Technical data

ManualsBrandsSeaDoo ManualsMarineSP

www.SeaDooManuals.net

Summary of content (316 pages)

PAGE 1
www.SeaDooManuals.
PAGE 2
0 0 ® SHOP MANUAL 0 www.SeaDooManuals.
PAGE 3
Legal deposit : National Library of Quebec 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. cBombardier Inc. 1995 Printed in Canada r*Registered trademarks of Bombardier Inc. Loctiter is a trademark of Loctite Corporation Snap-onr is a trademark of Snap-on Tools Corporation Gelcoter is a trademark of Gelcote International Limited www.SeaDooManuals.
PAGE 4
TABLE OF CONTENTS SECTION SUBJECT PAGE SAFETY NOTICE .............................................................................................................. II INTRODUCTION ............................................................................................................... III 01 SERVICE TOOLS AND PRODUCTS 01 - Mandatory Tools ..............................................................................................01-01-1 02 - Recommended Tools ..............................
PAGE 5
SAFETY NOTICE SAFETY NOTICE This manual was primarily published to be used by watercraft technicians trained by the manufacturer who are already familiar with all service and maintenance procedures relating to Bombardier made SeaDoo watercraft. Please note that the instructions will apply only if proper hand tools and special service tools are used. It is understood that this manual may be translated into another language. In the event of any discrepancy, the English version shall prevail.
PAGE 6
1996 BOMBARDIER WATERCRAFT SHOP MANUAL INTRODUCTION This Shop Manual covers BOMBARDIER made SEA-DOO® watercraft models SPþ5876, SPX 5877, SPI 5878, XPþ5858, HX 5881, GTSþ5817 and GTIþ5865þ/þ5866. ENGINE IDENTIFICATION NUMBER (E.I.N.) All Engines Except the 787 The Engine Identification Number is located on the upper side of the magneto housing. HULL IDENTIFICATION NUMBER (H.I.N.) 1 It is located at right rear side of hull. F01D01A 1. Engine Identification Number (E.I.N.) 1 F01L45A 1.
PAGE 7
1996 BOMBARDIER WATERCRAFT SHOP MANUAL ARRANGEMENT OF THIS MANUAL The manual is divided into 14 major sectionsþ: 01SERVICE TOOLS AND PRODUCTS 02MAINTENANCE 03TROUBLESHOOTING 04ENGINE 05COOLING SYSTEM 06FUEL SYSTEM 07LUBRICATION SYSTEM 08ELECTRICAL SYSTEM 09PROPULSION SYSTEM 10STEERING SYSTEM 11SUSPENSION 12HULL / BODY 13TECHNICAL DATA 14WIRING DIAGRAMS Several sections are divided in various sub-sections. There is a table of contents at the beginning of many sections. 00-0-4 www.SeaDooManuals.
PAGE 8
1996 BOMBARDIER WATERCRAFT SHOP MANUAL TYPICAL PAGE Page heading indicates section and sub-section detailed. Section 08 ELECTRICAL Sub-Section 01 (MAGNETO SYSTEM) Sub-section title indicates beginning of the sub-section. MAGNETO SYSTEM 587 and 717 Engines Italic sub-tiltle above exploded view indicate pertaining models. 11 12 5 N•m (44 lbf•in) Drop represents a liquid product to be applied to a surface. In this case Loctite 242 to screw threads.
PAGE 9
1996 BOMBARDIER WATERCRAFT SHOP MANUAL TYPICAL PAGE Sub-title beginning with part number(s) of above exploded view following by part name(s). Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) Title indicates main procedure to be carried-out. Service tool to be used to perform a certain procedure. Sub-sub title in italic indicates a particular procedure concerning a model.
PAGE 10
1996 BOMBARDIER WATERCRAFT SHOP MANUAL GENERAL INFORMATION The use of RIGHT and LEFT indications in the text, always refers to driving position (when sitting on watercraft). 2 1 ILLUSTRATIONS AND PROCEDURES The illustrations show the typical construction of the different assemblies and, in all cases, may not reproduce the full detail or exact shape of the parts shown, however, they represent parts which have the same or a similar function.
PAGE 11
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 01 (MANDATORY TOOLS) MANDATORY TOOLS o NOTE : The numbers outlined in black (example : ❑ ) are reference numbers to tools from other dlvlslons (Sea-Doo and/or Sea-Doo Jet Boats). Matchinq reference numbers indicate the same tool is being used on both products, even if the part numbers are different: ENGINE Degree wheel El Piston circlip installer 7 8 o m . m A) P / N 295000077 P / N 295000007 II ) B) P / N 290877016 1 5 2 .,.,.,,,.,.,,,., ,.
PAGE 12
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 01 (MANDATORY TOOLS) ENGINE (continued) E. Puller P / N 295000106 PTO flywheel remover/ instal Ier m P / N 295000001 F01JOT4 AOOC1A4 -—————————— ,4 m Pulier plate P / N 290876080 m B( Extension handle P / N 295000125 — - FO1 D164 IZew M8 x 35 (3) m P / N 290841 591 295000105 m ● =2 ~ — A) 657, 717 and 787 engines o NOTE : This tool is also used for the impeller. Replacement parts : 1. Locating sleeve P / N 290877181 m Puller m 2.
PAGE 13
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 01 (MANDATORY TOOLS) ENGINE (continued) R i n g g e a r b l o c k i n g t o o lm . : P / N 295000134 F01B264 APPLICATION 787 engine. Ring gear puller tool P / N 420976235 F01B294 APPLICATION 787 engine. Distance gauge ml ● P / N 290876826 FO1 BOH4 APPLICATION 587 and 657 engines. 01-01-3 www.SeaDooManuals.
PAGE 14
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 01 (MANDATORY TOOLS) COOLING / FUEL/ OIL SYSTEMS Hose pincher P / N 295000076 Q Pliers ● m 8 0 P / N 295000054 Calllau F01B1T4 APPLICATION , AO1 B214 All models. APPLICATION o All models. Gear holder NOTE : This tool is also used for the propulsion system. .4 m Flush kit P / N 290277 905 P / N 295500068 F01E014 AOOC164 APPLICATION APPLICATION 587, 717 and 787 engines. 717 engine, Coupler hose Pliers m .0 p,/ N 29.
PAGE 15
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 01 (MANDATORY TOOLS) PROPULS1ON SYSTEM Impeller remover / i nsta I Ie r Bearing / seal installer ● o~ m P / N 295000107 VTS tool *O m P/’ N 295000133 P / N 295000001 F01JOT4 F01B2P4 APPLICATION APPLICATION All models. o NOTE : This tool is also used for the PTO flywheel. Pliers m XP 1995 and 1996 models. F01J4K4 APPLICATION XP 8001995 model. All models. SPX 1996 model.
PAGE 16
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 02 (RECOMMENDED TOOLS) RECOMMENDED TOOLS o NOTE : The numbers outlined in black (example : ❑ ) are reference numbers to tools from other divisions (Sea-Doo and/or Sea-Doo Jet Boats). Matching reference numbers indicate the same tool is being used on both products, even if the part numbers are different.
PAGE 17
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 02 (RECOMMENDED TOOLS) ENGINE (continued) Timing mark pointer Ring halves and ring P / N 295000130 P / N 290876330 (halves) (2) Terminal remover m ● Not sold by Bombardier Snap-on TT 60@4 P/N 2 9 0 9 7 7 4 8 0 (ring) . o --——— —— F01B1J4 a G; F01B2D4 , FO1 B204 APPLICATION All engines except 787. Timing mark pointer P / N 295000135 APPLICATION All models.
PAGE 18
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 02 (RECOMMENDED TOOLS) ENGINE (continued) .. m Safety lanyard switch tool ~ Handle P / N 295000121 P / N 290877650 Ring compressor A) P / N 290876972 t m B) P / N 295000112 m F01B244 A01B1T4 APPLICATION APPLICATION DESS switch. A) 587 engine (76 mm). AOOC3V4 A) Four-pin magneto m . harness P / N 295000131 APPLICATION B) Six-pin magneto harness P / N 295000136 Exhaust m B) 657 engine (78 mm). 787 engine.
PAGE 19
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 02 (RECOMMENDED TOOLS) COOLING / FUEL/ OIL SYSTEMS Pump gauge m tester : . (carburetor P / N 295000114 Screwdriver Spring compressor Not sold by Bombardier P / N 529027100 Snap-on SDD-143 i--l F01B1P4 APPLICATION All models. Lighted adjustable mirror A01B404 Not sold by Bombardier APPLICATION F01BOX4 Snap-on 50101 APPLICATION Suspension adjustment m : wrench All models. Pump gauge tester (fuel / oil reservoirs) P / N 295000085 HX.
PAGE 20
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 02 (RECOMMENDED TOOLS) PROPULSION SYSTEM Fitting Machinist’s square Bearing remover P / N 295000086 Not sold by Bombardier P / N 295000144 Snap-on P~F I 22 ~01 Jl14 APPLICATION 0’ All models. ~! \ II “.. -. . - J ; ~ “’ -- -’ “’ - “$ --- “ “ - . - -& ;L:::j,,-.,,. ..7. !67 ,. h$,4. ,;. ,..+- ..,------.. ---=.k:4---—u;:LJ;;;:::;...m;:J::::. , FO1 BOZ4 APPLICATION F02B064 All models.
PAGE 21
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 02 (RECOMMENDED TOOLS) WATERC RAFT HANDING Dolley (with wheels) : . m Lift kit Tie-down with ratchet :m : 3.60 m (12 ft) long A) P / N 295100012 m : c :: t B) P / N 295100 0? 3 m P / N 295000126 P / N 295100 0! 1 APPLICATION AlI models. F01B014 .——————————— Beach wheels (2) . m ● P / N 295000005 F01B1N4 APPLICATION A) SP and XP series. B) GTS and GTX models. 1 : :A m’ Tie-down 1.
PAGE 22
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 03 (SERVICE PRODUCTS) SERVICE PRODUCTS o NOTE : The numbers outlined in black. (example : ❑ ) are reference numbers to tools from other divisions (Sea-Doo and/or Sea-Doo Jet Boats).
PAGE 23
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 03 (SERVICE PRODUCTS) General purpose instant adhesive Solvent P / N 293800019 m m Gasket eliminator P / N 293800007 m P i N 293800021 ~octlte 495 AOOB2VA Loctlte Safety Solvent 755 { 12 Oz! Loctite 515 !50 m i-; @@/rr m. * a AOOB2T4 APPLICATION = Rubber to metal bonding and most hard plastlc. * B ~ APPLICATION Cylinder sleeve / O-ring groove. 1400 B I Gasket stripper m P / N 295000110 (500 mL) ● Crankcase halves mating surface.
PAGE 24
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 03 (SERVICE PRODUCTS) ●. m Hylomar sealant P / N 293800001 Heat resistant sealant A m 8 m P / N 293550004 P / N 413709200 DL32 ‘ 100 g) Dielectric grease Dow Cornlncj ( 150 g) Dow Corning 736 (90 m L} AOOB3F4 AOOB3U4 ~01 B164 APPLICATION APPLICATION APPLICATION Tuned pipe. Battery posts and cable connectors. . . m Sealant ●8 m Sealant Thermosensor switch. P / N 413710300 P / N 293530011 .
PAGE 25
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 03 (SERVICE PRODUCTS) Anti-seize lubricant Lubricant Not sold Em ● (8 OZ) Loctlte anti-seize Iubrl cant 12 Oz (454 g) G E. Versllube G341 M m P / N 413408600 P / N 293800023 by B o m b a r d i e r Sea-Doo fuel stabilizer 7 II =ej ( Esso Be;;on 325 .dflll ~~wbo~ FUEL STABILIZER AOOB1T4 j~ APPLICATION D Sliding surface of starter armature shaft splines. F01B174 t APPLICATION AOOB3V4 Crankshaft thread / PTO flywheel.
PAGE 26
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 03 (SERVICE PRODUCTS) Bombard ier-Rotax injection oil .e m P / N 413803000 (3x 4 L) P / N 413803200 (205 L) Bombardier-Rotax Formula XP-S synthetic Injection oIl . m P/N 413710500 (12 X 1 L) ●* m A ) S i l i c o n e “ U l t r a Black” t m P / N 293800030 ‘o B) Silicone m “Ultra Black FIB” P / N 293800028 ● Loctlte 598 (300 n-l L! a MBARDIER ROTAX. u ~=K-~ ; c c2Eiz3 on - F01B1A4 ~ !I,,.,, m”s a OMBARDIER w o ROTAX. I“j.di.
PAGE 27
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 03 (SERVICE PRODUCTS) .
PAGE 28
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 03 (SERVICE PRODUCTS) Sea-Doo spray paint for gelcoat A) Super white (140 g) m P / N 293500076 Gelcoat (liquid) Gelcoat repair kit A) Super white (1 L) P / N 293500075 A) P / N 295500216 B) P / N 295500340 m m B) White (1 L) P / N 293500033 C) P / N 295500100 C) Green (140 g) P / N 293500062 . .
PAGE 29
Section 02 MAINTENANCE Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENTS PERIODIC INSPECTION CHART.............................................................................................. 02-01-1 FLUSHING AND LUBRICATION.............................................................................................. 02-02-1 GENERAL ............................................................................................................................. 02-02-1 PROCEDURE ............................
PAGE 30
Section 02 MAINTENANCE Sub-Section 01 (PERIODIC INSPECTION CHART) PERIODIC INSPECTION CHART 1 NOTE : Servicing period is given in hours. Shaded area shows the maintenance frequency .
PAGE 31
Sub-Section 02 Section 02 MAINTENANCE (FLUSHING AND LUBRICATION) FLUSHING AND LUBRICATION 2 GENERAL Flushing the cooling system with fresh water is essential to neutralize corroding effects of salt or other chemical products present in water. It will help to clean up sand, salt, shells or other particles in water jackets (engine, exhaust manifold, tuned pipe) and / or hoses.
PAGE 32
Section 02 MAINTENANCE Sub-Section 02 (FLUSHING AND LUBRICATION) 3 All Models Start the engine then immediately open the water tap. CAUTION : Always start the engine before opening the water tap. Open water tap immediately after engine is started to prevent overheating. Run the engine about 3 minutes at a fast idle around 3500 RPM. Pull plug from air intake silencer cover. Spray BOMBARDIER LUBE lubricant through air intake silencer cover keeping engine at fast idle. 1 - 2 F01E02A 2 1 787 ENGINE 1.
PAGE 33
Sub-Section 02 All Models Wipe up any residual water from the engine. Remove spark plug cables and connect them on the grounding device. 3 2 Section 02 MAINTENANCE (FLUSHING AND LUBRICATION) Remove both spark plugs and spray BOMBARDIER LUBE lubricant into each cylinder. Crank the engine a few turns to distribute the oil onto cylinder wall. Apply anti-seize lubricant on spark plug threads then reinstall them. Reinstall plug on air intake silencer cover.
PAGE 34
Section 02 MAINTENANCE Sub-Section 03 (WATER-FLOODED ENGINE) WATER-FLOODED ENGINE 3 XP Model Only General If engine is water-flooded, it must be serviced within a few hours after the event. Otherwise engine will have to be overhauled. CAUTION : A water-flooded engine must be properly lubricated, operated then lubricated again, otherwise parts will be seriously damaged. - Procedure Check fuel and oil reservoirs for water contamination. If necessary, siphon and refill with fresh fluids.
PAGE 35
Section 02 MAINTENANCE Sub-Section 03 (WATER-FLOODED ENGINE) NOTE : If engine does not start after several attempts, check ignition system for spark occurence. Refer to ELECTRICAL SYSTEM, 0802. Check crankshaft if needed, it can become misaligned or deflected. Refer to ENGINE, 04-03. After engine has started, spray BOMBARDIER LUBE lubricant through air intake silencer while engine is running. 2 1 3 F01F25A 1. Air intake silencer cover 2. Pull plug 3.
PAGE 36
Section 02 MAINTENANCE Sub-Section 04 (STORAGE) STORAGE 4 Engine Draining Fuel System Check engine drain hose. 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 necessary. CAUTION : Water in engine drain hose must be free to flow out, otherwise water could be trapped in engine. Should water freeze in engine, severe damage will occur. Check engine drain hose for obstructions.
PAGE 37
Section 02 MAINTENANCE Sub-Section 04 (STORAGE) Wash the body with soap and water solution (only use mild detergent). Rinse thoroughly with fresh water. Remove marine organisms from the hull. Apply a nonabrasive wax. CAUTION : Never clean apparent fiberglass and plastic parts with strong detergent, degreasing agent, paint thinner, acetone, etc.
PAGE 38
Section 02 MAINTENANCE Sub-Section 04 (STORAGE) All Models Except the HX Install coupler hose to fitting spigot. Install a hose pincher to engine water return hose (beside fitting spigot). 1 2 Disconnect engine water supply hose and engine water return hose. 3 F05E03A 1 2 1. Engine water supply hose 2. Engine water return hose F01E1EA 1. Coupler hose 2. Fitting spigot 3.
PAGE 39
Section 03 TROUBLESHOOTING TROUBLESHOOTING 0 The following is provided to help in diagnosing the probable source of troubles. It is a guideline and should not be assumed to have all causes for all problems.
