Smr-2004 BRP suppl 3d rfi ang.
004 Shop Manual Supplement 3DTM RFITM BOMBARDIER RECREATIONAL PRODUCTS INC.
Legal deposit: National Library of Quebec National Library of Canada 2004 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Recreational Products Inc. ©Bombardier Recreational Products Inc. 2004 Technical Publications Bombardier Recreational Products Inc. Valcourt (Quebec) Canada Printed in Canada ®TMRegistered trademarks of Bombardier Recreational Products Inc. or its affiliates. * Bombardier is a trademark of Bombardier Inc.
TABLE OF CONTENTS NOTE: Refer to shop manual for sections NOT covered in this supplement. SAFETY NOTICE .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. .. III INTRODUCTION .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. .. V HULL IDENTIFICATION NUMBER (H.I.N.) . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .
TABLE OF CONTENTS 10 FUEL SYSTEM 01 – FUEL CIRCUIT .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 31 11 LUBRICATION SYSTEM (2-STROKE) 02 – OIL INJECTION PUMP. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 33 ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair the 2004 3DTM RFITMSEA-DOO watercraft. This Shop Manual Supplement must be used in conjunction with the 2004 Sea-doo Shop Manual (P/N 219 100 192). Refer to this manual when a particular system is not covered in this Supplement. This edition was primarily published to be used by watercraft mechanical technicians who are already familiar with all service procedures relating to BRP made watercraft.
SAFETY NOTICE BRP disclaims liability for all damages and/or injuries resulting from the improper use of the contents. We strongly recommend that any services be carried out and/or verified by a highly skilled professional mechanic. It is understood that certain modifications may render use of the vehicle illegal under existing federal, provincial and state regulations.
INTRODUCTION INTRODUCTION This Shop Manual Supplement covers the following BRP made SEA-DOO® 2004 3DTM RFITM watercraft models. ENGINE TYPE MODEL NUMBER 3D RFI 787 RFI 6157 3D RFI International 787 RFI 6158 MODEL ENGINE IDENTIFICATION NUMBER (E.I.N.) The Engine Identification Number is located on the upper crankcase on PTO side. HULL IDENTIFICATION NUMBER (H.I.N.) It is located on platform at the rear of watercraft. F01D87A 1 1. Engine Identification Number (E.I.N.) 1 F22L06A 1.
Section 02 MAINTENANCE Subsection 01 (PERIODIC INSPECTION CHART) PERIODIC INSPECTION CHART The schedule should be adjusted according to operating conditions and use. NOTE: The chart gives an equivalence between number of hours and months/year. Perform the maintenance operation to whatever time comes first. IMPORTANT: Schedule for watercraft rental operations or higher number of hour use, will require greater frequency of inspection and maintenance. DESCRIPTION I: Inspect, verify, clean, adjust, lubricate.
Section 02 MAINTENANCE Subsection 01 (PERIODIC INSPECTION CHART) DESCRIPTION I: Inspect, verify, clean, adjust, lubricate. Replace if necessary C: Clean L: Lubricate R: Replace INTERVAL FIRST 10 HOURS EVERY 25 HOURS OR 3 MONTHS EVERY 50 HOURS OR 6 MONTHS EVERY 100 HOURS OR 1 YEAR LUBRICATION SYSTEM Oil injection pump (5) I I Oil lines I I Oil filter I I Oil reservoir straps I R ELECTRICAL SYSTEM Electrical connections and fastening (ignition system, starting system, fuel injectors, etc.
Section 02 MAINTENANCE Subsection 01 (PERIODIC INSPECTION CHART) DESCRIPTION I: Inspect, verify, clean, adjust, lubricate. Replace if necessary C: Clean L: Lubricate R: Replace INTERVAL FIRST 10 HOURS EVERY 25 HOURS OR 3 MONTHS EVERY 50 HOURS OR 6 MONTHS EVERY 100 HOURS OR 1 YEAR HULL/BODY Bailer pick-ups, check for obstructions I Kart seat (if so equipped) I Hull I I I I (1) Every 10 hours in salt water use. (2) These items have to be initially checked after 25 hours.
