beginning to expand.

• Page 284: Reverse System

  Section 10 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) REVERSE SYSTEM RX and RX DI Models PARTS 10-04-1 SMR2000-067_10_04A.FM www.SeaDooManuals.net…

• Page 285: Disassembly

  Section 10 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) DISASSEMBLY INSPECTION Visually inspect parts for wear or cracks. Replace Reverse Gate all defective parts. To remove reverse gate, refer to JET PUMP section. ASSEMBLY Reverse Cable Assembly is essentially the reverse of disassem- Unscrew bolt no.

• Page 286
  Section 10 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) GTX DI Model PARTS 10-04-3 SMR2000-067_10_04A.FM www.SeaDooManuals.net…

• Page 287: Disassembly

  Section 10 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) DISASSEMBLY Inside Lever Remove glove box to have access to the shifting Reverse Gate lever mechanism. To remove reverse gate, refer to JET PUMP sec- tion. Cable Lever Remove Allen screw no. 6 and detach cable lever from reverse gate.

• Page 288: Inspection

  Section 10 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) From outside of body, unscrew bolt no. 14 retain- Spring ing the interior lever. Make sure to properly install spring no. 15 into in- terior lever no. 11 as per following illustration. 1.

• Page 289: Adjustment

  Section 10 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) Spring and Pawl Lock ADJUSTMENT Make sure spring no. 8 is properly installed. One Put shift lever in forward position. end of the spring is hooked in the pawl lock no. 7 Pull shift lever approximately 50 mm (2 in) and and the other end is retained by the stopper lock nut.

• Page 290: Variable Trim System

  Section 10 PROPULSION SYSTEM Subsection 05 (VARIABLE TRIM SYSTEM) VARIABLE TRIM SYSTEM RX and RX DI Models 10-05-1 PARTS SMR2000-068_10_05A.FM www.SeaDooManuals.net…

• Page 291: General

  Section 10 PROPULSION SYSTEM Subsection 05 (VARIABLE TRIM SYSTEM) GENERAL DISASSEMBLY To test VTS control module, motor or switch, refer Cover to INSTRUMENTS AND ACCESSORIES. Remove VTS cover no. 7 by pressing on tabs. To have access to VTS module, remove seat. Remove screws retaining electrical box support and move it aside.

• Page 292: Inspection

  Section 10 PROPULSION SYSTEM Subsection 05 (VARIABLE TRIM SYSTEM) INSPECTION Install motor, worm and sliding shaft in VTS housing. Boot Make sure boot no. 3 is in good condition. If it is cracked or teared, replace boot. Worm Inspect threads and splines of worm no. 9 for wear. If worm replacement is necessary, renew also slid- ing shaft.

• Page 293: Adjustment

  Section 10 PROPULSION SYSTEM Subsection 05 (VARIABLE TRIM SYSTEM) Apply Loctite Primer N (P/N 293 800 041) to threads of VTS housing and Loctite 243 (blue) to nut no. 4. Install nut with sealing washer and torque to 6 N•m (53 lbf•in) using the VTS socket tool.

• Page 294: Table Of Contents

  Section 11 STEERING SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS STEERING SYSTEM ………………….11-02-1 DISASSEMBLY……………………11-02-2 ASSEMBLY……………………. 11-02-4 ADJUSTABLE STEERING ………………… 11-03-1 DISASSEMBLY……………………11-03-2 ASSEMBLY……………………. 11-03-6 ALIGNMENT …………………….. 11-04-1 11-01-1 SMR2000-037_11_01ATOC.FM www.SeaDooManuals.net…

• Page 295: Steering System

  Section 11 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) STEERING SYSTEM RX and RX DI Models PARTS 11-02-1 SMR2000-069_11_02A.FM www.SeaDooManuals.net…

• Page 296: Disassembly

  Section 11 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) DISASSEMBLY Remove 2 screws and flat washers each side of cover. Handle Grip and Grip Insert To remove handle grip no. 1, pull out cap no. 2 and remove screw no. 3. Pull out grip and remove grip insert from handlebar no.

• Page 297
  Section 11 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) Loosen bolts no. 11 each side of steering support Steering Support no. 12. Cut locking tie securing wiring harness boot. F07K02A F07K04A 1. Steering support 1. Boot 2. Bolt 2. Locking tie Carburetor-Equipped Models Disconnect the throttle and choke cables from car- buretor levers.

• Page 298: Assembly

  Section 11 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) Disconnect the steering cable from the steering Steering Stem Arm and Support stem arm no. 15. Loosen bolts no. 17 retaining steering stem arm no. 15 to support no. 16. 1. Steering stem arm 2.