PAGE 40
Section 03 TROUBLESHOOTING ENGINE MISFIRES, RUNS IRREGULARLY OTHER OBSERVATION POSSIBLE CAUSE REMEDY Weak spark • Fouled, defective, worn spark plugs • Faulty rev limiter or ignition • Check / verify heat range / gap / replace • Check, refer to section 08-02 • Sheared flywheel key • Check timing mark, refer to section 08-02 • Low fuel level • Stale or water fouled fuel • Check / refill • Check / siphon and refill • Fuel filter dirty or restricted • Check / clean / replace • Carburetion dirty o
PAGE 41
Section 03 TROUBLESHOOTING ENGINE DETONATION OR PINGING OTHER OBSERVATION Ignition Engine temperature POSSIBLE CAUSE REMEDY • Timing too far advanced • Check / reset • Spark plug heat range too high • Check / change to correct range • Engine overheats • Fuel of poor quality • Check, refer to engine overheats • Use good quality fuel ENGINE LACKS ACCELERATION OR POWER OTHER OBSERVATION Engine revs lower than its maximum operational RPM (787 engine) Peak performance is delayed until higher RPM ran
PAGE 42
Sub-Section 00 Section 04 ENGINE (TABLE OF CONTENTS) TABLE OF CONTENTS REMOVAL AND INSTALLATION ............................................................................................ GENERAL ............................................................................................................................. REMOVAL FROM WATERCRAFT ........................................................................................ CLEANING .................................................................
PAGE 43
Section 04 ENGINE Sub-Section 00 (TABLE OF CONTENTS) EXHAUST MANIFOLD, TUNED PIPE AND MUFFLER INSTALLATION ............................ 04-05-7 04-00-2 www.SeaDooManuals.
PAGE 44
Sous-section 01 Section 04 ENGINE (REMOVAL AND INSTALLATION) REMOVAL AND INSTALLATION GENERAL It is not necessary to remove engine from watercraft for TOP END nor PTO FLYWHEEL AND MAGNETO servicing. However engine removal is necessary to repair BOTTOM END. 1 All Models Disconnect thermosensor wire and spark plug cables. Connect spark plug cables onto grounding device. 3 HX Model Only Engine can be removed with jet pump in place.
PAGE 45
Section 04 ENGINE Sous-section 01 (REMOVAL AND INSTALLATION) HX Model Only Disconnect choke and throttle cables from carburetors. Disconnect fuel supply and fuel return hoses. Disconnect magneto wiring harness. 1 Engine Support Mounts All Models Except the HX Remove engine support mount screws. NOTE : Be careful when removing engine support mount screws, shims could have been installed between engine support and rubber mounts.
PAGE 46
Sous-section 01 HX Model Loosen screws of engine rubber mount adapters. NOTE : Rubber mount adapters sit on shims which control engine / jet pump alignment. Always note position of shims for reinstallation, to avoid altering engine alignment. 1 F05D09A Section 04 ENGINE (REMOVAL AND INSTALLATION) Using a chain block, a hoist or other suitable equipment, slightly lift engine to ease the remaining component removal. CAUTION : Take care not to damage cable or oil injection hoses.
PAGE 47
Section 04 ENGINE Sous-section 01 (REMOVAL AND INSTALLATION) All Models Install a hose pincher to oil supply hoses of oil injection pump and rotary valve shaft ; then, disconnect hoses. 1 F01D40A TYPICAL - ALL MODELS EXCEPT THE XP A01B2JB TYPICAL 1. Hose pincher (P / N 295 000 076) Install a hose pincher to oil return hose of rotary valve shaft ; then, disconnect hoses. Disconnect RED positive cable from starter post. F01D7RA XP MODEL CLEANING F01H1JB Wipe off any spillage in bilge.
PAGE 48
Sous-section 01 Section 04 ENGINE (REMOVAL AND INSTALLATION) : Strict adherence to this torque - CAUTION is important to avoid damaging threads of aluminum insert in bilge. NOTE : Always remove rubber mounts one at a time and reinstall each shim to its original location. Engine Support and Nut All Models Except the XP Properly install support on crankcase so that rounded portion of support matches with MAG side of crankcase.
PAGE 49
Section 04 ENGINE Sous-section 01 (REMOVAL AND INSTALLATION) Final Inspection Check throttle cable condition and lubricate cable with BOMBARDIER LUBE lubricant. After its installation, properly adjust and bleed oil injection pump as specified in LUBRICATION SYSTEM 0702. Pressure test fuel system, refer to FUEL SYSTEM 06-01. Verify all connections and hoses condition. Run engine and ensure there is no leakage. CAUTION : Water must be supplied to cool the engine.
PAGE 50
Section 04 ENGINE Sub-Section 02 (TOP END) TOP END 2 587 and 717 Engines 24 N•m (17 lbf•ft) Loctite 242 15 Synthetic grease 9 N•m (80 lbf•in) 14 717 Engine 9 N•m (80 lbf•in) Loctite 515 13 587 Engine 1 1 12 Synthetic grease 12 24 N•m 11 (17 lbf•ft) Synthetic grease 2 Loctite PST 592 Synthetic grease 24 N•m (17 lbf•ft) 2 Synthetic grease 17 Loctite 515 Loctite 242 10 24 N•m (17 lbf•ft) Loctite 515 9 34 rollers 6 9 5 16 7 8 717 Engine Synthetic grease 4 587 3 Engine 7 8 3 4 34 r
PAGE 51
Section 04 ENGINE Sub-Section 02 (TOP END) 787 Engine 15 Loctite 242 24 N•m (17 lbf•ft) Synthetic grease 1 12 2 19 Synthetic grease 23 22 20 Synthetic grease 40 N•m (30 lbf•ft) 18 Loctite 515 21 27 26 34 rollers 25 6 Loctite 515 24 7 8 4 4 Synthetic grease 7 8 3 F01D7DS 040-02-2 PARTS www.SeaDooManuals.
PAGE 52
Section 04 ENGINE Sub-Section 02 (TOP END) ENGINE DESCRIPTION 587, 717 and 787 Engines The 2-stroke ROTAX engine rotates counterclockwise seen from the rear (PTO flywheel). It has a rotary valve to control opening and closing of intake. Lubrication is provided by a variable rate oil injection pump. It is cooled by water supplied from the jet pump. It has a NIPPONDENSO Capacitor Discharge Ignition System. The fuel is provided by diaphragm MIKUNI carburetor(s) having an integrated fuel pump.
PAGE 53
Section 04 ENGINE Sub-Section 02 (TOP END) If the other cylinder has been removed, completely cover its opening with a clean rag. 1 2 3 5 4 1 F01B0VA F01D43A 1. Openings covered with rag and rubber pad To remove circlip, insert a pointed tool in piston notch then pry it out and discard. WARNING : Always wear safety glasses when removing piston circlips. ; PISTON PIN PULLER (P / N 290 877 092) 1. Bushing (P / N 290 877 181) 2. Expansion sleeve (P / N 290 877 041) 3. Extractor sleeve 4.
PAGE 54
Section 04 ENGINE Sub-Section 02 (TOP END) CLEANING Discard all gaskets and O-rings. Clean all metal components in a solvent. Clean water passages and make sure they are not clogged. Remove carbon deposits from cylinder exhaust port, cylinder head and piston dome. Clean piston ring grooves with a groove cleaner tool, or a piece of broken ring. INSPECTION F01D2YA – The needles, thrust washers and the expansion sleeve remain in the connecting rod bore and may be used again.
PAGE 55
Section 04 ENGINE Sub-Section 02 (TOP END) NOTE : Replacement cylinder sleeves are available if necessary. Also, oversize pistons of 0.25 mm (.010 in) are available for all engines and oversize pistons of 0.5 mm (.020 in) are available for the 587 and 717 engines. Cylinder Taper Using a cylinder bore gauge, measure cylinder diameter at 16 mm (5/8 in) from top of cylinder just below auxiliary transfer port, facing exhaust port.
PAGE 56
Section 04 ENGINE Sub-Section 02 (TOP END) Measure cylinder at 16 mm (5/8 in) below its top edge. Ring End Gap Position ring halfway between exhaust port and top of cylinder. NOTE : In order to correctly position ring in cylinder, use piston as a pusher. Using a feeler gauge, check ring end gap. If gap exceeds specified tolerance, rings should be replaced. A 1 B 2 1 F01D8CA 1. Measuring perpendicularly (90°) to piston pin axis A. 16 mm (5/8 in) B. 25 mm (1 in) F01D0OA 1. Top of cylinder 2.
PAGE 57
Section 04 ENGINE Sub-Section 02 (TOP END) GASKET THICKNESS IDENTIFICATION HOLES 0.3 mm (.012 in) 3 0.4 mm (.016 in) 4 0.5 mm (.020 in) 5 0.6 mm (.024 in) 6 0.8 mm (.031 in) 8 F01D7EA NOTE : Squish gap measurement is discussedfurther in this sub-section. ASSEMBLY Assembly is essentially the reverse of disassembly procedures. However pay particular attention to the following.
PAGE 58
Section 04 ENGINE Sub-Section 02 (TOP END) – Warm piston to approximately 50-60°C (122140°F) and install it over connecting rod. – Insert extractor spindle into the piston pin, screw on extracting nut. – Rotate handle to pull piston pin carefully into the piston. 1 F01D0VA 1. Thrust washer each side – Insert piston pin into piston until it comes flush with inward edge of piston hub.
PAGE 59
Section 04 ENGINE Sub-Section 02 (TOP END) F01D0SA F01D0WA – As necessary, pull halves of inner sleeve with long nose pliers. 1 1. Circlip opening at 6 o’clock (at bottom) : Always wear safety glasses ; WARNING when installing piston circlips. : Always use new circlips. At in- CAUTION stallation, take care not to deform them. Overstressed circlips will come loose and will damage engine. Circlips must not move freely after installation.
PAGE 60
Section 04 ENGINE Sub-Section 02 (TOP END) 1 F01D0YA F01D0ZA 3,7,8,9, Piston, Ring and Cylinder To easily slide cylinder over piston, install on piston ring compressor P / N 290 876 972 for the 587 engine or P / N 290 876 979 for the 717 and 787 engines. A01B1TA 1. Ring end gap aligned with piston locating pin Slide cylinder over piston. 1 1. Slide this edge NOTE : Ring compressor will not fit on oversize parts. Make sure to align ring end gap with piston locating pin. Slide tool over rings.
PAGE 61
Section 04 ENGINE Sub-Section 02 (TOP END) F01D44A 1 1 4 1 4 3 2 3 2 F01D35A ALL ENGINES EXCEPT THE 787 1. Exhaust flange aligning tool 787 Engine Prior installation, apply synthetic grease below screw head and Loctite 515 on screw threads. Install M10 x 105 screws on exhaust side and the M10 x 73,5 on opposite side. Torque screws in a criss-cross sequence for each cylinder to 20 N•m (15 lbf•ft). Repeat the procedure, retightening all cylinder screws to 40 N•m (30 lbf•ft).
PAGE 62
Section 04 ENGINE Sub-Section 02 (TOP END) Apply Loctite 515 in O-ring groove of cylinder sleeves. 4 2 6 8 10 1 8 10 9 6 2 4 3 1 7 9 12 11 5 3 7 11 5 F01D15A 1. Longer screws F01D14A 2,12, Cylinder Head and O-ring Make sure to install large O-rings around spark plug holes and small O-ring where shown. 1 717 and 787 Engines Make sure to install O-rings around spark plug holes and O-ring of cylinder head as shown in the following illustration.
PAGE 63
Section 04 ENGINE Sub-Section 02 (TOP END) Torque cylinder head screws to 12 N•m (9 lbf•ft) as per following illustrated sequence. Repeat the procedure, retightening all screws to 24 N•m (17 lbf•ft). 1 10 8 2 4 6 12 F01D5WA 1. Squish gap F01D46A 9 7 3 1 5 If the squish gap is increased, a loss in power will occur, while too small a squish gap will lead to detonation.
PAGE 64
Section 04 ENGINE Sub-Section 02 (TOP END) 1 A18C0OA 1. Measure here : Do not use acid core solder ; - CAUTION the acid can damage the piston and cylin- der. – Take another measurement at the opposite side of the piston. – Repeat procedure for the other cylinder. The lowest and the highest values of both cylinders must be within the specified range. Engine Squish Gap 587 1.2 - 1.8 mm (.047 - .071 in) 717 1.3 - 1.7 mm (.051 - .067 in) 787 1.2 - 1.6 mm (.047 - .
PAGE 65
Section 04 ENGINE Sub-Section 02 (TOP END) Item P1 in figure is the pressure of the return spring against the diaphragm. The exhaust pressure must be high enough to overcome this pressure before the valve begins opening. Item P2 is the pressure required to completely open the RAVE valve. Between P1 and P2, the usable power curve of the engine is moving from power curve 1 to power curve 2.
PAGE 66
Section 04 ENGINE Sub-Section 02 (TOP END) Boring Precaution 21, Allen Screw In its stock configuration the RAVE valve guillotine has a minimum of 0.5 mm (.020 in) clearance to the cylinder bore measured at the center line of the cylinder. This is the minimum production clearance. There is only a first oversize piston available for the 787 engine. That piston is 0.25 mm (.010 in) larger in diameter than the stock piston. When the oversize is installed, the guillotine will have a minimum clearance of 0.
PAGE 67
Section 04 ENGINE Sub-Section 02 (TOP END) Inspection 27, Valve Housing Check bellow for cracks. Check if passages of valve housing and cylinder are not obstructed. Position the valve housing onto the cylinder so that its opening is toward the bottom. F01D8JB 1 F01D8JA 1 1. Bottom of valve housing 1.
PAGE 68
Section 04 ENGINE Sub-Section 03 (BOTTOM END) BOTTOM END 3 587 Engine Loctite 515 11 1 Lithium grease Anti-seize lubricant 3 2 14 5 Loctite 642 Anti-seize lubricant Anti-seize lubricant Loctite 242 15 2 6 4 3 6 1 Loctite 515 Anti-seize lubricant Anti-seize lubricant Lithium grease 24 N•m 9 (17 lbf•ft) Loctite 515 Synthetic grease Loctite 515 8 40 N•m (30 lbf•ft) Synthetic grease Loctite 11 515 Loctite 7 24 N•m 515 (17 lbf•ft) 10 10 N•m (88 lbf•in) F01D4HS PARTS www.SeaDooManuals.
PAGE 69
Section 04 ENGINE Sub-Section 03 (BOTTOM END) 717 Engine Loctite 515 11 Lithium grease Anti-seize lubricant 2 14 1 3 65 Loctite 642 6 Anti-seize lubricant 2 Anti-seize lubricant 3 Loctite 515 Loctite 242 6 24 N•m (17 lbf•ft) 9 6 11 Synthetic grease 1 Loctite 515 7 24 N•m (17 lbf•ft) 10 10 N•m (88 lbf•in) Loctite 515 Synthetic grease 8 40 N•m (30 lbf•ft) F01D06S 04-03-2 4 PARTS www.SeaDooManuals.
PAGE 70
Section 04 ENGINE Sub-Section 03 (BOTTOM END) 787 Engine 30 mL (1 oz) FORMULA XP-S synthetic injection oil Loctite 515 Anti-seize lubricant 12 Lithium grease 1 5 3 6 13 2 6 Lithium grease 14 12 Anti-seize lubricant Loctite 642 Anti-seize lubricant Anti-seize lubricant 2 Lithium grease 3 4 Loctite 515 8 40 N•m (30 lbf•ft) 6 Loctite 242 Loctite 515 Synthetic grease 6 Synthetic grease Loctite 515 Synthetic grease 7 24 N•m (17 lbf•ft) F01D8GS PARTS www.SeaDooManuals.
PAGE 71
Section 04 ENGINE Sub-Section 03 (BOTTOM END) CRANKSHAFT MISALIGNMENT AND DEFLECTION Since it is an assembled crankshaft it can become misaligned or deflected. Crankshaft can be twisted on center main journal, changing timing of one cylinder in relation with the other. – Remove spark plugs. – Insert a screwdriver in one spark plug hole. – Insert a longer screwdriver in the other spark plug hole. – Lay one hand over both screwdriver handles to feel piston displacements.
PAGE 72
Section 04 ENGINE Sub-Section 03 (BOTTOM END) 1, Seal If crankshaft end seal(s) has / have to be replaced, bottom end must be opened (except for the MAG side seal on the 787 engine, which is mounted on the ignition housing). 1 2 3, Crankcase 3 4 Remove the following parts : – Engine support (except for the 787 engine). – PTO flywheel. Refer to PROPULSION SYSTEM 09-02. NOTE : PTO side flywheel must be removed prior removing MAG side flywheel. – Magneto flywheel. Refer to ELECTRICAL SYSTEM 08-01.
PAGE 73
Section 04 ENGINE Sub-Section 03 (BOTTOM END) 2 1 3 4 5 6 8 1 7 F01B09A F01D1KA 1. Separate halves by prying at provided lugs 1. 2. 3. 4. 5. 6. 7. 8.
PAGE 74
Section 04 ENGINE Sub-Section 03 (BOTTOM END) All Engines Clean all metal components in a solvent. Remove old Loctite from crankcase mating surfaces with gasket remover (P / N 295 000 110). CAUTION : Be careful not to spray cleaner on the painted surface of the engine. Never use a sharp object to scrape away old sealant as score marks incurred are detrimental to crankcase sealing. - 1 INSPECTION F01D1OA 1. Removing crankshaft bearing Or, use a bearing extractor such as Proto no.
PAGE 75
Section 04 ENGINE Sub-Section 03 (BOTTOM END) 1 1 F01D1QA 2 F01D1TA 1. Ruler must be aligned with edge of connecting rod here 2. Align ruler here 1. Measuring MAG side deflection in crankcase Remove crankshaft bearings and check deflection again on V-shaped blocks as illustrated. Crankshaft Deflection Crankshaft deflection is measured each end with a dial indicator. First, check deflection with crankshaft in crankcase.
PAGE 76
Section 04 ENGINE Sub-Section 03 (BOTTOM END) Connecting Rod Big End Axial Play 1 Using a feeler gauge, measure distance between thrust washer and crankshaft counterweight. 1 2 3 F01D1XA 1. Bearing against a steel plate 2. Propane torch 3. Heat plate through bearing bore 2 F01D1WA 5, Outer PTO Bearing 1. Measuring big end axial play 2. Feeler gauge ASSEMBLY Assembly is essentially the reverse of disassembly procedures. However pay particular attention to the following.