Section 02 MAINTENANCE Subsection 04 (STORAGE) STORAGE 2 ENGINE DRAINING Disconnect the water supply hose used to cool the magneto. It features a quick connect fitting. Press both tabs and pull fitting in order to disconnect hose. This hose is located at the bottom of the magneto cover beside the engine support. F17E0BA 1 1. Fitting 2. Hose 1 CAUTION: Water in heat exchanger system must be free to flow out. Should water freeze in engine, severe damage will occur. Reconnect hose when done.
Section 02 MAINTENANCE Subsection 04 (STORAGE) Seal Carrier Remove rear access cover. Lubricate seal carrier of drive shaft support with synthetic grease. Stop lubricating when grease is just coming out of seal. 1 WARNING Fuel is inflammable and explosive under certain conditions. Always work in a well ventilated area. Do not smoke or allow open flames or sparks in the vicinity. Fuel tank may be pressurized, slowly turn cap when opening. When fueling, keep watercraft level.
Section 02 MAINTENANCE Subsection 04 (STORAGE) BATTERY Engine and Tuned Pipe Disconnect battery cables. Remove rear access panel and engine cover. Lock steering pole in upright position with the holder. WARNING Battery BLACK negative cable must be disconnected FIRST. Disconnect vent tube from battery. Unfasten battery support. Using battery strap, remove battery. For battery cleaning and storage, refer to CHARGING SYSTEM in the Shop Manual.
Section 02 MAINTENANCE Subsection 04 (STORAGE) Insert a funnel into the temporary hose and pour antifreeze in engine until the colored solution appears at the cooling system bleed outlet. Use a container to recover the water/antifreeze. Expansion Pipe and Muffler Disconnect the tuned pipe water supply hose at T-fitting. 1 F07E0LA F22E06A TYPICAL 1. Disconnect hose from T-fitting Insert a funnel into the hose. Raise the hose as high as possible and pour 1.2 L (1.3 U.S. qt) of antifreeze.
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 show all causes for all problems. Only the systems not covered in the Shop Manual are outlined. Refer to the Shop Manual for the other systems.
Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) WARNING LIGHT IS ON/ENGINE NOT RUNNING OTHER OBSERVATION Beeper signal (4 short beeps every 3 seconds) POSSIBLE CAUSE Safety lanyard on DESS post REMEDY Remove safety lanyard from DESS post STEERING POLE IS HEAVIER THAN USUAL OTHER OBSERVATION POSSIBLE CAUSE REMEDY Steering pole return spring adjustment Adjust Broken steering pole return spring) Replace STEERING POLE IS STIFFER THAN USUAL OTHER OBSERVATION POSSIBLE CAUSE Dirty/dama
Section 04 ENGINE (2-STROKE) Subsection 07 (EXHAUST SYSTEM) EXHAUST SYSTEM 3D RFI 3 48 Nm (35 lbfft) 13 1 Loctite 592 Loctite 592 11 Nm (97 lbfin) 17 26 Nm (19 lbfft) 17 2 11 Loctite 592 5 18 24 15 17 26 Nm (19 lbfft) 18 17 Loctite 518 39 Nm (29 lbfft) 11 4 12 26 Nm (19 lbfft) Loctite 243 Loctite 592 16 25 40 Nm (30 lbfft) 7 Loctite 518 Molykote 111 F22D03S smr2004-3D 11
Section 04 ENGINE (2-STROKE) Subsection 07 (EXHAUST SYSTEM) 19 High temperature RTV sealant 22 23 21 8 14 10 9 High temperature RTV sealant 20 12 Loctite 5150 11 High temperature RTV sealant F22D04S 12 smr2004-3D
Section 04 ENGINE (2-STROKE) Subsection 07 (EXHAUST SYSTEM) REMOVAL Tuned Pipe Remove engine cover then lift and lock steering pole. Remove air intake silencer. NOTE: In some of the following illustrations, flame arrester and throttle body were removed for clarity only. Disconnect hoses from tuned pipe no. 1. F22D05B Remove: – screws no. 3. F22D05A F22D05C F22D07A Loosen clamp no. 2 then slide rearward to release the joint.
Section 04 ENGINE (2-STROKE) Subsection 07 (EXHAUST SYSTEM) – screw no. 4 and 5. Exhaust Manifold Disconnect hose from exhaust manifold no. 25. F22D08A F22D05D Remove screws no. 7 then withdraw exhaust manifold. Expansion Pipe F22D09A – tuned pipe. Inspection Do the test with the watercraft tied on a trailer in water.