• Page 299
  Section 11 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) Handle Grip and Grip Insert When installing the grip insert no. 21 in the han- dlebar no. 22, ensure that it is properly inserted in the slot at the end of the handlebar tubing. 1.

• Page 300: Adjustable Steering

  Section 11 STEERING SYSTEM Subsection 03 (ADJUSTABLE STEERING) ADJUSTABLE STEERING 11-03-1 PARTS SMR2000-069_11_03A.FM www.SeaDooManuals.net…

• Page 301: Disassembly

  Section 11 STEERING SYSTEM Subsection 03 (ADJUSTABLE STEERING) DISASSEMBLY Adjustment Handle Set handle bar to its lowest position by turning ad- justment handle no. 26 counterclockwise. While holding adjustment handle no. 26, turn sup- port bushing no. 28 clockwise. 1. Set screw Pull handle bar housings to disengage from steer- ing cover.

• Page 302
  Section 11 STEERING SYSTEM Subsection 03 (ADJUSTABLE STEERING) Remove 2 screws no. 20 each side of cover. Handle Bar Remove 4 elastic stop nuts M8 retaining steering clamp no. 31. 1. Remove screws 2. Upper cover 3. Lower cover 4. Adjuster screws Remove both upper and lower steering covers.
• Page 303
  Section 11 STEERING SYSTEM Subsection 03 (ADJUSTABLE STEERING) Cable Support Loosen bolts no. 9 and remove retaining block no. 10 holding cable adjusting nut to cable support no. 8. F07K03A RIGHT SIDE 1. Steering support 2. Bolts From inside bilge, pull down cable support no. 8 to detach it from steering support no.12.
• Page 304
  Section 11 STEERING SYSTEM Subsection 03 (ADJUSTABLE STEERING) Disconnect the wiring harnesses leading out of steering stem and cut locking tie. Disconnect the steering cable from the steering stem arm no. 15. F07K07A 1. Steering support 2. Bolt 3. Lock nut Remove bolts no.

• Page 305: Assembly

  Section 11 STEERING SYSTEM Subsection 03 (ADJUSTABLE STEERING) Steering Stem and Steering Support Unscrew nut and remove pivot bolt no. 25 retaining steering support no. 24 to steering stem no. 19. Remove adjuster screw from block and detach steering support from steering stem. Unscrew threaded pivots to remove threaded block from steering stem no.

• Page 306
  Section 11 STEERING SYSTEM Subsection 03 (ADJUSTABLE STEERING) Install steering support no. 24 to steering stem no. 19 and secure with pivot bolt no. 25. Install nut and torque to 26 N•m (19 lbf•ft). 1. Pad must not exceed stopper Position handle bar no.

• Page 307: Alignment

  Section 11 STEERING SYSTEM Subsection 04 (ALIGNMENT) ALIGNMENT Position handlebar in straight ahead position by If necessary, steering alignment adjustment should measuring each side the distance from handlebar be performed at steering cable support. grip end to floorboard. Open storage compartment cover and remove bas- ket.

• Page 308: Table Of Contents

  Section 12 HULL/BODY Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS ADJUSTMENT AND REPAIR ………………..12-02-1 GLOVE BOX ……………………12-02-9 SEAT ADJUSTMENT………………….12-02-10 STORAGE COMPARTMENT INNER SHELL …………..12-02-11 STORAGE COMPARTMENT COVER ADJUSTMENT …………12-02-11 MIRROR……………………..12-02-12 INLET GRATE ……………………12-02-12 RIDING PLATE……………………

• Page 309: Adjustment And Repair

  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) ADJUSTMENT AND REPAIR GTX DI (bow) PARTS 12-02-1 SMR2000-071_12_02A.FM www.SeaDooManuals.net…

• Page 310
  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GTX DI (stern) 12-02-2 PARTS SMR2000-071_12_02A.FM www.SeaDooManuals.net…
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  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GTX DI (cover) PARTS 12-02-3 SMR2000-071_12_02A.FM www.SeaDooManuals.net…
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  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GTX DI (seat) PARTS 12-02-4 SMR2000-071_12_02A.FM www.SeaDooManuals.net…
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  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) RX (bow) 12-02-5 PARTS SMR2000-071_12_02A.FM www.SeaDooManuals.net…
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  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) RX (stern) PARTS 12-02-6 SMR2000-071_12_02A.FM www.SeaDooManuals.net…
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  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) RX (cover) PARTS 12-02-7 SMR2000-071_12_02A.FM www.SeaDooManuals.net…
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  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) RX (seat) PARTS 12-02-8 SMR2000-071_12_02A.FM www.SeaDooManuals.net…

• Page 317: Glove Box

  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GLOVE BOX Open front storage cover and remove basket. Unscrew nut retaining vent tube to bracket. RX/RX DI models Removal Remove handle from shift lever. 1. Unscrew Pull vent tube out. From the engine compartment, insert a hand through the vent tube hole and press glove box lock tabs to release.