PAGE 77
Section 04 ENGINE Sub-Section 03 (BOTTOM END) 1 1 2 F01D1YA F01D80A TYPICAL 1. Distance gauge 2. PTO side outer bearing 1. Marks 15, Distance Ring Crankcase halves are factory matched and therefore, are not interchangeable or available as single halves. Prior to joining crankcase halves, apply a light coat of Loctite 515 on mating surfaces. Do not apply in excess as it will spread out inside crankcase.
PAGE 78
Section 04 ENGINE Sub-Section 03 (BOTTOM END) 587 and 717 Engines 11 7,8,9, Crankcase Screw 7 21 1 3 4 2 22 5 9 Torque crankcase screws to 24 N•m (17 lbf•ft) as per following illustrated sequence. 12 11 8 13 9 7 1 3 5 13 8 4 2 6 14 12 19 10 17 6 10 14 15 16 18 20 F01D81A F01D20A 8, Crankcase Screw 8, Crankcase Screw Torque 2 M10 crankcase screws to 40 N•m (30 lbf•ft). As a final step, torque only M10 screws of crankcase to 40 N•m (30 lbf•ft) as per following sequence.
PAGE 79
Section 04 ENGINE Sub-Section 03 (BOTTOM END) F01D4KA 1 1. Install starter before engine support 787 Engine Add 30 mL (1 oz) of FORMULA XP-S synthetic injection oil in the small hole near the transfer of the PTO cylinder. F01D86A 1 TYPICAL 1. Add 30 mL (1 oz) of injection oil 04-03-12 www.SeaDooManuals.
PAGE 80
Section 04 ENGINE Sub-Section 04 (ROTARY VALVE) ROTARY VALVE 4 9 5 6 10 14 15 7 8 11 3 13 1 4 12 Lithium grease 1 2 20 N•m (15 lbf•ft) 787 Engine 717 Engines 2 20 N•m (15 lbf•ft) F01D7SS PARTS www.SeaDooManuals.
PAGE 81
Section 04 ENGINE Sub-Section 04 (ROTARY VALVE) GENERAL 1 The following verification procedures such as clearance of rotary valve cover or rotary valve shaft gear backlash can be performed without removing engine from watercraft. However engine must be removed from watercraft to work on rotary valve shaft / components. Refer to ENGINE 04-01 for engine removal procedure. Bottom end must be opened to remove rotary valve shaft. Refer to ENGINE 04-03. INSPECTION ON WATERCRAFT F01D53A Remove carburetor(s).
PAGE 82
Section 04 ENGINE Sub-Section 04 (ROTARY VALVE) 1 2 1 F01D3PA TYPICAL 1. Solder If rotary valve cover clearance is out of specification, machine rotary valve cover seating surface or replace the cover. MACHINING INFORMATION The amount of material over tolerance must be removed from the rotary valve cover seating surface. Also cut the O-ring groove the same amount to keep the 1.0 ± 0.03 mm (.039 ± .001 in) depth between the bottom of the groove and the seating surface.
PAGE 83
Section 04 ENGINE Sub-Section 04 (ROTARY VALVE) DISASSEMBLY 3,4, Rotary Valve Shaft and Snap Ring To remove rotary valve shaft assembly, first remove snap ring from crankcase. 1 1 F01D61A 1. Hold bolt F01D22A 1. Removing snap ring : Bottom end must be opened - CAUTION to remove rotary valve shaft. To remove rotary valve shaft, use puller (P / N 290 876 487) for the 587 and 717 engines or puller (P / N 290 876 488) for the 787 engine.
PAGE 84
Section 04 ENGINE Sub-Section 04 (ROTARY VALVE) 7,8, Snap Ring and Bearing To remove bearing use a bearing extractor such as Snap-on no CJ-950 as illustrated. Slide off distance sleeve, remove snap ring and press shaft out. F01J0ZA Close puller claws so that they can be inserted in end bearing. Holding claws, turn puller shaft clockwise so that claws open and become firmly tight against bearing. Slide puller sleeve outwards and tap puller end.
PAGE 85
Section 04 ENGINE Sub-Section 04 (ROTARY VALVE) 8,9 Bearing 9, Bearing Inspect bearings. Check for scoring, pitting, chipping or other evidence of wear. Make sure plastic cage (on bigger bearing) is not melted. Rotate them and make sure they turn smoothly. To install end bearing in crankcase, use a pusher (P / N 290 876 500). 1 10, Gear Visually check gear wear pattern. It should be even on tooth length all around. Otherwise it could indicate a bent shaft, check deflection. Replace gear if damaged.
PAGE 86
Section 04 ENGINE Sub-Section 04 (ROTARY VALVE) 3,11, Rotary Valve Shaft and Seal Apply lithium grease on seal lips. Position seal with shielded portion against shaft splines. 3,4, Rotary Valve Shaft Ass’y and Snap Ring : Crankcase halves must be - CAUTION separated and crankshaft must not be 3,7,8, Rotary Valve Shaft, Snap Ring and Bearing present to install rotary valve shaft ass’y in crankcase. Install ball bearing as illustrated.
PAGE 87
Section 04 ENGINE Sub-Section 04 (ROTARY VALVE) 787 Engine To install rotary valve shaft in crankcase, use a pusher (P / N 290 876 609) and handle (P / N 290 877 650). All Engines At snap ring installation, position it so that its sharp edge faces outwards. 13, Rotary Valve 2 The rotary valve controls the opening and closing of the inlet ports. Therefore its efficiency will depend on the precision of its installation. IDENTIFICATION OF THE ROTARY VALVE 1 F01B2FA 1. Pusher 2.
PAGE 88
Section 04 ENGINE Sub-Section 04 (ROTARY VALVE) TEMPLATE 159°° 159 (cut-out angle) 290 924 502 actual size 147 147°° (cut-out angle) 290 924 508 actual size F01D89S 04-04-9 www.SeaDooManuals.
PAGE 89
Section 04 ENGINE Sub-Section 04 (ROTARY VALVE) ROTARY VALVE TIMING : Never use the ridge molded - CAUTION in crankcase as a timing mark. 1 The following tools are required to measure rotary valve opening and closing angles in relation with MAG side piston.
PAGE 90
Section 04 ENGINE Sub-Section 04 (ROTARY VALVE) 1 65° F01D3EB 2 CLOSING MARK Step 1 : Top of MAG inlet port. Align 360° line of degree wheel Step 2 : Find 65° on degree wheel and mark here – Remove degree wheel. – Position rotary valve on shaft splines to have edges as close as possible to these marks with the MAG piston at TDC. NOTE : Rotary valve is asymmetrical. Therefore, try flipping it over then reinstall on splines to obtain best installation position.
PAGE 91
Section 04 ENGINE Sub-Section 05 (EXHAUST SYSTEM) EXHAUST SYSTEM 5 SP Series, GTS and GTI Models SPI, SPX, GTS and GTI models SP model 11 Loctite 242 25 N•m 8 (18 lbf•ft) 9 20 25 N•m 7 (18 lbf•ft) 17 17 Loctite 242 15 9 Synthetic grease 19 18 18 Loctite 242 6 25 N•m (18 lbf•ft) 24 14 24 N•m (17 lbf•ft) 19 Loctite 242 19 19 4 N•m (35 lbf•in) 5 6 25 N•m (18 lbf•ft) 22 10 N•m (88 lbf•in) 21 Sealant 732 2 3 27 N•m (20 lbf•ft) 4 N•m (35 lbf•in) 1 4 N•m (35 lbf•in) SPX and GTI models 4
PAGE 92
Section 04 ENGINE Sub-Section 05 (EXHAUST SYSTEM) HX Model 10 N•m (88 lbf•in) 4 25 N•m 8 (18 lbf•ft) 10 Loctite 242 9 7 25 N•m (18 lbf•ft) Loctite 242 9 16 Sealant 736 18 19 20 19 17 12 15 6 Loctite 242 24 N•m (17 lbf•ft) 14 25 N•m (18 lbf•ft) 4 N•m 1 (35 lbf•in) 9 4 N•m (35 lbf•in) 3 Synthetic grease Loctite 592 25 4 N•m (35 lbf•in) 4 N•m (35 lbf•in) 2 13 F05D08S PARTS www.SeaDooManuals.
PAGE 93
Section 04 ENGINE Sub-Section 05 (EXHAUST SYSTEM) XP Model 25 N•m (18 lbf•ft) 23 25 N•m (18 lbf•ft) 6 12 Loctite 242 19 Loctite 242 19 17 19 19 Loctite 515 16 15 24 Loctite 648 4 40 N•m 14 (30 lbf•ft) 40 N•m 14 (30 lbf•ft) Sealant 736 10 N•m (88 lbf•in) 24 10 Synthetic grease 9 2 Loctite 242 4 N•m (35 lbf•in) 9 Loctite 242 7 40 N•m (30 lbf•ft) 8 40 N•m (30 lbf•ft) 4 N•m (35 lbf•in) 4 N•m (35 lbf•in) Sealant 732 27 N•m (20 lbf•ft) F01D7WS PARTS www.SeaDooManuals.
PAGE 94
Section 04 ENGINE Sub-Section 05 (EXHAUST SYSTEM) TUNED PIPE REMOVAL 6, Screw All Models Except HX and XP NOTE : For SP series, remove air vent tube support from body opening. Disconnect water inlet hose and water injection hose. Disconnect tuned pipe bleed hose. Remove tuned pipe retaining screw(s) from exhaust manifold side. 3 1 7,8,9, Screw, Nut and Flat Washer Remove screws, nut and flat washers from tuned pipe flange. NOTE : Slightly lift tuned pipe to release nut as necessary.
PAGE 95
Section 04 ENGINE Sub-Section 05 (EXHAUST SYSTEM) Disconnect water supply hose and water injection hose at tuned pipe head. F01D76A 1 1. Screw F01D3YA 1 2 Remove tuned pipe head. 1. Water supply hose 2. Water injection hose 6, Screw 1,3, Collar and Hose Loosen exhaust hose collar at tuned pipe cone outlet. Remove two screws retaining tuned pipe cone to engine. 4, Clamp Remove clamp securing tuned pipe cone to tuned pipe head.
PAGE 96
Section 04 ENGINE Sub-Section 05 (EXHAUST SYSTEM) 12, Tuned Pipe Cone HX Model Only Move tuned pipe cone in front of bilge between body and fuel tank. 1, Collar Loosen exhaust hose collar at tuned pipe cone outlet (only if tuned pipe cone is not removed). 2, Strap Remove rear access cover from body. Disconnect upper exhaust hose in front of muffler. Disconnect retaining strap of muffler. 1 F01D7JA Open storage cover and remove basket.
PAGE 97
Section 04 ENGINE Sub-Section 05 (EXHAUST SYSTEM) Test : – Use compressed air at 124 kPa (18 PSI) to pressurize tuned pipe. NOTE : Prior to verify 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 welding tuned pipe. XP Model Only Except for two screws, apply synthetic grease on screw threads. Apply Loctite 515 on the other two screws. Install screws.
PAGE 98
Section 04 ENGINE Sub-Section 05 (EXHAUST SYSTEM) 20, Gasket Make sure that gasket is properly located on exhaust manifold prior to finalizing pipe installation. 4 7 1 4,6,7,8,23, Clamp, Screw and Nut 6 Apply Loctite 242 (blue) on stud and retaining screw threads. Hand-tighten nut and screws and assure that tuned pipe bushing(s) rests against manifold. Refer to the following illustration for the torquing sequence.
PAGE 99
Section 04 ENGINE Sub-Section 05 (EXHAUST SYSTEM) SPI, SPX, GTS and GTI Models 5,21,22, Tuned Pipe Cone, Collar and Clamp Install tuned pipe cone with collar and clamp. Position clamp as illustrated. Do not tighten clamp yet. 1 F01D41A 2 1. Clamp 2. Exhaust collar With hose removed, align cone outlet with muffler inlet. NOTE : Due to exhaust cone angle, it may have to be rotated to obtain alignment.
PAGE 100
Section 05 COOLING SYSTEM Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENTS COMPONENTS ........................................................................................................................ SP / SPI AND GTS MODELS ............................................................................................... SPX AND GTI MODELS ...................................................................................................... HX MODEL .................................................
PAGE 101
Section 05 COOLING SYSTEM Sub-Section 01 (COMPONENTS) COMPONENTS 1 SP / SPI and GTS Models Loctite 592 Loctite 592 Loctite 592 3 Loctite 592 1 1 2 1 Loctite 592 Loctite 592 Loctite 592 F01E0SS PARTS www.SeaDooManuals.
PAGE 102
Section 05 COOLING SYSTEM Sub-Section 01 (COMPONENTS) SPX and GTI Models Loctite 592 3 1.2 N•m (11 lbf•in) Loctite 592 SP Model Only Loctite 592 1.2 N•m (11 lbf•in) 2 Loctite 592 1 1.2 N•m (11 lbf•in) 1 1.2 N•m (11 lbf•in) 2.5 N•m (22 lbf•in) Loctite 592 F01E1PS 05-01-2 PARTS www.SeaDooManuals.
PAGE 103
Section 05 COOLING SYSTEM Sub-Section 01 (COMPONENTS) HX Model Loctite 592 Loctite 592 1.2 N•m (11 lbf•in) Loctite 592 1 1.2 N•m (11 lbf•in) Loctite 592 1.2 N•m (11 lbf•in) Body 1 1.2 N•m (11 lbf•in) Loctite 592 1 Engine Water Outlet 1 Engine Water Outlet F05E04S PARTS www.SeaDooManuals.
PAGE 104
Section 05 COOLING SYSTEM Sub-Section 01 (COMPONENTS) XP Model Loctite 592 Loctite 592 Loctite 592 1.2 N•m (11 lbf•in) 1.2 N•m (11 lbf•in) 3 1 2 1 1 2 N•m (18 lbf•in) 1.2 N•m (11 lbf•in) 1 Loctite 592 1 Loctite 592 1.2 N•m (11 lbf•in) 5 6 9 0.11 N•m (1 lbf•in) 4 Loctite 592 10 8 0.6 N•m (5 lbf•in) 5 N•m 7 (44 lbf•in) F01E1QS 05-01-4 Loctite 592 PARTS www.SeaDooManuals.net 2.
PAGE 105
Section 05 COOLING SYSTEM Sub-Section 01 (COMPONENTS) GENERAL 3, Elbow Fitting - Water injection used on exhaust system cools the exhaust gases to obtain maximum performance from the tuned pipe. The elbow fitting has a calibrated inside diameter to optimize water flow in tuned pipe. The water injection also helps in reducing noise level and cools components of the exhaust system.
PAGE 106
Section 05 COOLING SYSTEM Sub-Section 01 (COMPONENTS) 4, Water Flow Regulator Valve XP Model A water flow regulator valve has been developed for the 787 engine so that it can produce the maximum horsepower output and yet maintain the necessary diameter of the injection fitting at the tuned pipe head for unobstructed water flow. The water flow regulator valve is mounted directly onto the muffler.
PAGE 107
Section 05 COOLING SYSTEM Sub-Section 01 (COMPONENTS) 1 1 2 F01E1RA F01E1TA 1. Spring 2. Cover 1. Tapered needle Remove the tapered needle from valve housing. 7, Fitting 1 Remove fitting from valve housing. 1 F01E20A 1. Remove tapered needle F01E1SA 9,10, Valve and Bellows 1. Fitting 8, Tapered Needle Unscrew the tapered needle. NOTE : Hold the valve to prevent it from turning. Pull the valve slightly. Using pliers, release the clamp which retains the bellows. Remove valve and bellows.
PAGE 108
Section 05 COOLING SYSTEM Sub-Section 02 (CIRCUIT) CIRCUIT 2 GENERAL The cooling system is equipped with a fitting spigot for flushing purposes (a hose adapter for the HX model). For flushing operation, a coupler hose is available (unnecessary for the HX model) to connect to fitting spigot. The other end of coupler hose is to be connected to a garden hose to flush the whole system by backwash. For flushing procedure, refer to MAINTENANCE 02-02.
PAGE 109
Section 05 COOLING SYSTEM Sub-Section 02 (CIRCUIT) For a minimum back pressure in the exhaust, engine water outlet hose is not connected to the exhaust. It has its own fitting at the rear of the hull. TECHNICAL DATA TYPE : TLCS (Total Loss Cooling System). COOLANT FLOW : Pressure build-up at impeller housing (no water pump). TEMPERATURE CONTROL : Calibrated outlet fittings (no thermostat). SYSTEM BLEEDING : Self-bleed type (hose at uppermost point of circuit).
PAGE 110
www.SeaDooManuals.
PAGE 111
05-02-4 www.SeaDooManuals.
PAGE 112
787 ENGINE COOLING SYSTEM Section 05 COOLING SYSTEM Sub-Section 02 (CIRCUIT) Water regulated by the water flow regulator valve and injected directly into exhaust gas for noise reduction and performance improvement Calibrated cylinder head limits water flow Temperature sensor activates monitoring beeper when temperature exceeds 96-99°C (205-210°F) Uppermost point of circuit (tuned pipe) allows bleeding Cooling System Indicator (CSI) : small stream of water flows out of bleed outlet located near stern eye
PAGE 113
Section 06 FUEL SYSTEM Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENTS FUEL CIRCUIT.......................................................................................................................... SP, SPI AND GTS MODELS................................................................................................. SPX, XP AND GTI MODELS................................................................................................ HX MODEL ....................................................
PAGE 114
Section 06 FUEL SYSTEM Sub-Section 01 (FUEL CIRCUIT) FUEL CIRCUIT 1 SP, SPI and GTS Models 2 N•m (18 lbf•in) 6 N•m (53 lbf•in) 6 7 22 N•m (16 lbf•ft) 1 N•m (9 lbf•in) 4 N•m (35 lbf•in) 4 5 3 N•m (27 lbf•in) 4 4 N•m (35 lbf•in) 8 Loctite 242 3 N•m (27 lbf•in) (SP) 1 3 2 F01F19S PARTS www.SeaDooManuals.