Section 04 ENGINE (2-STROKE) Subsection 07 (EXHAUST SYSTEM) 2 WARNING 1 Pay attention not to bend injection oil cable or throttle cable. – hoses from rear fittings no. 11 1 F22D0DA 1. Hose moved away 2. Foam support F22D0CA 1. Disconnect hoses from fittings here – – – – small clamp no. 12 from muffler no. 15 strap no. 13 from muffler clamps no. 21 and no. 22 from exhaust hoses T-fitting no. 23 with hoses and resonator no.
Section 04 ENGINE (2-STROKE) Subsection 07 (EXHAUST SYSTEM) F22D0HA F22D0FA – rotate left/right as shown Muffler Pull muffler out. Inspect muffler, shell and boot condition. Resonators Upper Resonator Remove strap no. 8, loosen clamps no. 9 then pull out resonator no. 10. F22D0GA – pull foam out NOTE: If tuned pipe is still in place, firmly push muffler rearward to disengage expansion pipe from tuned pipe. – pull out expansion pipe forward.
Section 04 ENGINE (2-STROKE) Subsection 07 (EXHAUST SYSTEM) F22D0BA INSTALLATION Installation is essentially the reverse of removal procedures. However, pay particular attention to the following. Tuned Pipe CAUTION: Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking tabs, elastic stop nuts, self-locking fasteners, etc.) must be installed or replaced with new ones where specified. If the efficiency of a locking device is impaired, it must be renewed.
Section 04 ENGINE (2-STROKE) Subsection 07 (EXHAUST SYSTEM) NOTE: Press the pipe support on the engine before torquing the pipe support bolts.
Section 04 ENGINE (2-STROKE) Subsection 07 (EXHAUST SYSTEM) Expansion Pipe and Muffler Apply Loctite 592 on threads of fittings no. 11. Tighten fittings to 5 N•m (44 lbf•in) then position as per following illustration. Do not screw more than 1 turn while positioning. Do not unscrew to reposition. 90° 90° F22D0IA 30° F22D0JA Pressurize the wall jacket to 103 kPa (15 PSI) through the fittings. No leak should occur. Position muffler no. 15 in its location. Do not install the strap and the small clamp yet.
Section 04 ENGINE (2-STROKE) Subsection 07 (EXHAUST SYSTEM) To ensure pipe end is well inserted in muffler, measure the distance as shown in the following illustration. A F22D0KS A. 322 mm (12.68 in) Insert foam under expansion pipe. Ensure foam is not against muffler bellow. Position foam under bracket edge so that it is properly retained. – Ensure there is a gap between clamp ends. Otherwise, try another clamp. 2 A F22D0MA F22D0LA 1 1. Bracket edge 2. Foam A.
Section 04 ENGINE (2-STROKE) Subsection 07 (EXHAUST SYSTEM) A 2 1 F22D0PA F22D0NA A. Gap between hose and fuel tank Ensure there is a gap between muffler and bilge/cooling hose. 1. All around 2. Opposite vertical lines Finalizing Assembly WARNING Ensure that tubes and hoses are properly routed away from any rotating, moving, heating or vibrating parts. Also ensure that hot parts are properly positioned away from any part that can be damaged by the heat. A A F22D0OA Reinstall remaining parts.
Section 06 ENGINE MANAGEMENT (RFI) Subsection 02 (DIAGNOSTIC PROCEDURES ) DIAGNOSTIC PROCEDURES ADVANCED DIAGNOSTIC VCK (Vehicle Communication Kit) Electrical Connections Connect VCK components and open the software B.U.D.S. 1 2 After all connections are done, connect the safety lanyard to the DESS post to activate the communication. IMPORTANT: When using the software B.U.D.S.
Section 06 ENGINE MANAGEMENT (RFI) Subsection 05 (ADJUSTMENT) ADJUSTMENT 2 1 THROTTLE CABLE ADJUSTMENT NOTE: For throttle cable replacement, refer to STEERING SYSTEM. Right throttle cable adjustment is to be done at the adjuster on top of steering pole. However, first ensure adjuster at throttle body is fully screwed in. F22K09A 1. Steering pole at its lowest position 2. Handlebar at its lowest position and in straight ahead position Fully depress throttle lever and hold.