• Page 318: Seat Adjustment

  GTX DI MODELS — REAR SEAT 1. Lock pin 2. Adjustment nut (apply Loctite 271) A. 33.5 ± 1 mm (1-5/16 ± 3/64 in) RX MODELS 1. Lock pin 2. Adjustment nut (apply Loctite 271) A. 36 ± 1 mm (1-5/16 ± 13/32 in) 12-02-10 SMR2000-071_12_02A.FM…

• Page 319: Storage Compartment Inner Shell

  Remove retaining screws. Gently pull on large end (rear end) and pull apart towards the small end (front). See illustration. RX AND SOME GTX DI MODELS 1. Lock pin (apply Loctite 271) 2. Adjustment nut A. 34 ± 1 mm (1-11/32 ± 3/64 in) 1.

• Page 320: Mirror

  When reinstalling inlet grate, apply Loctite 271 on threads and torque screws to 11 N•m (8 lbf•ft). RX/RX DI models Follow this sequence referring to the illustration: Hand tighten screw numbers ➀, ➁ then ➂.

• Page 321: Jet Pump Support

  Remove ball joint, boot, nut, half rings and O-rings from reverse cable. Apply Loctite The Right Stuff Gasket as indicated Remove boot and nut from VTS sliding shaft (RX by the shaded areas in the next illustrations. Fol- models). low also the torquing sequence (if applicable) as shown in the same illustrations.

• Page 322: Deflector

  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) DEFLECTOR SEAT COVER REPLACEMENT GTX DI Models Install staples with an electric tacker such as Ar- row tacker no. ETN-50 or with a manual tacker Removal such as Arrow tacker no. T-50. Using a heat gun, heat deflector and pry it using a NOTE: For an easier installation, it’s highly recom- piece of wood.

• Page 323: Bumper Replacement

  10. Repeat procedure for the other side. DECALS REPLACEMENT SPONSON REPLACEMENT Removal RX Models Using a heat gun warm up one end of decal for a Remove retaining screw from rear of sponson. few seconds until decal can roll off when rubbing with your finger.

• Page 324: Hull And Body Repair

  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) Installation INSTALLATION ON PLASTIC (storage cover) There are 2 types of decals used on watercraft. Clean surface with isopropyl alcohol. One has a protective film on back side and the other has a protective film on both sides. They are Using a pencil and the decal as a template, mark used on 3 types of materials;…

• Page 325
  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) Air Bubbles A blister is a visible bump on the watercraft surface that may not necessarily come right through the Possible cause: gelcoat layer. In the case of only a few blisters, follow –…
• Page 326
  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) Test spray the gelcoat mixture on paper to verify Outside its consistency and pattern. You may have to apply Remove the damaged gelcoat and fiberglass with 5 or 6 coats to cover the area properly. Overlap a 24-grit disk using a power sander.

• Page 327: Tools And Materials List

  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) Inside Materials Wipe down the area with acetone on a cloth. Ap- – fiberglass mat ply the same procedure as for outside repair when – fiberglass cloth laminating the alternating pieces of fiberglass ma- –…