PAGE 115
Section 06 FUEL SYSTEM Sub-Section 01 (FUEL CIRCUIT) SPX, XP and GTI Models Loctite 242 3 N•m (27 lbf•in) Body 2 N•m (18 lbf•in) 6 N•m (53 lbf•in) 6 7 1 3 2 1 N•m (9 lbf•in) 22 N•m (16 lbf•ft) 4 N•m 4 (35 lbf•in) 5 3 N•m (27 lbf•in) 4 4 N•m (35 lbf•in) 8 Engine F01F2ZS 06-01-2 PARTS www.SeaDooManuals.
PAGE 116
Section 06 FUEL SYSTEM Sub-Section 01 (FUEL CIRCUIT) HX Model Body 7 6 2 N•m (18 lbf•in) 3 N•m (27 lbf•in) 6 N•m (53 lbf•in) Loctite 242 1 3 Body 2 1 N•m (9 lbf•in) 22 N•m (16 lbf•ft) 4 3 N•m (26 lbf•in) 4 N•m (35 lbf•in) 5 4 4 N•m (35 lbf•in) Engine 8 F05F09S PARTS www.SeaDooManuals.
PAGE 117
Section 06 FUEL SYSTEM Sub-Section 01 (FUEL CIRCUIT) GENERAL : Whenever repairing the fuel ; WARNING system, always verify for water infiltration in reservoir. To open or secure reusable clamps on fuel lines, use pliers (P / N 295 000 054). To open clamp, place flat side of plier on clamp embossment, squeeze and twist plier. 1 F01B03A 1. Cutting clamp F01B1VA To secure clamp, place notch side of plier on clamp embossment and squeeze plier. 1 F01B04A 1.
PAGE 118
Section 06 FUEL SYSTEM Sub-Section 01 (FUEL CIRCUIT) 1,2, Fuel Filter and Bowl REMOVAL All Models Except HX Open storage compartment cover. Remove basket. HX Model Only Open hood. 1 GTS and GTI Models Only Press on vent tube upper part to enable to withdraw tube from body. F01F01A 2 TYPICAL Pull fuel filter toward the bottom. 1 F02L1MA TYPICAL 1. Press on vent tube F01F04A All Models Turn the fuel valve to OFF position.
PAGE 119
Section 06 FUEL SYSTEM Sub-Section 01 (FUEL CIRCUIT) 6, Pressure Relief Valve 1 This valve will eliminate fuel spillage when the watercraft is upside down. If pressure is built up in fuel system the valve should open at 10 kPa (1.5 PSI) to release the pressure. WARNING : If pressure relief valve is stuck, the pressure in fuel system will build up and it may cause fuel leakage in engine compartment. NOTE : It is a one-way valve with an arrow to indicate the air flow.
PAGE 120
Section 06 FUEL SYSTEM Sub-Section 01 (FUEL CIRCUIT) : Fuel is flammable and explo; WARNING sive under certain conditions. Always work in a well ventilated area. Do not smoke or allow open flames or sparks in the vicinity. Always wipe off any fuel spillage from the watercraft. All Models Except HX Remove storage basket from watercraft. On GTS and GTI models, remove vent tube. Refer to fuel filter removal procedure in this sub-section. Disconnect filler neck hose from fuel tank.
PAGE 121
Section 06 FUEL SYSTEM Sub-Section 01 (FUEL CIRCUIT) Install baffle pick up into fuel tank and push it until it sits on fuel tank neck. Install clamp and torque both clamps to 3 N•m (27 lbf•in). RE S OU T HX Model Only Make sure to align notch of baffle pick up with the mark on the fuel tank. 1 2 F01F0KA TYPICAL 1. Disconnect air inlet hose 2. Install a hose pincher to vent hose F05F04A 2 1 1. Baffle pick up notch 2.
PAGE 122
Section 06 FUEL SYSTEM Sub-Section 02 (AIR INTAKE) AIR INTAKE 2 1 9 10 N•m (88 lbf•in) 2 4 Loctite 242 10 N•m (88 lbf•in) 8 8 Loctite 242 Loctite 242 6 5 10 Twin carbs Loctite 242 10 N•m (88 lbf•in) 3 7 Loctite 515 Single carb Loctite 515 7 F01F1WS PARTS www.SeaDooManuals.
PAGE 123
Section 06 FUEL SYSTEM Sub-Section 02 (AIR INTAKE) REMOVAL 5,6,7,8, Flame Arrester, Support, Base and Screw 1, Air Intake Silencer Cover Remove flame arrester. Remove screws holding support of flame arrester base to the cylinder head cover (587 and 717 engines) or to the tuned pipe (787 engine). Remove screws from flame arrester base then withdraw base. NOTE : On single carburetor models, remove choke cable from flame arrester base.
PAGE 124
Section 06 FUEL SYSTEM Sub-Section 02 (AIR INTAKE) 5, Flame Arrester Inspect condition of flame arrester. Replace or clean as necessary. WARNING : Do not operate watercraft without flame arrester. ; 9, Gasket Inspect condition of gasket. Make sure to properly installed gasket. 06-02-3 www.SeaDooManuals.
PAGE 125
Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) CARBURETORS 3 587 Engine 12 3 14 1 13 8 9 7 Loctite 242 11 10 19 5 4 Loctite 242 15 6 13 2 Anti-seize lubrifiant 18 17 16 F02F0KS PARTS www.SeaDooManuals.
PAGE 126
Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) 717 and 787 Engines Loctite 242 12 6 20 N•m (15 lbf•ft) 3 13 14 20 9 Loctite 242 21 11 Loctite 242 MAG 8 7 10 1 15 Anti-seize lubricant 19 5 13 2 Synthetic grease Synthetic grease PTO 18 17 16 F01F05S 06-03-2 PARTS www.SeaDooManuals.
PAGE 127
Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) GENERAL Twin Carburetor Models Only The following illustration shows which part of the carburetor begins to function at different throttle plate openings. 16,17, Screw and Lock Washer Remove screws and lock washers retaining carburetors. Remove carburetors. Single Carburetor Models Only 2 4 Remove 4 bolts and lock washers from rotary valve cover then move carburetors and rotary valve on top of engine.
PAGE 128
Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) 2, Low Speed Screw PUMP VERIFICATION Check tip for a grooved condition. Replace if necessary. Check fuel pump valves operation as follows : Connect a clean plastic tubing to the inlet nipple and alternately apply pressure and vacuum with the mouth. The inlet valve should release with pressure and hold under vacuum. WARNING : Some fuel may be present in fuel pump. Be careful not to swallow fuel when under vacuum. ; 1 2 F01F0WA 3 TYPICAL 1.
PAGE 129
Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) CARBURETOR ASSEMBLY 1 When assembling pump, ensure to properly position components together. Refer to previous illustrations if necessary. 6,7, Choke Plate and Throttle Plate When installing plate onto shaft, close plate so that it centers into carburetor bore. Firmly tighten screws. CAUTION : Always apply Loctite 242 (blue) on screw threads prior to installing screws. F01F0XA 2 8, Needle Valve Lever TYPICAL 1. Pump gauge tester 2.
PAGE 130
Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) 1 Refer to the following table for specifications of the pop off pressure for each model. 2 MODELS POP OFF PRESSURE (PSI) MINIMUM STABILIZED PRESSURE SP 21-37 14 SPX 40-56 24 SPI 21-37 14 GTS 21-37 14 GTI 40-56 24 XP 27-39 15 HX 40-56 24 F01F0HA HIGH LEVER Step 1 depress here Step 2 push tab down 1 2 NOTE : Pressure test should be performed three times to obtain a valid reading.
PAGE 131
Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) 13, O-ring When installing O-rings of low speed and high speed screws, apply some BOMBARDIER LUBE (P / N 293 600 016) to prevent sticking. 2 1 CARBURETOR INSTALLATION 3 At installation, pay attention to the following : Install carburetor(s) with gasket(s) to intake manifold (rotary valve cover for the 787 engine). Single Carburetor Models Only Install lock washers and apply Loctite 242 (blue) on threads then torque nuts to 25 N•m (18 lbf•ft).
PAGE 132
Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) : Make sure there is no leak in ; WARNING fuel system. For fuel system pressurization, refer to FUEL SYSTEM 06-01. 1 ADJUSTMENTS Throttle Cable Lubricate cable with BOMBARDIER LUBE lubricant. Throttle lever must reach handlebar grip without causing strain to cable or carburetor cable bracket. 2 3 F01F1YA 1. Jam nuts 2. Adjustment nut 3. Flat surfaces Tighten jam nuts and torque to 3 N•m (27 lbf•in).
PAGE 133
Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) 1 F01F32B 2 F01F33A 1 2 717 AND 787 ENGINES 1. Throttle lever stoppers (behind levers) 2. Adjustment nut 717 AND 787 ENGINES 1. Low speed screw (PTO) 2. Low speed screw (MAG) Tighten jam nut and recheck adjustment. WARNING : Make sure idle speed screw contacts stopper when throttle lever is fully released at handlebar. After throttle cable adjustment, always proceed with oil injection pump adjustment. Refer to LUBRICATION SYSTEM 07-02.
PAGE 134
Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) 15, Idle Speed Screw Turning screw clockwise increases engine idle speed and turning screw counterclockwise decreases engine idle speed. 1 1 F01F0VA TYPICAL - 587 ENGINE 1. High speed screw F01F0TE 587 ENGINE 1. Idle speed screw 1 F01F2QA 1 TYPICAL - 717 AND 787 ENGINES 1. High speed screws F01F32C 717 AND 787 ENGINES 1. Idle speed screw 06-03-10 www.SeaDooManuals.
PAGE 135
Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) NOTE : On twin carburetor engines, there is only one idle speed screw. Connect an induction-type tachometer (P / N 295 000 100) on spark plug cable of magneto side to measure engine speed. NOTE : To adjust idle speed, ensure flame arrester and air intake silencer are installed. Start engine and bring to normal operating temperature. CAUTION : If watercraft is out of water, water must be supplied to cool engine.
PAGE 136
Section 07 LUBRIFICATION SYSTEM Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENTS OIL INJECTION SYSTEM ........................................................................................................ ALL MODELS EXCEPT HX .................................................................................................. HX MODEL ........................................................................................................................... 0-01-1 0-01-1 0-01-2 OIL INJECTION PUMP .....
PAGE 137
Section 07 LUBRIFICATION SYSTEM Sub-Section 01 (OIL INJECTION SYSTEM) OIL INJECTION SYSTEM 1 All Models Except HX 3 1 SP Model Only 3 2 4 N•m (35 lbf•in) 1 1.2 N•m (11 lbf•in) 1.2 N•m (11 lbf•in) 4 1.2 N•m (11 lbf•in) F01G0CS PARTS www.SeaDooManuals.
PAGE 138
Section 07 LUBRIFICATION SYSTEM Sub-Section 01 (OIL INJECTION SYSTEM) HX Model 3 4 1.2 N•m (11 lbf•in) 1.2 N•m (11 lbf•in) F05G02S 07-01-2 PARTS www.SeaDooManuals.
PAGE 139
Section 07 LUBRIFICATION SYSTEM Sub-Section 01 (OIL INJECTION SYSTEM) GENERAL 1 Whenever repairing the oil injection system, always verify for water infiltration in reservoir. Perform also a pressure test of the oil injection system. 1,2, Clamp and Hose Verify oil filler neck hose for damage. Always ensure that clamps are well positioned and tightened. Torque clamps to 3 N•m (27 lbf•in). 3, Check Valve Black side of the one-way check valve is the valve outlet. It allows air to get in reservoir.
PAGE 140
Section 07 LUBRIFICATION SYSTEM Sub-Section 02 (OIL INJECTION PUMP) OIL INJECTION PUMP 2 All Models Except XP Loctite 242 6 N•m 2 (53 lbf•in) 4 Twin Carbs Single Carb 1 6 N•m (53 lbf•in) 6 Loctite 242 1 3 2 10 N•m (89 lbf•in) Loctite 242 5 6 N•m (53 lbf•in) 6 6 N•m (53 lbf•in) 8 N•m (71 lbf•in) 4 4.5 N•m (40 lbf•in) Loctite 242 8 N•m (71 lbf•in) 5 N•m (44 lbf•in) F01G0DS PARTS www.SeaDooManuals.
PAGE 141
Section 07 LUBRIFICATION SYSTEM Sub-Section 02 (OIL INJECTION PUMP) XP Model 6 N•m (53 lbf•in) 11 9 8 10 4.5 N•m (40 lbf•in) 4.5 N•m (40 lbf•in) Loctite 242 7 4.5 N•m (40 lbf•in) F01G0TS 07-02-2 PARTS www.SeaDooManuals.
PAGE 142
Section 07 LUBRIFICATION SYSTEM Sub-Section 02 (OIL INJECTION PUMP) REMOVAL CLEANING All Models Except XP Remove air intake silencer (refer to FUEL SYSTEM 06-02). Remove rotary valve cover (refer to ENGINE 0405). Remove 6 Allen screws retaining intake manifold to rotary valve cover. Separate intake manifold from rotary valve cover. Discard all seals and O-rings. Clean metal components in a solvent.
PAGE 143
Section 07 LUBRIFICATION SYSTEM Sub-Section 02 (OIL INJECTION PUMP) 587 and 717 Engines 1 2 F01D4RC A TYPICAL A. 10 N•m (89 lbf•in) 3 F01D4RE TYPICAL 1. Jam nut 2. Adjustment nut 3. Aligned marks XP Model Only 8,9,10,11, Screw, Flat Washer, Pump and Shaft Install shaft in crankshaft end. Install pump. Secure with flat washers and screws. Torque to 3 N•m (26 lbf•in). Install oil injection pump cable.
PAGE 144
Section 07 LUBRIFICATION SYSTEM Sub-Section 02 (OIL INJECTION PUMP) 787 Engine Final Synchronization Eliminate throttle cable free-play by depressing throttle lever until a slight resistance is felt. In this position, marks on pump body and lever must align. NOTE : A mirror may be used to facilitate this verification. If necessary, turn cable adjustment screw to obtain pump mark alignment. Refer to above illustrations. Tighten jam nut and recheck alignment marks.
PAGE 145
Section 07 LUBRIFICATION SYSTEM Sub-Section 02 (OIL INJECTION PUMP) Bench Test The oil pump must be removed out of watercraft. Connect a hose filled with injection oil to main line fitting. Insert other hose end in an injection oil container. Using a counterclockwise (reverse position) rotating drill rotate pump shaft. Oil must drip from fittings in parts of rotary valve cover while holding lever in a fully open position.
PAGE 146
Section 08 ELECTRICAL SYSTEM Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENTS MAGNETO SYSTEM ............................................................................................................... 587 AND 717 ENGINES ....................................................................................................... 787 ENGINE ......................................................................................................................... GENERAL .....................................
PAGE 147
Section 08 ELECTRICAL SYSTEM Sub-Section 01 (MAGNETO SYSTEM) MAGNETO SYSTEM 1 587 and 717 Engines 11 12 5 N•m (44 lbf•in) 13 9 N•m (80 lbf•in) Loctite 242 8 6 Loctite 242 4 7 6 N•m (53 lbf•in) Loctite 242 6 N•m (53 lbf•in) 5 Loctite 242 3 14 Loctite 242 9 6 N•m (53 lbf•in) 1 4 Loctite 648 10 15 145 N•m (107 lbf•ft) Anti-seize lubricant F01D4WS PARTS www.SeaDooManuals.
PAGE 148
Section 08 ELECTRICAL SYSTEM Sub-Section 01 (MAGNETO SYSTEM) 787 Engine 7 10 Loctite 242 9 Lithium grease 10 N•m (88 lbf•in) 8 4 Loctite 648 10 N•m 11 (88 lbf•in) Loctite 648 Loctite 242 5 105 N•m 6 (77 lbf•ft) 4.5 N•m (40 lbf•in) 16 13 10 N•m (88 lbf•in) 10 N•m (88 lbf•in) 15 14 2 9 N•m (80 lbf•in) 12 Anti-seize lubricant 3 1 Synthetic grease F01D7TS 08-01-2 PARTS www.SeaDooManuals.
PAGE 149
Section 08 ELECTRICAL SYSTEM Sub-Section 01 (MAGNETO SYSTEM) GENERAL The following procedures can be performed without removing engine from watercraft. However, battery removal will be required (except for the XP and HX). 1 REMOVAL 587 and 717 Engines 1,2, Magneto Housing Cover and Screw Remove screws, wire support and spark plug grounding device then withdraw cover.
PAGE 150
Section 08 ELECTRICAL SYSTEM Sub-Section 01 (MAGNETO SYSTEM) Engine Crankcase Replacement A00C1AA Fully thread on puller in puller plate. Tighten puller bolt and at the same time, tap on bolt head using a hammer to release MAG flywheel from its taper. 587 and 717 Engines Since replacement crankcases do not have timing mark for armature plate location, indexing marks should be made on armature plate and crankcase to ease reassembly and further ignition timing.
PAGE 151
Section 08 ELECTRICAL SYSTEM Sub-Section 01 (MAGNETO SYSTEM) The new mark on crankcase will be used for further assembly positioning as a pre-timing position. 1 2 1 F01D4GA F01D4EA TYPICAL 1. For further assembly, use these marks TYPICAL 1. Lug end of crankcase 2. Align mark and lug end here 787 Engine – Find manufacturer’s mark on armature plate. In line with this mark, punch another mark on adjacent crankcase lug. 1,2, Magneto Housing Cover and Screw Remove engine magneto cover.
PAGE 152
Section 08 ELECTRICAL SYSTEM Sub-Section 01 (MAGNETO SYSTEM) If desired, magneto rotor can be removed without the engine flywheel. Remove the 6 screws. : Clean coils and magnets us- CAUTION ing only a clean cloth. Clean crankshaft taper and threads. DISASSEMBLY 587 and 717 Engines 3,10, MAG Flywheel and Ring Gear Lay MAG flywheel on a steel plate. Tap lightly on ring gear using a hammer to release it from MAG flywheel. 1 F01D7XA 1 1.