Section 06 ENGINE MANAGEMENT (RFI) Subsection 05 (ADJUSTMENT) When released, throttle lever must have a free play of 1 - 7 mm (1/32 - 9/32 in). To adjust cable, remove top cover of steering pole. Refer to STEERING SYSTEM. Set cable with the adjuster. 1 F22R05A 1. Cable adjuster NOTE: When throttle cable is adjusted from this adjuster, there is no need to readjust throttle cable at the OTAS solenoid. Reinstall removed parts. Reset the Closed TPS. Ensure the OTAS system works adequately.
Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) CIRCUIT, COMPONENTS AND CARE 3D RFI Cooling System Indicator hose (CSI) Tuned pipe water jacket supply hose Magneto heat exchanger inlet hose Cylinder head outlet hose Magneto view To crankcase heat exchanger inlet To tunel pipe Magneto heat exchanger outlet hose Loctite 592 Hull Loctite 592 Hose protector Crankcase heat exchanger outlet hose Engine water outlet hose Engine drain hose (from cylinders) Tuned pipe water-jacket su
Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) CIRCUIT CARE CAUTION: All hoses and fittings of the cooling system have calibrated inside diameters to assure proper cooling of the engine. Always replace using appropriate Bombardier part number. For flushing purposes, the cooling system is equipped with a hose adapter. A garden hose is used to flush the whole system by backwash. For flushing procedure, refer to FLUSHING AND LUBRICATION in the Shop Manual.
Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) Snugly install the hose pincher on the water supply hose as shown in the following illustration. NOTE: Pinch the hose with the red tape. 1 2 3 F22E01A 1. Engine water supply hose 2. Hose pincher this side of T-fitting 3. T-fitting CAUTION: When finished towing the watercraft, the hose pincher must be removed before operating it.
Section 10 FUEL SYSTEM Subsection 01 (FUEL CIRCUIT) FUEL CIRCUIT Fuel Tank Removal and Installation The engine removal is necessary to remove fuel tank. Disconnect battery. To have access to the rear fuel tank holding strap, remove exhaust hoses with the resonator. 1 WARNING Always disconnect BLACK negative cable first. Pull out both vent tubes. 1 F22D06A 1. Loosen clamps and pull out hoses with resonator Detach all 3 fuel tank straps. Pull out fuel tank.
Section 10 FUEL SYSTEM Subsection 01 (FUEL CIRCUIT) Fuel System Pressurization High Pressure Test (fuel pump circuit) Proceed as follows: – Fill up fuel tank (recommended but not mandatory). – Install a hose pincher (P/N 295 000 076) on fuel tank vent hose. – Connect pump gauge tester (P/N 529 021 800) to air inlet hose fitting. NOTE: This pump is included in the ENGINE LEAK TESTER KIT (P/N 295 500 352). Install safety lanyard on DESS post to activate fuel pump.
Section 11 LUBRICATION SYSTEM (2-STROKE) Subsection 02 (OIL INJECTION PUMP) OIL INJECTION PUMP ADJUSTMENT NOTE: On the 3D RFI, if the throttle cable is readjusted, it does not change the oil injection pump adjustment. CAUTION: Proper oil injection pump adjustment is very important. Any delay in the opening of pump can result in serious engine damage. The oil injection pump should be adjusted as follows; the mark on the pump lever should be offset (richer side) by 1 mm (.
Section 12 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) CHARGING SYSTEM GENERAL Fuse If the battery is regularly discharged, check fuse condition. The rectifier/regulator could be the culprit of a blown fuse. To check, simply disconnect the rectifier/regulator from the circuit. If the fuse still burns, check for a defective wire. CAUTION: Do not use a higher rated fuse as this cause severe damage. NOTE: Since charging current flows through the main fuse, check its condition.
Section 12 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) – Note the reading. This is the current supplied by the regulator. – Remove jumper wire and reconnect the 2-pin connector. Remove the main fuse from its holder: – Connect an ammeter across the fuse holder. 1 2 F22H08A 1. Main fuse holder 2. Ammeter – Start engine. – Bring engine to approximately 6000 RPM. – Note the reading. This is the current actually consumed – Reinstall fuse. Substract the consumed current from the regulator current.