• Page 328
  Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) Mix epoxy glue (3M-05900), follow manufacturer instructions. Apply epoxy glue on aluminum insert (P/N 292 000 075) knurled surface and on plastic insert inner bore. CAUTION: If you notice any clearance between plastic insert and aluminum insert, fill gap with epoxy glue to obtain good adhesion of alumi- num insert.
• Page 329
  Section 13 TECHNICAL DATA Subsection 01 (RX MODEL) RX MODELS ENGINE RX (5513/5514) Engine type BOMBARDIER-ROTAX 947 Induction type Reed valve Type Water cooled, water injected with regulator Water injection fitting 3.5 mm (.139 in) (head) Exhaust system Water injection fitting…
• Page 330
  Section 13 TECHNICAL DATA Subsection 01 (RX MODEL) ELECTRICAL RX (5513/5514) Magneto generator output 180 W @ 6000 RPM Ignition system type Digital DC-CDI Make and type NGK BR8ES Spark plug 0.5 — 0.6 mm (.020 — .024 in) mm (in) 2.99 (.118)
• Page 331
  Section 13 TECHNICAL DATA Subsection 01 (RX MODEL) PROPULSION RX (5513/5514) Propulsion system BOMBARDIER Formula Pump Jet pump type Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive SEA-DOO JET PUMP SYNTHETIC Oil type POLYOLESTER OIL 75W90 GL5 Steering nozzle pivoting angle 20°…
• Page 332
  Section 13 TECHNICAL DATA Subsection 01 (RX MODEL) MATERIALS RX (5513/5514) Hull Composite Inlet grate Aluminum Impeller housing/stator/venturi/nozzle Plastic/plastic/aluminum/aluminum Air intake silencer Thermoplastic Flame arrester Tubular wire screen Steering padding Thermoplastic Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat Polyurethane foam…
• Page 333
  Section 13 TECHNICAL DATA Subsection 01 (RX MODEL) TIGHTENING TORQUES RX (5513/5514) Exhaust manifold screw 40 N•m (30 lbf•ft) Magneto flywheel nut 115 N•m (85 lbf•ft) Flywheel screw (PTO side) 115 N•m (85 lbf•ft) 27 N•m (20 lbf•ft) (3) (4) Crankcase screws 40 N•m…
• Page 334
  Section 13 TECHNICAL DATA Subsection 02 (RX DI AND GTX DI MODELS) RX DI AND GTX DI MODELS ENGINE RX DI (5646/5656) GTX DI (5649/5659) Engine type BOMBARDIER-ROTAX 947 DI, 2-stroke Induction type Reed valve Type Water cooled, water injected with regulator Water injection fitting (head) 3.5 mm (.139 in)
• Page 335
  Section 13 TECHNICAL DATA Subsection 02 (RX DI AND GTX DI MODELS) ELECTRICAL RX DI (5646/5656) GTX DI (5649/5659) Magneto generator output 270 W @ 6000 RPM Ignition system type Digital Inductive Make and type NGK ZFR4F Spark plug 1.1 mm (.04 in) 5.39 mm (.212 in) (direct) measured through direct injector hole…
• Page 336
  Section 13 TECHNICAL DATA Subsection 02 (RX DI AND GTX DI MODELS) PROPULSION RX DI (5646/5656) GTX DI (5649/5659) Propulsion system BOMBARDIER Formula Pump Jet pump type Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive…
• Page 337
  Section 13 TECHNICAL DATA Subsection 02 (RX DI AND GTX DI MODELS) MATERIALS RX DI (5646/5656) GTX DI (5649/5659) Hull Composite Inlet grate Aluminum Impeller housing/stator/venturi/nozzle Plastic/plastic/aluminum/aluminum Air intake silencer Thermoplastic Flame arrester Tubular wire screen Steering padding Thermoplastic Fuel tank…
• Page 338
  Section 13 TECHNICAL DATA Subsection 02 (RX DI AND GTX DI MODELS) TIGHTENING TORQUES RX DI (5646/5656) GTX DI (5649/5659) Exhaust manifold screw 40 N•m (30 lbf•ft) Magneto flywheel nut 115 N•m (85 lbf•ft) Flywheel screw (PTO side) 115 N•m (85 lbf•ft) 27 N•m (20 lbf•ft)

• Page 339: Wire Color Codes

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

• Page 340: Packard Connector

  Section 14 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) – Pull back on the contact wire to be sure the re- tention fingers are holding the contact. – After all required contacts have been inserted, the lock must be installed. MALE HOUSING 1.

• Page 341
  Section 14 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) WARNING Ensure all terminals are properly crimped on wires and connector housings are properly fas- tened. AMP PLUG CONNECTOR These connectors are found on the MPEM. When servicing electrical system, special care must be taken when working with AMP Plug Con- nectors in order to prevent any malfunction of the system.
• Page 342
  Section 14 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) Each plug assembly is mechanically keyed to mate only with identical mechanical keyed header on the MPEM. F00H0OA 1. Screwdriver between wedge lock and connector 2. Locking tab Repeat the same steps for the other locking tab retaining the wedge lock.
• Page 343
  Section 14 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) Insert a 4.8 mm (.189 in) wide screwdriver blade inside the front of the contact cavity. F00H0QA 1. Rotate wire back and forth 2. Pull wire POWER WIRE CONTACT NOTE: The wedge lock must be removed to ex- tract power contact.
• Page 344
  Section 14 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) CAUTION: If contacts are not crimped using the CAUTION: Do not pierce the diaphragm with a proper crimping tool, the wire seal may be dam- sharp point for electrical troubleshooting. The aged. resulting pinholes in the insulation will allow moisture to penetrate the system and possibly result in system failure.
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