PAGE 153
Section 08 ELECTRICAL SYSTEM Sub-Section 01 (MAGNETO SYSTEM) – Remove screws. – Uncrimp and unsolder BLACK / RED wire from coil. – BLACK wires from coil. — Uncrimp and unsolder ground wire (BLACK) from coil core. 1 1 A25E0SA A25E0QA 2 1. .Uncrimp and unsolder ground wire (BLACK) here 2. Uncrimp and unsolder YELLOW and YELLOW / BLACK wires here 1.
PAGE 154
Section 08 ELECTRICAL SYSTEM Sub-Section 01 (MAGNETO SYSTEM) 420 8769 22 F01D3BA A25E0RD 1 1. Magneto coil centering tool (P / N 290 876 922) 1. Teeth chamfer : Before reinstalling the magne- CAUTION to, remove the loose epoxy from harness. NOTE : Ensure that ring gear contacts MAG flywheel flange. Whenever replacing either ring gear or MAG flywheel, Gun Kote must be applied to prevent possible corrosion. CAUTION : Always assemble MAG flywheel and ring gear prior to apply Gun Kote.
PAGE 155
Section 08 ELECTRICAL SYSTEM Sub-Section 01 (MAGNETO SYSTEM) 4,5, Armature Plate and Screw Position the armature plate on the crankcase, aligning the marks on both parts. Apply a drop of Loctite 242 (blue) on screw threads and torque to 6 N•m (53 lbf•in). 3,14,15, Magneto Flywheel, Woodruff Key and Nut Apply Loctite 242 (blue) on crankshaft taper. Position Woodruff key and magneto flywheel. Apply Loctite 242 (blue) on nut threads. Install nut with lock washer and torque to 145 N•m (107 lbf•ft).
PAGE 156
Section 08 ELECTRICAL SYSTEM Sub-Section 01 (MAGNETO SYSTEM) : Never use any type of impact - CAUTION wrench at magneto installation. All Engines 1,2, Magneto Housing Cover and Screw Properly install O-ring in magneto housing. Apply Loctite 767 Anti-seize on screw threads, install cover, wire support and spark plug grounding device (587 and 717 engines) then torque screws in a criss-cross sequence to 9 N•m (80 lbf•in). 08-01-10 www.SeaDooManuals.
PAGE 157
Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) IGNITION SYSTEM 2 GENERAL Ignition Coil 587 and 717 Engines The Capacitor Discharge Ignition system includes the following components : It receives its energy from the generating coil via a BLACK / RED wire. The generating coil allows a current flow through ignition coil with its integrated CDI module and through primary windings. Ignition coil induces voltage to a high level in secondary windings to produce a spark at spark plug.
PAGE 158
Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) 787 Engine The 787 engine has a digital DC-CDI (Direct Current-Capacitor Discharge Ignition) system. The high amperage / voltage components are located into a rear electrical box (next to the battery). The other components are located in the conventional electrical box. The ignition system includes the following components : 1 2 3 4 6 3 1 5 1 N N 2 2 S S A00E4JA 1. 2. 3. 4. 5. 6.
PAGE 159
Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) WIRE WH/GY FUNCTION Communication for DESS lanyard TA Power to the monitoring beeper and sensor PU Power BK/YL Safety lanyard switch (DESS) YL/RE Start/stop witch (handlebar) WH/BL Data transfer (low voltage) GY/WH RPM data to MPEM BK Ground between CDI and MPEM BK External ground BK Ground for safety lanyard YL/RE Starter relay RE/PU Power to instrument (oil/fuel/etc.
PAGE 160
Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) Static Test 1 All Engines 1. Disconnect MAG side spark plug wire and connect wire to grounding device then remove spark plug. 2. Remove PTO flywheel guard. 587 and 717 Engines 3. Install timing mark pointer tool on engine using wing nuts previously removed. F01H5TA TYPICAL 1. TDC gauge on MAG side 80 70 60 1 30 1. Timing mark pointer tool (P / N 295 000 102) 40 20 50 1 10 F01H5SA 0 90 5.
PAGE 161
Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) ENGINE IGNITION TIMING (BTDC) 587 2.41 mm (.095 in) 717 2.59 mm (.102 in) 787 3.38 mm (.133 in) 1. Connect timing light pick-up to MAG side spark plug wire. 2. Connect an induction-type tachometer (P / N 295 000 100) to spark plug wire. 7. Scribe a thin mark on PTO flywheel in the middle of tool slot (587 and 717 engines) or aligned with timing mark pointer tool (787 engine). F01H5SB 1 2 TYPICAL 1. Tool slot 2.
PAGE 162
Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) 3. Start engine and point timing light straight in line with timing tool slot. Bring engine to 6000 RPM . 00 60 Ignition Timing Adjustment 587 and 717 Engines Remove battery (except HX). Remove magneto housing cover and grounding device. For removaI of magneto, refer to ELECTRICAL SYSTEM 08-01. Timing is performed by moving armature plate ; clockwise to retard spark occurrence or counterclockwise to advance. 1 1 F01H2IA TYPICAL 1.
PAGE 163
Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) 1 1 1 A25E0VA F01H5VA 1 1. Retarded timing TYPICAL 1. Retaining screw Example 1 When PTO flywheel mark is on right side of timing tool slot, it indicates advanced timing. In this case, turn armature plate counterclockwise when facing it. After adjustment, tighten armature plate retaining screws. CAUTION : Armature plate screws must have Loctite 242 (blue) applied before tightening. Make sure armature plate screws are well secured.
PAGE 164
Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) The timing mark refer to the physical component position when the spark must occur. The DC-CDI module must be synchronized with the mark. For instance, on a particular engine, the timing correction may need to be advanced to 2° so that the mark aligns with timing mark pointer tool. This is not the real spark advance, just a correction for the tolerances of the mechanical components.
PAGE 165
Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) 10. Press 8 to choose Save + Quit (even if item no. 8 is not visible on the display, it is active when you select it). 11. Press Enter to confirm yes you want to save modifications to the MPEM. 12. You must see Operation successful . This confirms that the new timing has been stored in the MPEM. 13. Unplug communication cable from safety lanyard switch on craft. 14. .Press Off to close the programmer.
PAGE 166
Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) SAFETY PRECAUTIONS WARNING : To prevent powerful electric shocks while cranking engine, neither touch any electronic ignition components (ignition coil, high tension wires, etc.) nor tester lead clips. Also make sure that tester leads do not touch any metallic object. Ventilate bilge at least two minutes prior to performing any test. ; IGNITION SYSTEM TESTING PROCEDURE Delay Timer Verification The timer is integrated into the MPEM.
PAGE 167
Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) Most of circuit can be tested with an ohmmeter but a 100 % test doesn’t mean the MPEM is in perfect condition. CAUTION : Whenever connecting MPEM, always have battery disconnected from circuit. If MPEM must be connected when circuit is activated, always connect BLACK / RED wire first to ignition coil / CDI module to prevent wire from touching solenoid positive terminal.
PAGE 168
Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) 5. Measure resistance; it should be between 190300 ohms. F01H5XA 1. 2. 3. 4. 1 3 4 2 Bombardier ignition tester Four-pin magneto harness adapter Probe ‘’N’’ to RED / BLUE wire Probe ‘’P’’ to BLACK wire F01H5YA 1. 2. 3. 4. 7. Crank engine and observe indicator. 8. Push reset button and repeat test twice. 4 3 Multimeter Six-pin magneto harness adapter WHITE wire BLACK / YELLOW wire Results : a.
PAGE 169
Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) DC-CDI Module Verification STATIC TEST : CONTINUITY + Meter Lead - Meter Lead Value RE/PU (male connector) RE <1Ω + Meter Lead - Meter Lead Value RE/PU BK 2.6 kΩ YL/WH BK 0.380 MΩ WH BK 2.208 MΩ RE/PU (male connector) BK (ring terminal) > 20 kΩ BK/OR BK infinity WH/GY BK (ring terminal) > 100 kΩ BK/GR BK infinity BK BK 0.2 Ω TA/BL BK (ring terminal) > 10 kΩ WH/BL BK 30.38 kΩ PU/WH BK RE/PU 2.
PAGE 170
Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) Ignition Coil Verification STATIC TEST NOTE : An ignition coil with good resistance measurement can still be faulty. Voltage leak can occur at high voltage level which is not detectable with an ohmmeter. 1. Install the test adapter to spark plug cable close to MAG side spark plug. 2.
PAGE 171
Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) 787 Engine Only As an alternate method, use KOWA ignition coil tester (or equivalent), available from after market tool / equipment suppliers. CAUTION : Do NOT use coil tester on metal work bench. Follow manufacturer instructions. 1. With ignition coil removed from craft, disconnect spark plug caps from high tension cables. 2. Hook high tension leads from tester to ignition coil high tension cables. 3.
PAGE 172
Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) Fouling 1 Fouling of the spark plug is indicated by irregular running of the engine, decreased engine speed due to misfiring, reduced performance, and increased fuel consumption. This is due to a loss of compression. Other possible causes are : prolonged idling, or running on a too rich mixture due to a faulty carburetor adjustment or incorrect fuel.
PAGE 173
Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) Spark Plug Symbol Explanation WIDE GAP SUFFIX PREFIX 15 B P 5 E S Thread diameter Heat rating numbers A : 18 mm 2 B : 14 mm C : 10 mm D : 12 mm E : 8 mm mm x 19 mm J : 12 Reach mm E : 19 (3/4") A : Special Design F : Taper Seat Ground B : Single Special Alloy mm H : 12.7 (1/2") Ground C : Dual Special Alloy 4 5 G : Racing Type mm L : 11.2 (7/16") Z: 6 Construction M: Firing end construction Reach Hot 10 : 1.0 mm (.
PAGE 174
Section 08 ELECTRICAL SYSTEM Sub-Section 03 (CHARGING SYSTEM) CHARGING SYSTEM GENERAL Magneto The purpose of the charging system is to keep the battery at a full state of charge. The magneto is the primary source of electrical energy. It transforms magnetic field into electric current (AC). 3 The rectifier / regulator is often 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.
PAGE 175
Section 08 ELECTRICAL SYSTEM Sub-Section 03 (CHARGING SYSTEM) NOTE : If it is continually necessary to add distilled water to the battery, this indicates an over voltage situation, requiring replacement of the rectifier / regulator. If, on the other hand, the battery will not stay charged, the problem can be any of the charging circuit components. If these all check good, you would be accurate in assuming the problem to be in the rectifier / regulator. 2.
PAGE 176
Section 08 ELECTRICAL SYSTEM Sub-Section 03 (CHARGING SYSTEM) 3. Check resistance between two of the YELLOW wires. The resistance should be between 0.1 1.0 ohm. 3 4 3 1 1 F01H60A F01H5ZA 3 1. 2. 3. 4. 2 1. Multimeter 2. Magneto harness adapter 3. YELLOW wires 4. Place either meter lead into the remaining YELLOW wire and note the resistance (same as step no. 3). If the readings are out of specification, the stator will need to be replaced. STATIC TEST : INSULATION 1.
PAGE 177
Section 08 ELECTRICAL SYSTEM Sub-Section 03 (CHARGING SYSTEM) BATTERY Cleaning Clean the battery casing, caps, cables and battery posts using a solution of baking soda and water. CAUTION : Do not allow cleaning solution to enter battery. Remove corrosion from battery cable terminals and battery posts using a firm wire brush. Rinse with clear water and dry well. Troubleshooting - SYMPTOM : DISCHARGED OR WEAK BATTERY CAUSE REMEDY 1. Battery posts and/ or cable terminal oxidized.
PAGE 178
Section 08 ELECTRICAL SYSTEM Sub-Section 03 (CHARGING SYSTEM) This chart will be useful to find the correct reading. ELECTROLYTE TEMPERATURE °C °F 38 32 27 100 90 80 21 70 16 10 4 –1 60 50 40 30 OPERATION TO PERFORM During the storage period, recheck electrolyte level and specific gravity readings at least every month. If necessary, keep the battery at its upper level line and near full charge as possible (trickle charge). Activation of a New Battery .012 .008 .
PAGE 179
Section 08 ELECTRICAL SYSTEM Sub-Section 03 (CHARGING SYSTEM) 3. Allow the battery to stand for 30 minutes MINIMUM so that electrolyte soak through battery cells. : If charging rate raises higher - CAUTION than 2.4 A reduce it immediately. If cell temperature rises higher than 50°C (122°F) or if the casing feels hot, discontinue charging temporarily or reduce the charging rate. WARNING : Always charge in a well ventilated area. Keep battery away from cigarettes or open flames.
PAGE 180
Section 08 ELECTRICAL SYSTEM Sub-Section 03 (CHARGING SYSTEM) 10.Reinstall battery. Hook up battery cables observing correct polarity and coat terminals with dielectric grease. Install vent line. NOTE : A check valve is installed on vent line to prevent water infiltration into battery. CAUTION : Negative battery terminal should always be disconnected FIRST and reconnected LAST. WARNING : Vent line must be free and open. NOTE : It is recommended to verify the battery charge once a month.
PAGE 181
Section 08 ELECTRICAL SYSTEM Sub-Section 03 (CHARGING SYSTEM) – If the charging current is measurable before the end or at the end of about 10 hours, the battery is good and charging should be completed in the normal manner as specified in Activation of a new battery. – It is recommended that any battery recharged by this procedure be load tested prior to returning it to service. Battery Charging Equipment The battery charger should have an adjustable charging rate.
PAGE 182
Section 08 ELECTRICAL SYSTEM Sub-Section 04 (STARTING SYSTEM) STARTING SYSTEM 6 4 8 7 9 10 11 12 1 2 3 13 5 4 5 N•m (44 lbf•in) Dielectric grease 15 16 Loctite 271 Ground cable Dielectric grease F01H1MT 17 14 22 N•m (16 lbf•ft) PARTS www.SeaDooManuals.
PAGE 183
Section 08 ELECTRICAL SYSTEM Sub-Section 04 (STARTING SYSTEM) GENERAL Solenoid Causes of troubles are not necessarily related to starter but may be due to a burnt fuse, faulty battery, start /stop switch, safety lanyard switch, solenoid, electrical cables or connections. Check these components before removing starter. Consult also the starting system troubleshooting table on next page for a general view of possible problems.
PAGE 184
Section 08 ELECTRICAL SYSTEM Sub-Section 04 (STARTING SYSTEM) STARTING SYSTEM TROUBLESHOOTING SYMPTOM CAUSE REMEDY Starter does not turn. Burnt fuse 5A. Check wiring condition and replace fuse. Poor contact of battery terminal(s). Clean and tighten terminal(s). Poor battery ground cable connection. Clean and tighten. Weak battery. Recharge or replace battery. Poor contact of start / stop switch, safety lanyard switch or solenoid. Replace.
PAGE 185
Section 08 ELECTRICAL SYSTEM Sub-Section 04 (STARTING SYSTEM) STARTER REMOVAL Disconnect BLACK cable ground connection from battery. WARNING : Always disconnect ground cable first and reconnect last. Disconnect RED cable connection from battery. Remove the following parts. – cables from starter – screw of starter rear support – starter mount screws 1 ; A03E04A 1.
PAGE 186
Section 08 ELECTRICAL SYSTEM Sub-Section 04 (STARTING SYSTEM) Check commutator for roughness, burnt or scored surface. If necessary, turn commutator on a lathe, enough to resurface only. Check commutator for mica depth. If depth is less than 0.20 mm (.008 in), undercut mica. Be sure that no burrs are left and no copper dust remains between segments after undercutting operation is completed. 2 1 1 A03E05A 1. New 2. Wear limit, 8.5 mm (.335 in) Overrunning Clutch F01H0RA 1. Commutator undercut 0.
PAGE 187
Section 08 ELECTRICAL SYSTEM Sub-Section 04 (STARTING SYSTEM) 1 4 1 2 3 F01H0SA A03E0EA 1. 2. 3. 4. Armature shaft Circlip Pinion stop collar Punch 1. Locating protrusion is the higher one 1 1,10, Housing and Yoke Ass’y Align previously traced indexing marks. 1 F01H0TA 1. Brush holder locating notch To ease end frame installation, retain brush holder with a small screwdriver while installing end frame. F01H0QA TYPICAL 1.
PAGE 188
Section 08 ELECTRICAL SYSTEM Sub-Section 04 (STARTING SYSTEM) 15, Nut Connect the RED battery cable to the starter and torque nut to 6 N•m (53 lbf•in). Apply dielectric grease on terminal and nut. 16,17, Screw and Teeth Washer Apply Loctite 271 (red) on screw. Connect BLACK cable to starter using flat washer, teeth washer and screw. Torque screw to 22 N•m (16 lbf•ft). Apply dielectric grease on terminal and screw.
PAGE 189
Section 08 ELECTRICAL SYSTEM Sub-Section 04 (STARTING SYSTEM) STARTER SPECIFICATION Nominal output 0.6 kW Voltage 12 V Rated time 30 seconds Rotation Counterclockwise (viewed from pinion side) Weight Approx. 2 kg (4.4 lb) Performance Specification at 20 °C (68 °F) Battery No load 11.5 V 20 A max. 5500 RPM Load 8.5 V 170 A max. 2200 RPM Stall 5V 350 A max. 0 RPM 19 Ah 08-04-8 www.SeaDooManuals.
PAGE 190
Section 08 ELECTRICAL SYSTEM Sub-Section 05 (INSTRUMENTS AND ACCESSORIES) INSTRUMENTS AND ACCESSORIES GENERAL 5 1 It is possible to activate the fuel gauge / low oil warning light, multifunction gauge or VTS gauge when the engine is not running. Make sure the safety lanyard is removed, then depress the start / stop button. The gauge(s) will be activated during 33 seconds : the time the delay timer of the MPEM will stay on.