Section 12 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) Start and rev engine to 3500 RPM. The obtained value should be between 12 and 25 Vdc. NOTE: If the rectifier/regulator is within the specification, either the MPEM or wiring harness between the rectifier and battery is defective. If the rectifier/regulator is out of specification and the battery charging coil (or stator) test good, the rectifier/regulator is defective. Properly reinstall terminals in connector and plug connectors.
Section 12 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) STARTING SYSTEM GENERAL Fuse Make sure the following fuses are in good condition. 5 A fuse on the MPEM. Main fuse besides the VCM. 3 2 1 F22H02B 1. VCM 2. Main fuse 3. Starting solenoid Solenoid NOTE: Solenoid is located besides the VCM. See illustration above.
Section 12 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) INSTRUMENTS AND ACCESSORIES GENERAL Install safety lanyard to activate MPEM and VCM to perform testing procedures that requires the device to be supplied with electricity. VEHICLE CONTROL MODULE (VCM) The VCM is directly powered by the battery through the 20A main fuse.
Section 12 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) As a reserve indicator, the beeper will turn on when approximately 6 L (1.6 U.S. gal.) is left and the low level light will continuously blink. It will turn off when approximately 3 L (.8 U.S. gal.) is left. Refer to the DIGITALLY ENCODED SECURITY SYSTEM (DESS) section for the coded signals. The warning light will turn on whenever there is a problem with the engine management system. It will blink when there is a problem with the O.T.
Section 12 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) – The O.T.A.S. should come on for 1/2 second and increase engine RPM within 2900 to 3900. – If steering is kept in this position, the O.T.A.S. will come on again every 2 seconds. – Turn handlebar to other side quickly (within 1/2 second). – The O.T.A.S. should still be active and come on every 2 seconds. If the RPM is not within the specified range, perform the O.T.A.S. THROTTLE CABLE ADJUSTMENT as described below.
Section 12 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) Disconnect the switch 4-pin connector. O.T.A.S. Throttle Cable Adjustment WARNING Whenever solenoid or throttle cable has been replaced, ensure to perform the O.T.A.S throttle cable adjustment. Strictly follow the described procedure.
Section 12 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) NOTE: In BUDS, position and hold the mouse pointer over the needle of the throttle opening to get the actual value. 1 2 F22H0BB 1. OTAS solenoid 2. Adjust here MULTI-PURPOSE ELECTRONIC MODULE (MPEM) Value= 17.3% MIN= MAX= Throttle Opening F22H0HA THROTTLE OPENING GAUGE IN BUDS Alternately, the MPEM Programmer can be used. Adjust throttle opening to get a value of 18.4° +/-1.
Section 12 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) Always ensure safety lanyard is not left on its post after engine is stopped. IMPORTANT: Leaving the safety lanyard on its post when engine is not running will slowly discharge the battery.
Section 12 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) Fuse ratings are identified on the MPEM. Look for them beside the fuse holder. SPR means spare (fuse). Main Fuse The main fuse is located beside the VCM. 2 1 1 2 F22H02A 3 1. VCM 2. Main fuse INSPECTION Fuel Baffle Pick-Up Sender F17H05A 1. 15 A (battery) 2. 5 A (MPEM) 3. 10 A (fuel pump) Remove fuse cover from MPEM. Use the tabs of the fuse cover to remove and reinstall fuses.
Section 12 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) The resistance measured between PINK/BLACK and PINK wires must be in accordance with fuel level (measured from under the flange) as specified in the following charts. When the oil level goes at critical LOW level inside the oil tank (and therefore in sensor reservoir), the sensor detects the absence of liquid and the light TURNS ON. To check the oil sensor, unplug its connector and pull sensor out of oil tank.
Section 12 ELECTRICAL SYSTEM Subsection 05 (DESS (CARBURETED AND RFI ENGINES)) DESS (CARBURETED AND RFI ENGINES) DESS KEY PROGRAMMING Programming Keys with B.U.D.S. Connect VCK components and open the software B.U.D.S. 1 2 After all connections are done, connect the safety lanyard to the DESS post to activate the communication. IMPORTANT: When using the software B.U.D.S.
Section 13 PROPULSION Subsection 01 (JET PUMP) JET PUMP Impeller Identification 1 F02J0VA 1.
Section 13 PROPULSION Subsection 02 (DRIVE SYSTEM) DRIVE SYSTEM F22J09S smr2004-3D 53
Section 13 PROPULSION Subsection 02 (DRIVE SYSTEM) REMOVAL PTO Flywheel Guard Lift and lock steering pole, remove hood and remove storage tray. Pull down vent tubes from body. Rear Drive Shaft Remove rear access panel. Remove clamps from exhaust hoses where shown. Pull out T-fitting with hoses and resonator. 1 1 F22D06A 1. Disconnect those clamps Move remaining hose away to make room. Pull rear drive shaft until coupler is disengaged from splines.
Section 13 PROPULSION Subsection 02 (DRIVE SYSTEM) Front Drive Shaft Remove top foam and protective plate, bracket then side foam. NOTE: For detailed instructions pertaining to side foam removal, refer to EXHAUST SYSTEM. 2 1 F22J0DA 1. Protective plate 2. Bracket Remove front drive shaft.
Section 13 PROPULSION Subsection 04 (VARIABLE TRIM SYSTEM) VARIABLE TRIM SYSTEM 3D RFI 10 Nm (89 lbfin) 6 7 8 10 Nm (89 lbfin) 9 2 4 3 5 1 3 10 Loctite 243 12 24 Nm (18 lbfft) 12 Loctite 243 11 F22J07S smr2004-3D 57
Section 13 PROPULSION Subsection 04 (VARIABLE TRIM SYSTEM) REMOVAL Remove nut no. 1, bolt no. 2, flat washers no. 3, and bushing no. 4. Remove venturi screw. 1 2 3 F22J08A 1. Nut 2. Bolt 3. Venturi screw To remove trim ring/nozzle no. 11, loosen screws no. 12. DISASSEMBLY Loosen nut no. 6 from support no. 9. Remove rubber spacer no. 7 and half bushings no. 8. Unscrew adjustment knob no. 10 from pivot no. 5. ASSEMBLY Assembly is essentially the reverse of disassembly procedures.
Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) STEERING SYSTEM 3D RFI 12 6 11 8 7 Nm (62 lbfin) 25 9 7 16 13 10 5 Nm (44 lbfin) 43 42 10 Nm (89 lbfin) 40 39 11 14 26 29 28 13 7 Nm (62 lbfin) 39 23 7 Nm (62 lbfin) 21 Nm (15 lbfft) 24 37 46 Synthetic grease 18 17 15 Synthetic grease 41 Loctite 243 Synthetic grease 27 21 Nm (15 lbfft) F22K0DS smr2004-3D 38 21 22 7 Nm (62 lbfin) 30 45 44 59
Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) 3 20 33 11 Nm (97 lbfin) 36 32 35 19 Nm (168 lbfin) 31 34 F22K0ES 60 smr2004-3D
Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) 19 1 2 15 Nm (133 lbfin) 10 Nm (89 lbfin) Synthetic grease Loctite 243 4 Synthetic grease 5 Nm (44 lbfin) 7 Nm (62 lbfin) 5 Loctite 243 Synthetic grease F22K0FS smr2004-3D 61
Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) INSPECTION Handlebar and Adjuster NOTE: A mechanism that is hard to move might only need to be disassembled, cleaned, lubricated then reinstalled. If there is excessive play in the following inspections, replace worn bushings or any other worn component. Move handlebar to each position. It should move easily and lock in each position. Make sure there is no excessive play in the handlebar and in the steering stem.
Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) DISASSEMBLY Unscrew DESS switch nut using safety lanyard switch tool (P/N 529 034 600). Moto Seat Deploy moto seat. Disconnect latch rod no. 19. F18K0FA 1 TYPICAL 1. DESS switch nut Pull plastic rivet no. 1 out. F22K0XA Remove screws of lower cover no. 3 then slide cover rearward. F22K0GA 1 F22K0IA Position seat post in the receiver. 2 1. Lower cover 2.
Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) Using a plastic hammer, push moto seat axle no. 2 out while holding seat. Handle Grip and Grip Insert To remove handle grip no. 7, pull out cap no. 8 and remove screw no. 9. 1 2 F22K0KA F22K0HA Post Partially peel seat cover to expose screw no. 4. 1. Handle grip 2. Remove cap and screw Pull out grip and remove grip insert from handlebar no. 10. NOTE: Verify grip insert for damage. Steering Cover Pull up steering padding no. 6.
Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) Loosen set screws no. 11 of handlebar housings no. 12 and no. 13. 2 1 1 2 Pull out throttle housing no. 12. Remove cover. LH Cover Pull out start/stop switch housing no. 13. Remove switches from housing. Remove cover. F22K0MA 1. Cover 2. Screw RH Cover Unhook throttle cable. 1 F22K0PA 1. Retaining screws Handlebar and Adjuster Lift adjuster cover.
Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) Remove screws no. 43 and remove handlebar no. 10. F22K0RA Remove screws no. 13 of adjuster blocks. Remove spring no. 17, steering padding support no. 16 then latch lever no. 18. F22K0UA Inspect notches of blocks no. 14 and the pin no. 15 for wear or other damage.
Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) Steering Stem and Support Remove top cover no. 20. Unbend lock tab no. 21 then unscrew steering stem screw no. 22. 1 F22K0YA Detach steering cable, switch harness and throttle cable from steering support. Remove OTAS switch. F22K0ZA 1. Unbend tab Pull steering stem no. 23 out. Remove steering support screws no. 24. F22K0CA F22K12A Raise steering pole.
Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) Steering Cable Remove screws no. 25. 3 2 1 4 1 F22L14A 1. 2. 3. 4. Return spring Adjustment To increase preload To reduce preload F22K13A 1. Srews removed Remove retaining block no. 26. Remove ball joint no. 28 and adjustment knob no. 29 from cable. Disconnect ball joint no. 27 from jet pump nozzle then from cable. Use steering cable tool (P/N 295 000 145) and remove nut no. 44, then remove half rings no. 45 and O-ring no. 30.
Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) Release rear metal tabs.
Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) Using the provided openings, release side metal tabs while pulling cover outward. 1 F22K1CS 1.
Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) Push cover forward then lift front part to unlock cover.
Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) For the center rear locks, push plastic tabs rearward to release. F22K1JS Unscrew side and bottom screws then slide caps no. 32 forward to remove. Remove end screws and clamp screws no. 33. 2° 1° F22K1PA F22K1OA NOTE: It is suggested to hook-up steering pole to the ceiling to hold it while removing from vehicle and particularly while removing steering cable. 72 Maintain steering pole vertically and pull steering cable out.
Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) ASSEMBLY Assembly is essentially the reverse of disassembly procedures. However, pay particular attention to the following. CAUTION: Apply all specified torques and service products as per main illustration at the beginning of this subsection. 2 Steering Pole NOTE: It is suggested to hook-up steering pole to the ceiling to hold it while installing to vehicle and particularly while installing steering cable.
Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) Ensure spring washer and washer are positioned as shown. Torque screw no. 22 then bend tab lock edge against a flat side of screw head. 1 3 2 1 F22K1TA 1. Spring washers 2. Washer 3. Notice the square end Install steering stem into steering support and position its lever on the RH side. Position rounded edge of washer no. 38 opposite of screw head and position washer square hole into square end of stem. Using a new tab lock no.
Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) F22K22A 1 F22K25A 1. Wiring harness routing Handlebar and Adjuster When installing blocks no. 14 on handlebar, ensure to position block pin into handlebar hole. NOTE: Block must be centered on handlebar. If not, it is in reverse position. F22K23A 1 1. Throttle cable routing Secure throttle cable to steering support with clamp no. 41.
Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) Torque screws no. 13 as per the following sequence. 2 1 F22K1ZA 4 3 F22K0SB TORQUE SEQUENCE Install handlebar on steering support then upper clamps no. 40. Position pin no. 15 into slots of blocks no. 14. Lubricate friction areas and bushings no. 39 then slide bushings against blocks no. 14. Compress spring no. 7. F22K20A F22K1YA Install pin no. 15. Hold latch lever depressed. 76 Lubricate pin no. 15 and the notches on blocks no. 14.
Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) Snap cover of steering padding support no. 16 on screw heads. Install flat washer and screw no. 9. Torque screw to 7 N•m (62 lbf•in). Install cap no. 8. 1 3 4 2 F02K0KA 5 TYPICAL 1. Grip insert 2. Grip 3. Flat washer 4. Screw. Torque to 7 N•m (62 lbf•in) 5. Cap CAUTION: Ensure to install flat washer otherwise screw will damage grip end. F22K21A Ensure handlebar adjuster works adequately. Secure steering cable ball joint no.
Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) Finalizing the Assembly Install remaining components. Ensure steering works adequately. Ensure throttle cable works adequately in all handlebar adjustment position and in all steering pole position. Perform throttle cable adjustment. Refer to ENGINE MANAGEMENT. Ensure moto seat works and locks adequately. STEERING ALIGNMENT For steering alignment procedure, refer to ALIGNMENT.
Section 14 STEERING SYSTEM Subsection 02 (ALIGNMENT) ALIGNMENT Alignment is to be performed when moto seat is deployed and installed. 1 F01J5ZA TYPICAL 1. Measure the distance on each side of the straight edge F22L0PA Position handlebar in straight ahead position by measuring each side the distance from handlebar grip end to floorboard. If necessary, steering alignment adjustment should be performed at steering cable support. Remove top cover. 1 F22K0YA F22J06A 1.
Section 14 STEERING SYSTEM Subsection 02 (ALIGNMENT) Loosen 2 bolts retaining block at cable support. Turn adjustment nut as required. 1 2 F22K0AA 3 1. Support 2. Adjustment nut 3. Loosen bolts After adjustment, torque retaining block bolts to 5 N•m (44 lbf•in). CAUTION: Verify when the handlebar is turned completely to the left or right side, that there is no interference with venturi or VTS ring. Reinstall top cover.
Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) ADJUSTMENT AND REPAIR CLEANING 3 To clean the engine cover and the steering pole nose and top pieces, use only flannel cloths or an equivalent. 5 10 1 7 8 2 9 1 6 4 F22L3BA KART SEAT F22L0HB Check seat tab and anchor plate for wear or damage. Check latch mechanism for tightness, wear, cracks or other damage. Try pulling out the seat without releasing the latch. 1.
Section 17 TECHNICAL DATA Subsection 06 (3D RFI MODEL) 3D RFI MODEL ENGINE 3D RFI Engine type BOMBARDIER-ROTAX 787 RFI, 2-stroke Induction type Rotary valve Type Exhaust system Water cooled (water jacket), water injection in muffler only Water injection fitting (head) Not applicable Water injection fitting (cone) Not applicable Water injection fitting (muffler) 3 x 3.5 mm (.
Section 17 TECHNICAL DATA Subsection 06 (3D RFI MODEL) ENGINE 3D RFI Connecting rod/piston pin radial clearance Counterbalance shaft oil New 0.020 - 0.033 mm (.0008 - .0013 in)) Wear limit 0.050 mm (.002 in) Type SAE 30 motor oil Capacity 30 mL (1 U.S. oz) ADDITIONAL INFORMATION: ELECTRICAL 3D RFI Wattage Magneto generator output Amperage 270 W @ 6000 RPM 7 A @ 6000 RPM/13.5 volts Ignition system type Spark plug Ignition timing (BTDC) Digital Inductive Make and type NGK BR8ES 0.4 - 0.
Section 17 TECHNICAL DATA Subsection 06 (3D RFI MODEL) FUEL SYSTEM 3D RFI RAVE solenoid 30 Fuel injector 2.4 - 0.1 Type Fuel Minimum octane no.
Section 17 TECHNICAL DATA Subsection 06 (3D RFI MODEL) CAPACITIES 3D RFI Fuel tank (including reserve) 41 L (10.8 U.S. gal) Fuel tank reserve (from low level signal) 6 L (1.6 U.S. gal) Oil injection reservoir 4 L (1.05 U.S. gal) Capacity Jet pump impeller shaft reservoir Oil level height 100 mL (3.4 U.S.
Section 18 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) WIRING DIAGRAMS VCM CONNECTORS Open housing by lifting 4 tabs. 32-Pin Connector Push down tab and hold to unlock connector while pulling it out. 1 A33Z02A TYPICAL 1. Tabs (2 on each side) Lift the top plastic lock of the female terminal to be removed and hold in position. Lift the female terminal to unlock from the housing and push out of housing. 1 A34E0KA 1 TYPICAL 1.
Section 18 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) Refer to the illustrations for the connector pinout. 7-Pin Connector Push down tab and hold to unlock connector while pulling it out. 13 24 2 12 1 1 F22H0JA A34E0LA 1. VCM (vehicle control module) 2. Push down this tab and hold while pulling out connector TYPICAL 17 Refer to the illustration for the connector pinout.
NOTES
NOTES
2004 3D RFI F22Z01S
Smr-2004 BRP suppl 3d rfi ang.