PAGE 191
Section 08 ELECTRICAL SYSTEM Sub-Section 05 (INSTRUMENTS AND ACCESSORIES) – Adjust potentiometer to the resistance values as per following chart to test accuracy of gauge. NOTE : Gauge must be activated to obtain a reading. RESISTANCE (Ω) FUEL LEVEL LCD GRAPHIC LOW FUEL LEVEL RED LIGHT 0 ± 2.2 0 FULL OFF 17.8 ± 2.2 7/8 OFF 27.8 ± 2.2 3/4 OFF 37.8 ± 2.2 5/8 OFF 47.8 ± 2.2 1/2 OFF 57.8 ± 2.2 3/8 OFF 67.8 ± 2.2 1/4 OFF 77.8 ± 2.2 1/8 ON 89.0 ± 2.
PAGE 192
Section 08 ELECTRICAL SYSTEM Sub-Section 05 (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. FUEL LEVEL AND RESISTANCE (SPI, SPX, XP) FUEL LEVEL (mm) RESISTANCE (Ω) From 206.1 ± 5 and more 0 ± 2.2 0 From 189.1 @ 206 ± 5 17.8 ± 2.2 From 162.1 @ 189 ± 5 27.8 ± 2.2 From 135.1 @ 162 ± 5 37.8 ± 2.2 From 108.1 @ 135 ± 5 47.8 ± 2.2 From 81.
PAGE 193
Section 08 ELECTRICAL SYSTEM Sub-Section 05 (INSTRUMENTS AND ACCESSORIES) NOTE : This sensor turns the low-level oil light to ON if the connector has been forgotten unconnected even when there is enough oil in tank. Speed Sensor The speedometer gives a reading through a speed sensor. Speed sensor is installed on ride shoe. 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 speedometer.
PAGE 194
Section 08 ELECTRICAL SYSTEM Sub-Section 05 (INSTRUMENTS AND ACCESSORIES) VTS Motor Always confirm first that the fuse is in good condition. Motor condition can be checked with an ohmmeter. Install test probes on both BLUE / ORANGE and GREEN / ORANGE wires. Measure resistance, it should be close to 1.5 ohm. If motor seems to jam and it has not reached the end of its stroke, the following test could be performed. First remove motor, refer to PROPULSION SYSTEM 09-04.
PAGE 195
Section 08 ELECTRICAL SYSTEM Sub-Section 06 (DIGITALLY ENCODED SECURITY SYSTEM) DIGITALLY ENCODED SECURITY SYSTEM 6 GENERAL The Digitally Encoded Security System (DESS) features an anti-start protection against unauthorized use of the watercraft. The following components are specially designed for this system : Multi-Purpose Electronic Module (MPEM), safety lanyard cap and safety lanyard switch. The safety lanyard cap has a magnet and a ROM chip. The chip has a unique digital code.
PAGE 196
Section 08 ELECTRICAL SYSTEM Sub-Section 06 (DIGITALLY ENCODED SECURITY SYSTEM) Basic Self-Diagnostic Mode It is self-activated when the safety lanyard is being installed on the watercraft switch. It gives immediate monitoring. Some codes may occur only when pressing the start / stop button. Refer to the following chart. SIGNAL CAUSE REMEDY 2 short beeps (while installing safety lanyard on watercraft switch) • Everything is correct with the safety lanyard (good contact and right lanyard cap).
PAGE 197
Section 08 ELECTRICAL SYSTEM Sub-Section 06 (DIGITALLY ENCODED SECURITY SYSTEM) Advanced Self-Diagnostic Mode It needs to be enabled manually. Proceed as follows : 1. Remove safety lanyard 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. Install safety lanyard on watercraft switch. 4. Press the watercraft start / stop button again.
PAGE 198
Section 09 PROPULSION SYSTEM Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENTS JET PUMP ................................................................................................................................ ALUMINUM PUMP.............................................................................................................. PLASTIC PUMP.................................................................................................................... GENERAL ..............................
PAGE 199
Section 09 PROPULSION SYSTEM Sub-Section 00 (TABLE OF CONTENTS) VARIABLE TRIM SYSTEM ....................................................................................................... SPI AND HX MODELS.......................................................................................................... REMOVAL ............................................................................................................................. DISASSEMBLY ....................................................
PAGE 200
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) JET PUMP 1 ALUMINUM PUMP Loctite 598 Ultra Black 12 Loctite 242 28 15 8 N•m 27 (71 lbf•in) 14 70 N•m (52 lbf•ft) 19 20 Loctite 242 10 N•m (88 lbf•in) 13 4.
PAGE 201
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) PLASTIC PUMP Loctite 598 Ultra Black Loctite 242 28 15 12 27 8 N•m (71 lbf•in) 14 19 70 N•m (52 lbf•ft) 10 N•m (88 lbf•in) 13 20 Loctite 518 Loctite PST 16 22 21 Loctite 242 16 Loctite PST 11 Loctite 242 4 N•m (35 lbf•in) 15 N•m (11 lbf•ft) 35 N•m 6 (26 lbf•ft) Loctite 271 (If required) 22 24 25 Loctite 271 23 8 GTI Loctite 242 3 Loctite 518 Loctite 518 26 1 20 N•m (15 lbf•ft) 3 N•m (27 lbf•in) Loctite PST 4 2 17 Loctite 242
PAGE 202
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) GENERAL The impeller housing, venturi and nozzle are either made of aluminum or plastic, depending on which model of watercraft. Plastic is a light weight material and it is not affected by corrosion. All watercraft powered by a 717 or 787 engines have a stator made of bronze which offers greater strength than aluminum. 1 JET PUMP INSPECTION ON WATERCRAFT To work on watercraft, securely install it on a stand.
PAGE 203
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) Oil Check 1 Remove housing cover plug. F01J0EA F01J5IA MEASURING FROM WATER INLET SIDE 1. Feeler gauge F01J0FA 1 TYPICAL 1. Remove plug Check oil level, it should be at bottom of hole threads. If oil level is low, check impeller shaft housing for leaks. A pressure test must be performed. Refer to PUMP PRESSURIZATION in this section. To check oil condition, insert a wire through oil level hole then withdraw.
PAGE 204
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) Pour approximately 90 mL (3 oz) of oil through hole until oil reaches the bottom of hole threads. Use SEA-DOO JET PUMP SYNTHETIC OIL (P / N 293 600 011) only. Oil will drain slowly into center area of housing, wait a few minutes and readjust oil level. CAUTION : This is a synthetic oil. Do not mix with mineral based oil. Do not mix oil brands. Apply Loctite PST 592 on plug and reinstall it on cover. Properly reinstall removed parts.
PAGE 205
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) SP, GTS and GTI Models 1,2,4,5, Screw, Sleeve, Locking Disk and Nozzle Remove 2 retaining screws, 2 sleeves, 4 locking disks and withdraw nozzle. 3 F01I0CA 1 2 2 1 1. Floating seal 2. O-ring Disconnect engine water inlet hose and both bailer pick-up tubes from impeller housing. 1 F01J3BE 3 2 TYPICAL 1. Screw 2. Locking disks 3.
PAGE 206
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) 6,7, Nut and Impeller Housing 1 Remove nuts retaining impeller housing to hull. Using screws previously removed from nozzle, install impeller housing remover tool (P / N 295 000 113) on venturi. NOTE : It may be possible to remove jet pump without using puller. 2 1 F01J0OA TYPICAL 1. Ride shoe screws 2. Intake grate screws Using a low height hydraulic bottle jack and two steel plates, pry out ride shoe.
PAGE 207
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) JET PUMP SUPPORT REMOVAL HX Model Only Remove ball joint, boot, nut, half rings and O-rings from steering cable. F05D04A F05K02A Remove nuts, lock washers and flat washers retaining jet pump support. Using a heat gun, heat jet pump support until it is possible to pull it off. 1 1. Unscrew nut JET PUMP DISASSEMBLY Disconnect water supply and water return hoses, drain hose and bailer hoses.
PAGE 208
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) 14,15, Boot and Ring Pull out ring from boot 1 1 F01J0SA 1. Hold raised with drive shaft while striking F01J09A 16, Fitting 1. Pull out ring Insert a screwdriver blade between impeller and boot flange. Carefully pry boot all around to release from impeller. 1 Fittings can be removed with deep socket or vise grip. Do not contact hose mounting area.
PAGE 209
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) 17,18, Housing Cover and Screw 20, Wear Ring With pump assembly in horizontal position, remove 3 retaining screws of housing cover. Place container under cover to catch oil. Using a fiber hammer, gently tap cover to release it from impeller housing. Place impeller housing in a vise with soft jaws. It is best to clamp housing using a lower ear. Cut wear ring at two places.
PAGE 210
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) 21, Seal To remove seal, proceed as follows : CAUTION : It is not recommended to push seal out with a punch. Housing and / or bearing(s) could be damaged. Seal should be removed using the following suggested tool. Seal puller, Snap-on no. S6129. - Close puller claws so that they can be inserted between seal and bearing. Holding claws, turn puller shaft clockwise so that claws open and tighten against seal.
PAGE 211
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) 22, Needle Bearing CLEANING NOTE : It is always recommended to renew both bearings, even if only one bearing needs to be replaced. Bearings can be easily removed with the following suggested driver. Use a 30 mm dia. x 345 mm (1-1/8 dia. x 13-1/2 in) long steel shaft. Machine shaft as per the following drawing. Sealant can be removed with a wire brush (disc) mounted on a drill or a scraper. Properly clean all threads.
PAGE 212
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) 1 1 F01J16A F02J0VA 1. Replaced if blunted round or damaged 1. Stamped part number Check impeller for cavitation damage, deep scratches or any other damage. WATERCRAFT MODEL IMPELLER MATERIAL P/N PITCH SP 271 000 016 Aluminium 18.
PAGE 213
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) 20, Wear Ring Check wear ring for deep scratches, irregular surface or any apparent damage. If impeller / wear ring clearance is too large and impeller is in good shape, renew wear ring. To check both bearings, proceed the same way with other shaft end. Position gauge tip on diameter, close to flats on shaft. 1 22,23, Needle Bearing and Impeller Shaft Wear Inspect needle bearings and their contact surface.
PAGE 214
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) 24,25, Thrust Washer and Thrust Bearing Visually inspect thrust washer, thrust bearing and their contact surface. Check for scoring, pitting, flaking, discoloration or other evidence of wear. For best inspection, use a 7X magnifying glass to check wear pattern. 1 2 3 1 F01J2SA 1. Tip on shaft end Excessive play comes from worn end stop inside housing cover and wear of impeller shaft nose. Visually inspect end stop inside cover.
PAGE 215
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) 1 F01J53A 2 1 1. Impeller shaft nose F01J5DA 21, Seal Carefully inspect seal lips. Make sure that lips are not worn, distorted, cracked or show signs of any other damage. Renew as necessary. JET PUMP ASSEMBLY 20, Wear Ring The wear ring features a lip on one edge ; position lip outwards of housing. NOTE : To ease insertion into housing, apply BOMBARDIER LUBE lubricant (P / N 293 600 016) onto outside circumference of wear ring.
PAGE 216
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) 21,22, Seal and Needle Bearing Bearings and seal will be properly installed in housing using bearing / seal installer tool (P / N 295 000 107). 1 1 2 F01J4KA BEARING / SEAL INSTALLER TOOL 1. Seal side 2. Bearing side F01J1IA Stamped end of bearings (showing identification markings) must be located toward outside of housing. Properly insert bearing on tool. Using an arbor press only, push tool until tool flange contacts housing.
PAGE 217
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) Apply Loctite 518 (P / N 293 800 038) to seal housing, all around outer diameter and on seal seat. Properly insert seal on tool. NOTE : It is important when installing seals to pack seal lip with grease before inserting bearing / seal installer tool. Properly insert tool in seal with a rotating movement. 1 2 F01J1MA 1. Loctite 518 all around and behind 2.
PAGE 218
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) To prevent seal lip damage when inserting impeller shaft, use impeller shaft guide (P / N 295 000 002). 1 F01J1OA Insert tool onto shaft end then carefully slide housing over shaft. F01J1Q A 1. Apply Loctite 271 (red) on threads 1 2 Using 2 screws previously removed from venturi, secure impeller shaft holder tool to housing. Install shaft holder tool in a vice. To ease impeller installation, apply BOMBARDIER LUBE lubricant on wear ring.
PAGE 219
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) : This is a synthetic oil. Do not - CAUTION mix with mineral based oil. Do not mix oil 1 brands. NOTE : When filling reservoir, oil must be poured into cover quite slowly to allow complete housing fill. 1 2 F01J2HA 1. Impeller remover / installer tool 2. Impeller shaft holder tool 17,26, Housing Cover and O-ring Install O-ring to cover. Apply Loctite 518 on Oring.
PAGE 220
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) Aluminum Impeller Housing Apply Loctite 242 (blue) on screw threads. Install screws and washers then torque to 25 N•m (18 lbf•ft) in a criss-cross sequence. 14,15,19, Boot, Ring and Impeller Apply synthetic grease (P / N 293 550 010) on impeller splines. Insert a new boot and ring to impeller. 1 1 F01J4ZB F01J1UA 1. Torque screws to 25 N•m (18 lbf•ft) 1. Insert boot and ring Plastic Impeller Housing Apply Loctite 242 (blue) on screw threads.
PAGE 221
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) F05J05A Installation of support is essentially the reverse of removal procedure. F01J2IA – Pump must maintain this pressure for at least 10 minutes. CAUTION : Repair any leak, failure to correct a leak will lead to premature wear of pump components. –NOTE : If there is a pressure drop spray soapy water around housing cover.
PAGE 222
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) Miscellaneous Generously apply synthetic grease on drive shaft splines. Make sure rubber damper is on drive shaft ends. Apply Loctite 598 Ultra Black around bailer and water inlet supply fittings. 1 1 F05J06A HX MODEL 1. Apply Loctite 598 Ultra Black as indicated by shaded area Carefully install ride shoe on hull. Apply Loctite 242 (blue) on screw threads, install and tighten in a criss-cross sequence. Torque to 10 N•m (88 lbf•in).
PAGE 223
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) Apply Loctite 242 (blue) on stud threads of jet pump housing. Install flat washers, lock washers and nuts. Tighten nuts of impeller housing in a criss-cross sequence and torque to 35 N•m (26 lbf•ft). Push the floating ring to compress the protective hose. Insert the O-ring in the drive shaft groove. 2 1 F01I0DA 1. O-ring 2. Floating ring Position the floating ring between the carbon ring and the PTO flywheel boot.
PAGE 224
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) 1 1 2 2 F01J0IA 1 1. Bailer tubes 2. Water inlet hose F01J3BA Secure flywheel guard to engine studs using 1 nut and 1 washer on each side of guard. Reinstall air vent tube support onto body (SP / XP series). TYPICAL 1. Locking disks 2. Torque to 20 N•m (15 lbf•ft) HX Model Only Make sure rear drive shaft is properly installed. Install jet pump. If necessary, wiggle jet pump to engage drive shaft splines in impeller.
PAGE 225
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) Steering Cable Secure ball joint of steering cable. 1 F02J02C 2 1 TYPICAL - PLASTIC NOZZLE 1. Torque nut of steering cable ball joint to 7 N•m (62 lbf•in) 2. Torque nut of reverse cable ball joint to 7 N•m (62 lbf•in) (if applicable) 2 F01J58A TYPICAL 1. Ball joint on top of arm 2. Torque nut to 7 N•m (62 lbf•in) HX, SPI, SPX and XP Models 5, Nozzle Trim Systems Install nozzle / trim ring assembly. Torque screws to 14 N•m (10 lbf•ft).
PAGE 226
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) SPI and HX Models Secure support of manual trim. 1 F05J08B 1. Torque nut to 10 N•m (89 lbf•in) All Models NOTE : Ball joint must be parallel. If not, loosen jam nut and adjust ball joint. Torque jam nut to 2.5 N•m (23 lbf•in). Check steering alignment. Refer to STEERING SYSTEM 10-04. Slightly lubricate wear ring with BOMBARDIER LUBE lubricant before starting to minimize friction during initial start. 09-01-27 www.SeaDooManuals.
PAGE 227
Section 09 PROLPUSION SYSTEM Sub-Section 02 (DRIVE SYSTEM) DRIVE SYSTEM 2 All Models Except HX Loctite 271 11 1 2 6 5 18 10 2 N•m (18 lbf•in) 9 2 N•m (18 lbf•in) 8 15 Synthetic grease 3 Loctite 495 Synthetic grease Loctite 495 15 F01I0ES PARTS www.SeaDooManuals.
PAGE 228
Section 09 PROLPUSION SYSTEM Sub-Section 02 (DRIVE SYSTEM) HX Model 11 17 16 22 N•m (16 lbf•ft) 7 Loctite 242 17 16 22 N•m (16 lbf•ft) Loctite 242 Loctite 242 22 N•m (16 lbf•ft) 6 5 Loctite 515 Synthetic grease 13 18 2 N•m (18 lbf•in) Loctite 271 14 13 2 N•m (18 lbf•in) Loctite 242 Synthetic grease 10 12 10 N•m (89 lbf•in) 9 Loctite 242 8 4 Loctite 598 Ultra Black 30 N•m (22 lbf•ft) F05I02S 09-02-2 PARTS www.SeaDooManuals.
PAGE 229
Section 09 PROLPUSION SYSTEM Sub-Section 02 (DRIVE SYSTEM) GENERAL Jet pump must be removed to replace any components of the drive system. Refer to PROPULSION SYSTEM 09-01 for jet pump removal procedure. REMOVAL All Models Except the HX 1, Large Clamp Unfasten large clamp of PTO flywheel boot as follows : – Use pliers (P / N 295 000 069). 1 F01J29A TYPICAL 1. Locking hooks 2, Small Clamp Unfasten small clamp of PTO flywheel boot as follows : Use pliers (P / N 295 000 054).
PAGE 230
Section 09 PROLPUSION SYSTEM Sub-Section 02 (DRIVE SYSTEM) 3, Drive Shaft 1 If the drive shaft is jammed into PTO flywheel, make the following tool and use it in conjunction with impeller housing remover (P / N 295 000 113) to withdraw drive shaft. 2 Raw Material : – 1 aluminum alloy square of 51 mm (2 in) x 305 mm (12 in). – 2 aluminum rods of 28.5 mm (1-1/8 in) dia. x 30 mm (1-3/16 in). F01I06A 1 2 J TYPICAL 1. Impeller housing remover 2. Drive shaft puller 3.
PAGE 231
Section 09 PROLPUSION SYSTEM Sub-Section 02 (DRIVE SYSTEM) 7, Front Drive Shaft 11, PTO Flywheel Remove bolt, lock nut and sleeve from support. Remove magneto housing cover. Refer to ELECTRICAL SYSTEM 08-01. 3 2 All Models Except XP To remove PTO flywheel, magneto is locked with puller plate (P / N 290 876 080), sleeves (P / N 290 847 220) and extension handle (P / N 295 000 111). 1 2 F05I04A 3 1 1. Bolt 2. Lock nut 3. Sleeve 4 F01D47A Remove front drive shaft. 1. Screw 2.
PAGE 232
Section 09 PROLPUSION SYSTEM Sub-Section 02 (DRIVE SYSTEM) Lock ring gear using special tool (P / N 295 000 134). 1 F01D49A TYPICAL 1. Extension handle locking crankshaft 1. Ring gear blocking tool All Models Except HX PTO flywheel is loosen using PTO flywheel remover (P / N 295 000 001). As an alternate method to remove PTO flywheel when splines are worn out and PTO flywheel remover cannot be used. Use a pipe wrench and install it on PTO flywheel as illustrated.
PAGE 233
Section 09 PROLPUSION SYSTEM Sub-Section 02 (DRIVE SYSTEM) HX Model Only PTO flywheel is loosen using flywheel remover. A B C D F01J11A A. B. C. D. F05I0CA 1 22 mm (.865 in) dia. 28 mm (1.115 in) dia. 90 mm (3-1/2 in) 345 mm (13-1/2 in) Properly support seal carrier when removing seals and bearing. 1. PTO flywheel remover PARTS INSPECTION 3, Drive Shaft Inspect condition of splines. Inspect condition of groove. With your finger nail, feel contact surface of floating ring.
PAGE 234
Section 09 PROLPUSION SYSTEM Sub-Section 02 (DRIVE SYSTEM) Place drive shaft on V-blocks and set-up a dial gauge in center of shaft. Slowly rotate shaft ; difference between highest and lowest dial gauge reading is deflection. Refer to the following illustration. Maximum permissible deflection is 0.5 mm (.020 in). 6, O-ring Check also condition of drive shaft O-ring. Replace as necessary. All Model Except HX 11, PTO Flywheel Inspect spline condition of PTO flywheel.
PAGE 235
Section 09 PROLPUSION SYSTEM Sub-Section 02 (DRIVE SYSTEM) NOTE : Bearing can also be installed with the same driver used at disassembly. Center bearing in longitudinal axis of housing. Push seals until tool comes in contact with housing. 1 F01J2TA F01J1YA 1. Push bearing centered in its housing TYPICAL 13, Seal Install double-lip seal with protector toward impeller side. On both seals, raised edge of lip must be located outwards of seal carrier.
PAGE 236
Section 09 PROLPUSION SYSTEM Sub-Section 02 (DRIVE SYSTEM) Install alignment tool at rear of watercraft. 1 Torque seal carrier nuts to 10 N•m (89 lbf•in) in a criss-cross sequence as per following illustration. NOTE : It is very important to tighten nuts of seal carrier in a criss-cross sequence to maintain its alignment. 2 6 1 3 F01L2RC 4 1. Housing (P / N 295 000 090) 2.
PAGE 237
Section 09 PROLPUSION SYSTEM Sub-Section 02 (DRIVE SYSTEM) 1 1 2 F01J23A PRE-CLAMPING POSITION 1. Holding hook 2. Large window F02J0IA 1. Press to engage hooks in windows – Insert pointed tips of pliers first in closing hooks. NOTE : At installation, clamp tail should be in opposite direction of engine rotation. 1 2 F01J23B 1. Engine rotation (counterclockwise) 2. Tail in opposite direction F01J2BA 1 2, Small Clamp TYPICAL 1.
PAGE 238
Section 09 PROLPUSION SYSTEM Sub-Section 02 (DRIVE SYSTEM) 1 F02J0PB 1. Squeeze plier 09-02-12 www.SeaDooManuals.
PAGE 239
Section 09 PROPULSION SYSTEM Sub-Section 03 (REVERSE SYSTEM) REVERSE SYSTEM 3 GTS and GTI Models 2 5 1 Synthetic grease 6 4 2.5 N•m (22 lbf•in) 8 N•m (71 lbf•in) 3 7 N•m (62 lbf•in) 10 N•m (88 lbf•in) 3 N•m (27 lbf•in) 6 N•m (53 lbf•in) 8 N•m (71 lbf•in) 7 7 N•m (62 lbf•in) 10 N•m (88 lbf•in) 3 N•m (27 lbf•in) Loctite 242 20 N•m (15 lbf•in) Loctite 242 F02J0NS PARTS www.SeaDooManuals.
PAGE 240
Section 09 PROPULSION SYSTEM Sub-Section 03 (REVERSE SYSTEM) GENERAL It is not necessary to remove reverse system from watercraft for servicing. However reverse system removal is necessary to replace reverse support. DISASSEMBLY Remove storage basket from watercraft. Press on vent tube upper part to enable to withdraw tube from body. 2 1 F02J04A TYPICAL 1. Sliding block 2. Spring 1 Withdraw selector lever stem and locking lever from sliding block, then slide off locking lever from stem.
PAGE 241
Section 09 PROPULSION SYSTEM Sub-Section 03 (REVERSE SYSTEM) 7, Reverse Gate Unhook reverse gate springs and remove ball joint fasteners to release reverse cable from reverse gate. 1 3 1 2 F02J06A TYPICAL 1. Reverse support 2. Reverse cable 3. Triangular lever F02J08A 6, Reverse Support In order to have access to screw holding lower part of reverse support, remove front seat by pulling on each side to release it from body. Remove screw, lock nut and washers holding lower part of support.
PAGE 242
Section 09 PROPULSION SYSTEM Sub-Section 03 (REVERSE SYSTEM) : Always hook reverse gate - CAUTION springs in order to ease reverse gate oper- Install sliding block to lever and torque nut to 8 N•m (71 lbf•in). ation. 1,5, Locking Lever and Sliding Block Insert locking lever end in support hole then align lever and sliding block holes. F02J02B 1 1.
PAGE 243
Section 09 PROPULSION SYSTEM Sub-Section 03 (REVERSE SYSTEM) 2, Spring Insert spring in lever stem hole and then install curved end in sliding block groove. Using a square, set it to 129 ± 3 mm (5-5/64 ± 7/ 64 in), then position square end at the top middle of nozzle. 1 A F02J0HA F02J0KA A. 129 ± 3 mm (5-5/64 ± 7/64 in) TYPICAL 1. Sliding block groove Pull selector lever to REVERSE position.
PAGE 244
Section 09 PROPULSION SYSTEM Sub-Section 03 (REVERSE SYSTEM) Tighten adjustment nuts and recheck gate position. Reinstall vent tube. WARNING : Vent tube must be in place to provide proper bilge ventilation. ; 1 F02J0FA 1 1. REVERSE position If reverse gate needs to be readjusted, it can be done at support with adjustment nuts. Turn cable nuts to obtain position. NOTE : If reverse gate adjustment is not done adequately, performance and steering control will be reduced at reverse position. F02L14A 1.
PAGE 245
Section 09 PROPULSION SYSTEM Sub-Section 04 (VARIABLE TRIM SYSTEM) VARIABLE TRIM SYSTEM 4 SPI and HX Models 6 7 8 2 21 N•m (16 lbf•ft) 1 10 Loctite 242 9 13 N•m (10 lbf•ft) 10 N•m 3 (89 lbf•in) Loctite 242 5 Loctite 242 4 13 N•m (10 lbf•ft) Loctite 242 13 N•m (10 lbf•ft) F05J07S PARTS www.SeaDooManuals.
PAGE 246
Section 09 PROPULSION SYSTEM Sub-Section 04 (VARIABLE TRIM SYSTEM) REMOVAL 1,2,3, Screw, Bolt and Lock Nut Loosen venturi screw, bolt and nut retaining support from trim ring. 3 1 2 F05J08A 1. Screw 2. Bolt 3. Lock nut Remove manual trim. 4,5, Trim Ring and Screws To remove trim ring / nozzle assembly from venturi, loosen side screws of trim ring. DISASSEMBLY 6,7,8, Nut, Rubber Washer and Half Bushings Loosen nut from support; then, remove rubber washer and half bushings.
PAGE 247
Section 09 PROPULSION SYSTEM Sub-Section 04 (VARIABLE TRIM SYSTEM) SPX and XP Models 7 12 7 N•m (62 lbf•in) 11 6 8 9 10 5 4 2 6 N•m (53 lbf•in) 3 2 10 N•m (88 lbf•in) 1 13 N•m (10 lbf•ft) 2.5 N•m (23 lbf•in) 13 N•m (10 lbf•ft) Loctite 242 7 N•m (62 lbf•in) Loctite 242 Loctite 242 13 N•m (10 lbf•ft) F01J56S PARTS www.SeaDooManuals.
PAGE 248
Section 09 PROPULSION SYSTEM Sub-Section 04 (VARIABLE TRIM SYSTEM) GENERAL 8, Motor To test VTS control module, motor or switch, refer to ELECTRICAL SYSTEM 08-05. Disconnect wires of motor. Remove retaining nuts. REMOVAL 1 1,2,3, Ball Joint, Boot and Gear Clamp Disconnect ball joint of link rod. Loosen gear clamps of boot. RRemove boot. 4,5, Nut and Seal To loosen nut, use VTS socket tool (P / N 295 000 133). F01J1XA 2 1. Remove nuts 2. Disconnect wires Pull on motor to remove it.
PAGE 249
Section 09 PROPULSION SYSTEM Sub-Section 04 (VARIABLE TRIM SYSTEM) 9, Worm Inspect threads and splines of worm for wear. If worm replacement is necessary, renew also sliding shaft. F01J2GA F01J25A Tighten nuts of motor to 7 N•m (62 Ibf•in). Connect wires of motor. CAUTION : Make sure wire color codes match. Install cover. NOTE : Make sure seal is in place. - 1 1. Inspect threads and splines 2. Nuts ASSEMBLY Assembly is essentially the reverse of disassembly procedures.
PAGE 250
Section 09 PROPULSION SYSTEM Sub-Section 04 (VARIABLE TRIM SYSTEM) 1, Ball Joint Install ball joint on right side of sliding shaft. Torque fasteners to 10 N•m (88 lbf•in). NOTE : Install boot on sliding shaft before securing ball joint. If an adjustment is necessary, loosen jam nut of ball joint at link rod. Turn adjustment nut of ball joint to obtain the desired gap between trim ring and venturi. ADJUSTMENT Push on VTS button up position until motor stops.
PAGE 251
Section 10 STEERING SYSTEM Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENTS SPÞ/ÞXP SERIES ..................................................................................................................... 10-01-1 REMOVAL AND ASSEMBLY ............................................................................................... 10-01-2 GTS AND GTI MODELS .......................................................................................................... 10-02-1 REMOVAL AND ASSEMBLY ..........
PAGE 252
Section 10 STEERING SYSTEM Sub-Section 01 (SP /XP SERIES) SP /XP SERIES 1 Two types of assembly 1 14 N•m (10 lbf•ft) 5 5 6 6 7 4 7 4 6 N•m (53 lbf•in) Loctite 242 12 8 26 N•m (19 lbf•ft) 3 2 8 8 N•m (72 lbf•in) 15 N•m (11 lbf•ft) 14 9 Loctite 242 15 N•m (11 lbf•ft) Synthetic Synthetic grease grease 11 2.5 N•m (23 lbf•in) 10 15 13 7 N•m (63 lbf•in) Loctite 242 13 Only with plastic nozzle 6 N•m (53 lbf•in) Synthetic grease 6 N•m (53 lbf•in) 2.
PAGE 253
Section 10 STEERING SYSTEM Sub-Section 01 (SP /XP SERIES) REMOVAL AND ASSEMBLY 1,2,3, Cover, Screw and Washer 3 5 To replace the cover, just remove and reinstall 4 screws and washers. 1 2 4 F01K1PA 1 1. 2. 3. 4. 5. 2 : Ensure to install flat washer - CAUTION otherwise bolt will damage grip end. F01K0WA Grip insert Grip Flat washer Torque bolt to 14 N•m (10 lbf•ft) Cap TYPE B 1. Screw 2.
PAGE 254
Section 10 STEERING SYSTEM Sub-Section 01 (SP /XP SERIES) : While performing this proce- CAUTION dure, take precautions to avoid damaging throttle cable and wiring harnesses. 1 4 2 5 3 To install handlebar assembly: Installation is essentially the reverse of removal procedures. However, pay particular attention to the following. 6 Lubricate with synthetic grease thrust ring of rear and front supports. F01K1QA 1. 2. 3. 4. 5. 6.
PAGE 255
Section 10 STEERING SYSTEM Sub-Section 01 (SP /XP SERIES) 9,10,11,12, Steering Stem, Arm, Support and Handlebar 1 Install support to steering stem arm. NOTE : Insert lock nuts in support. Screw only a few threads of the bolts. 3 1 2 F01K0AA 2 1. Install handlebar assembly 2. Route throttle cable and wiring harnesses at the same time Push handlebar assembly until steering stem is well seated into steering supports. 1 4 F01K09A TYPICAL 1. Support 2. Steering stem arm 3. Insert lock nuts 4.
PAGE 256
Section 10 STEERING SYSTEM Sub-Section 01 (SP /XP SERIES) 1 3 4 2 5 F01K1NA 1. 2. 3. 4. 5. Steering stem Steering stem arm Support Torque to 6þN•m (53þlbf•in) Integrated flat key must be seated in keyway and steering stem arm locked in place NOTE : Once steering stem arm is properly tightened, look between body and front support to make sure there is no gap between steering stem arm and its support. If there is a gap, components are not properly installed. Connect wiring harnesses.
PAGE 257
Section 10 STEERING SYSTEM Sub-Section 02 (GTS AND GTI MODELS) GTS AND GTI MODELS 2 1 3.5 N•m (30 lbf•in) 4 8 Loctite 242 5 26 N•m (19 lbf•ft) 7 3 2 3.
PAGE 258
Section 10 STEERING SYSTEM Sub-Section 02 (GTS AND GTI MODELS) REMOVAL AND ASSEMBLY 1,2,3, Cover, Screw and Washer To replace the cover, just remove and reinstall 4 screws and washers. Install grip on handlebar matching it to the U form of the handlebar. Apply Loctite 242 (blue) on bolt threads. Install flat washer and bolt; torque to 6 N•m (53 lbf•in). 1 4 5 1 2 2 3 6 F01K1QA 1. 2. 3. 4. 5. 6. F01K0WA 1. Screw 2.
PAGE 259
Section 10 STEERING SYSTEM Sub-Section 02 (GTS AND GTI MODELS) TO INSTALL HANDLEBAR ASSEMBLY : 14, Grommet 2 Insert throttle cable through dashboard hole and slide grommet on cable. Insert grommet in dashboard hole and pull it from inside bilge. NOTE : To ease installation, apply water on grommet. Insert wires of monitoring beeper and start / stop button. 1 3 5 6 15,16,17,18, Spring Washer, Shim, Steering Stem and Support Insert spring washer and the shim onto steering stem.
PAGE 260
Section 10 STEERING SYSTEM Sub-Section 02 (GTS AND GTI MODELS) 24,25,26,27, Nut, Half Ring, Rubber Washer and Retaining Ring From bilge, unscrew nut retaining steering cable to hull. Remove half rings, rubber washer and retaining ring. NOTE : Move selector lever in reverse position to lower reverse gate. It will ease part removal. Remove steering cable from tie-block and clips. Pull out steering cable. Assembly is essentially the reverse of disassembly procedures.
PAGE 261
Section 10 STEERING SYSTEM Sub-Section 03 (HX MODEL) HX MODEL 3 7 5 1 6 6 N•m (53 lbf•in) 4 8 3 2 26 N•m (19 lbf•ft) 7 N•m (62 lbf•in) 7 N•m (62 lbf•in) 3 N•m (27 lbf•in) 15 16 17 6 N•m (53 lbf•in) 6 N•m (53 lbf•in) 18 Synthetic grease 6 N•m (53 lbf•in) 10 Synthetic grease Synthetic grease 12 11 13 7 N•m (62 lbf•in) 6 N•m (53 lbf•in) 15 N•m (11 lbf•ft) 14 19 9 2.5 N•m (22 lbf•in) 10 N•m (89 lbf•in) F05K03S PARTS www.SeaDooManuals.
PAGE 262
Section 10 STEERING SYSTEM Sub-Section 03 (HX MODEL) REMOVAL 11, Retaining Block Remove retaining block of cable support. 1,2,3, Cover, Screw and Washer To remove the cover, just remove 4 screws and washers. 1 2 F01K0WA 1. Screw 2. Thermoplastic cover 1 4,5,6,7,8, Grip, Cap, Bolt, Washer and Grip Insert To remove grip, pull out cap from grip end and remove bolt. Pull out grip. F01K18C 1.
PAGE 263
Section 10 STEERING SYSTEM Sub-Section 03 (HX MODEL) 1 F05L0FA 1 F05K06A 1. Boot 1. Steering stem arm 12,13,14, Steering Support, Bolts and Nuts 12,18,19, Steering Support, Steering Stem and Cable Support Loosen bolts and nuts of steering support. Pull out steering stem from steering support. Remove lever from cable support. 2 STEERING CABLE REMOVAL Disconnect steering cable from lever of steering stem arm. Remove retaining block of cable support.
PAGE 264
Section 10 STEERING SYSTEM Sub-Section 03 (HX MODEL) : Make sure integrated flat ; WARNING keys of steering stem arm and support are properly seated in steering stem keyways. 4 2 1 3 F01K1RA 1 1. Notch inserted in handlebar hole F05K08A 1. 2. 3. 4. 5. Install grip on handlebar matching it to the U form of the handlebar. Apply Loctite 242 (blue) on bolt threads. Install flat washer and bolt ; torque to 6 N•m (53 lbf•in).
PAGE 265
Section 10 STEERING SYSTEM Sub-Section 04 (ALIGNMENT) ALIGNMENT 4 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 near steering stem. Slacken retaining block at cable support. Turn adjustment nut as required. SP / XP Series and HX Models 1 F01K07A TYPICAL 1.
PAGE 266
Section 00 STEERING SYSTEM Sub-Section 04 (ALIGNMENT) GTS / GTI Models 2 3 F03K03A 1 1. Retaining block 2. Adjustment nut 3. Bolts All Models After adjustment, torque retaining block bolts to 6 N•m (53 Ibf•in). CAUTION : Verify when the handlebar is turned completely to the left or right side, that there is no interference with venturi housing. - 10-04-2 www.SeaDooManuals.
PAGE 267
Section 11 SUSPENSION Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENTS DIRECT ACTION SUSPENSION ............................................................................................................. 11-01-1 HX MODEL .......................................................................................................................................... COIL OVER SHOCK REMOVAL ...........................................................................................................
PAGE 268
Section 11 SUSPENSION Sub-Section 01 (DIRECT ACTION SUSPENSION) DIRECT ACTION SUSPENSION 1 HX Model Loctite 242 11 10 34 N•m 2 (25 lbf•ft) Loctite 242 5 N•m (44 lbf•in) 3 10 N•m (88 lbf•in) 12 1 5 N•m (44 lbf•in) 9 34 N•m 7 (25 lbf•ft) 5 4 5 N•m (44 lbf•in) 6 Loctite 242 10 N•m (88 lbf•in) 8 F05L0GS PARTS www.SeaDooManuals.
PAGE 269
Section 11 SUSPENSION Sub-Section 01 (DIRECT ACTION SUSPENSION) COIL OVER SHOCK REMOVAL 1 Remove bottom cover of seat with grab handle. F05L0JA 1. Collar 1 F05L0HA 2 5,6 Bolt and Lock Nut 1. Grab handle 2. Cover Remove bolt and lock nut from shock absorber lower support. 1,2, Outer Boot and Collar 1 Loosen collar of coil over shock outer boot ; then, pull outer boot downward. F05L0KA 1. Bolt 2. Lock nut F05L0IA Tilt seat upward. 1 1.
PAGE 270
Section 11 SUSPENSION Sub-Section 01 (DIRECT ACTION SUSPENSION) 3,7, Inner Boot and Collar Loosen upper collar of coil over shock inner boot ; then, remove boot. COIL OVER SHOCK DISASSEMBLY Remove boot. Install spring compressor tool (P / N 529 027 100) in a vise. WARNING : Do not attempt to dismantle a spring without using the proper tool. Install coil over shock in spring compressor tool. ; 1 F05L0LA 1. Collar 8,9, Bolt and Lock Nut Remove bolt and lock nut from shock absorber upper support.
PAGE 271
Section 12 HULL / BODY Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENTS ADJUSTMENT AND REPAIR.................................................................................................................. 12-01-1 SP / XP SERIES .................................................................................................................................... GTS / GTI MODELS .............................................................................................................................
PAGE 272
Sub-Section 01 Section 12 HULL / BODY (ADJUSTMENT AND REPAIR) ADJUSTMENT AND REPAIR 1 SP / XP Series 2 1 3 Loctite 271 Loctite 271 Loctite 271 5 N•m (44 lbf•in) 8 N•m (71 lbf•in) Sealant 732 5 N•m (44 lbf•in) Loctite 242 5 N•m (44 lbf•in) 10 Sealant 732 7 9 8 Loctite 242 Loctite 271 Sealant 732 6 15 N•m (11 lbf•ft) Body F01L6HS PARTS www.SeaDooManuals.
PAGE 273
Section 12 HULL / BODY Sub-Section 01 (ADJUSTMENT AND REPAIR) 4 12 Loctite 242 6 N•m (53 lbf•in) 15 N•m (11 lbf•ft) Sealant 732 Loctite 271 SPX / XP models Loctite 271 12 Sealant 732 Sealant 732 4 5 4 12 4 1.5 N•m (13 lbf•in) 12 5 F01L6IS 12-01-2 PARTS www.SeaDooManuals.
PAGE 274
Sub-Section 01 Section 12 HULL / BODY (ADJUSTMENT AND REPAIR) GTS / GTI Models 2 1 Loctite 271 Loctite 271 3 Loctite 271 5 N•m (44 lbf•in) 8 N•m (71 lbf•in) Loctite 242 5 N•m (44 lbf•in) Loctite 242 Sealant 732 7 9 10 5 N•m 8 (44 lbf•in) 6 Sealant 732 11 15 N•m (11 lbf•ft) Loctite 271 F02L26S PARTS www.SeaDooManuals.
PAGE 275
Section 12 HULL / BODY Sub-Section 01 (ADJUSTMENT AND REPAIR) 7 N•m (62 lbf•in) Loctite 242 4 12 15 N•m (11 lbf•ft) Loctite 271 Sealant 732 4 5 4 12 12 1.5 N•m (13 lbf•in) 4 5 12 F02L27S 12-01-4 PARTS www.SeaDooManuals.
PAGE 276
Sub-Section 01 Section 12 HULL / BODY (ADJUSTMENT AND REPAIR) HX Model 3 Loctite 271 Body Body 5 N•m (44 lbf•in) 5 N•m (44 lbf•in) Loctite 271 Body 15 N•m (11 lbf•ft) 1.5 N•m (13 lbf•in) Sealant 732 F05L0PS PARTS www.SeaDooManuals.
PAGE 277
Section 12 HULL / BODY Sub-Section 01 (ADJUSTMENT AND REPAIR) 4 N•m (35 lbf•in) Body Loctite 242 4 N•m (35 lbf•in) 4 N•m (35 lbf•in) 4 N•m (35 lbf•in) 8 N•m (71 lbf•in) Loctite 242 8 N•m (71 lbf•in) F05L0QS 12-01-6 PARTS www.SeaDooManuals.
PAGE 278
Sub-Section 01 Section 12 HULL / BODY (ADJUSTMENT AND REPAIR) 4 N•m (35 lbf•in) 4 N•m (35 lbf•in) 1.2 N•m (11 lbf•in) 5 N•m (44 lbf•in) Loctite 242 4 N•m (35 lbf•in) 4 N•m (35 lbf•in) 5 N•m (44 lbf•in) Body 13 N•m (10 lbf•ft) F05L0RS PARTS www.SeaDooManuals.
PAGE 279
Section 12 HULL / BODY Sub-Section 01 (ADJUSTMENT AND REPAIR) 13 Loctite 242 6 N•m (53 lbf•po) 6 N•m (53 lbf•po) 15 N•m (11 lbf•pi) F05L0SS 12-01-8 PARTS www.SeaDooManuals.
PAGE 280
Sub-Section 01 Section 12 HULL / BODY (ADJUSTMENT AND REPAIR) SEAT ADJUSTMENT 2, Lock Pin All Models Except HX Adjust lock pin of seat as per following specifications. 1, Front Hook 1 Adjust front hook as per following specifications : 1 2 2 A A 3 F02L25C 3 SP / XP SERIES 1. Lock pin 2. Adjustment nut (Loctite 271) 3. Lock nut. Torque to 5 N•m (44 lbf•in) A. 37 ± 1 mm (1-29/64 ± 3/64 in) F02L24A SP / XP SERIES 1. Front hook 2. Adjustment nut (Loctite 271) 3. Nut (Loctite 242).
PAGE 281
Section 12 HULL / BODY Sub-Section 01 (ADJUSTMENT AND REPAIR) STORAGE COMPARTMENT COVER ADJUSTMENT ACCESS PANEL ADJUSTMENT HX Model Only 3, Lock Pin All Models Except HX Adjust lock pin of access panel as per following specifications. 3, Lock Pin Adjust lock pin of storage compartment cover as per following specifications. 1 1 2 2 A A 3 F02L25C 3 F02L25C SP / XP SERIES 1. Lock pin 2. Adjustment nut (Loctite 271) 3. Lock nut. Torque to 5 N•m (44 lbf•in) A. 37 ± 1 mm (1-29/64 ± 3/64 in) 1. 2. 3.
PAGE 282
Sub-Section 01 DRAIN PLUG INSTALLATION Section 12 HULL / BODY (ADJUSTMENT AND REPAIR) Loosen collar of coil over shock outer bootþ; then, pull outer boot downward. 14, Drain Plug Refer to the following illustration for drain plug installation. 2 1 4 F05L0IA 3 1 1. Collar Loosen upper collar of coil over shock inner bootþ; then, pull boot downward. 4 F05L13A 1. 2. 3. 4. Drain plug Gasket and 732 sealant Torque screws to 1.
PAGE 283
Section 12 HULL / BODY Sub-Section 01 (ADJUSTMENT AND REPAIR) Remove bolt and lock nut from shock absorber upper support. F05L0MA 1 2 1. Bolt 2. Lock nut 1 Tilt seat. Loosen side screws retaining seat frame to pivot blocks. Lower seat. Loosen upper screws retaining seat frame to pivot blocks. Remove seat. Seat installation is essentially the reverse of removal procedure.
PAGE 284
Sub-Section 01 4. Slide bumper rail under front bumper. 5. Using a 4.80 mm (3/16 in) drill bit, drill first hole through bumper rail at front of bow section. Use locating mark as a guide. Then install a rivet. CAUTION : When drilling, be careful not to damage bumper rail and / or hull. 6. Position bumper rail properly onto body and cut excess length if necessary. 7. Slide bumper rail in corner bumper. 8. Using hole positions previously marked on body, drill holes in bumper rail and install rivets. 9.
PAGE 285
Section 12 HULL / BODY Sub-Section 01 (ADJUSTMENT AND REPAIR) If decal tears while pulling off, it has to be heated for a few seconds longer. If decal tends to stretch while pulling off, stop heating and wait a few seconds to let it cool, then peel it off. Installation There are 2 types of decals used on watercraft. One has a protective film on back side and the other has a protective film on both sides. They are used on 3 types of materials ; plastic, gelcoat and metal.
PAGE 286
Sub-Section 01 : Protect skin, wear gloves ; WARNING when in contact with resin, hardeners and gelcoat. A barrier skin cream may also be used. Do not expose area to open flame or lit cigarette. Some of the materials are flammable. Protect eyes, wear safety glasses when grinding, sanding or spraying. Use a dust mask when sanding or grinding. When spraying wear a respirator or paint mask. Always read warning labels on products.
PAGE 287
Section 12 HULL / BODY Sub-Section 01 (ADJUSTMENT AND REPAIR) FILLING THE REPAIR AREA Small Fractures : Refer to the same procedure as in the air bubbles. Numerous Fractures Over Large Surface : Prepare the area for spray application of liquid gelcoat. Wipe down the surface with acetone. Mask the area off to protect the watercraft from overspray. Mix the needed quantity of gelcoat and catalyst according to suppliers recommendations. The gelcoat can be thinned with acetone up to 10%.
PAGE 288
Sub-Section 01 Wait until the repair has hardened before moving on to the interior repair. If the size of the opening is too large for the pieces to maintain the proper shape, you will have to use a backing support. It is a shaped piece of cardboard that fits flush to the interior surface and has a plastic layer on the repair side. It is held in place by tape or a support. Inside : Wipe down the area with acetone on a cloth.
PAGE 289
Section 12 HULL / BODY Sub-Section 01 (ADJUSTMENT AND REPAIR) : If you notice any clearance be- CAUTION tween plastic insert and aluminum insert, fill gap with epoxy glue to obtain good adhesion of aluminum insert. 1 2 F01L2VA 1. Knurled surface 2. Inner bore Install aluminum insert into plastic hull insert. NOTE : Align aluminum insert as much as possible with PTO flywheel. 1 F01L2WA 1. Aluminum insert NOTE : The epoxy glue curing time is 30 minutes. 12-01-18 www.SeaDooManuals.
PAGE 290
Section 12 HULL/BODY Sub-Section 02 (PAINTING) PAINTING 0 GENERAL The following was prepared in conjunction with PPG Industries Inc. It contains a list of SEA-DOO parts with their respective PPG color codes and 2 painting procedures ; CONCEPT ™ the most commonly used and DELTA ™ (with low VOC) mainly used in California. PPG Industries Inc. sells paint and related products and these are not available through Bombardier Inc. network. To find your nearest PPG dealer, dial one of the following numbers.
PAGE 291
Section 12 HULL/BODY Sub-Section 02 (PAINTING) PARTS THAT CAN BE PAINTED 1 3 11 2 5 10 9 4 12 7 8 6 14 15 F02B03S 1. 2. 3. 4. 5. 6. 7. 8. 9. Body Hull Storage Cover (if applicable) Engine Tuned Pipe Muffler Exhaust Manifold Engine Support Magneto Housing 10. Magneto Housing Cover 11. Flame Arrester Base 12. Ride Shoe 13. Impeller Housing* 14. Venturi* 15. Steering Nozzle* *Except for parts made of plastic. 12-02-2 www.SeaDooManuals.
PAGE 292
Section 12 HULL/BODY Sub-Section 02 (PAINTING) SEA-DOO MODELS PPG COLOR CHART SP SPI SPX XP HX GTS GTI COLOR PPG no. White 98260 White 98260 Yellow M506 White 98260 White 98260 White 98260 COLOR PPG no. White 98260 Marine green M511 Yellow M506 Yellow 88243 White 98260 White 98260 COLOR PPG no. Not applicable Not applicable Not applicable Yellow 88243 Marine green M511 Yellow M506 1. Body 2. Hull 3. Storage cover (hood for the HX model) 4. Engine COLOR PPG no.
PAGE 293
Section 12 HULL/BODY Sub-Section 02 (PAINTING) CONCEPTTM PAINTING PROCEDURE For additional information refer to PPG P-Bulletin no. 168. SURFACE PREPARATION FULL PANEL AND OVERALL REPAIRS Prepare and clean surface consistent with good painting practices. Primer DP Epoxy Primer / DP 401 Catalystþ; DX 1791 / 1792 (Prime before top coating). Primer Surfacer K36 / K201, K200 / K201 or DZ KONDAR® Primer Surfacers. NOTE : KONDAR must be sealed before applying CONCEPT color.
PAGE 294
Section 12 HULL/BODY Sub-Section 02 (PAINTING) DELTATM PAINTING PROCEDURE (with low VOC, mainly in California) For additional information refer to PPG P-Bulletin no. 157. SURFACE PREPARATION Primerþ: DELTATM PRIME DPU 166. DELTATM 2800, COLOR How to Mix Mix DELTATM 2800 2:1, 2 parts Colors to 1 DU 6 Catalyst. Application Apply 2 coats of DELTATM Polyurethane Color. Apply the first coat at 1.5 -1.8 wet mils. Allow a minimum of 15 minutes flash time prior application of the second coat.
PAGE 295
Section 13 TECHNICAL DATA Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENTS SP AND SPI MODELS ............................................................................................................. 13-01-1 SPX AND XP MODELS............................................................................................................ 13-02-1 GTS AND GTI MODELS .......................................................................................................... 13-03-1 HX MODEL....................
PAGE 296
Section 13 TECHNICAL DATA Sub-Section 01 (SP AND SPI MODELS) SP AND SPI MODELS 1 ENGINE Engine type Induction type Exhaust system SP (5876) SPI (5878) Bombardier-Rotax 587 Rotary valve Type Water cooled, water injected Water injection fitting 4.6 mm (.181 in) Starting system Electric start Lubrication Fuel / oil mixture VROI (Variable Rate Oil Injection Oil injection pump Gear driven Oil type BOMBARDIER-ROTAX injection oil Number of cylinders 2 Bore Standard 76.0 mm (2.992 in) First oversize 76.
PAGE 297
Section 13 TECHNICAL DATA Sub-Section 01 (SP AND SPI MODELS) ELECTRICAL Magneto generator output Ignition system type Spark plug Make and type Gap Ignition timing mm (in) (BTDC) Degrees Generating coil Battery charging coil Ignition coil Primary Secondary Engine rev limiter setting Battery Fuse Starting system Charging system ADDITIONAL INFORMATION : ➀Engine cold @ 6000 RPM.
PAGE 298
Section 13 TECHNICAL DATA Sub-Section 01 (SP AND SPI MODELS) PROPULSION Propulsion system Jet pump type Impeller rotation (seen from rear) Transmission Coupling type Oil type SP (5876) SPI (5878) Bombardier Formula Pump Axial flow single stage Counterclockwise Direct drive Crown splines SEA-DOO JET PUMP SYNTHETIC POLYOLESTER OIL 75W90 GL5 Steering nozzle pivoting angle 26° Trim nozzle pivoting angle Not applicable Minimum required water level 90 cm (35 in) Drive shaft deflection (maximum) 0.5 mm (.
PAGE 299
Section 13 TECHNICAL DATA Sub-Section 01 (SP AND SPI MODELS) MATERIALS Hull Air intake silencer Flame arrester Exhaust muffler Steering padding Fuel tank Oil injection reservoir Seat ADDITIONAL INFORMATION : SP (5876) SPI (5878) Composite Thermoplastic Multi-layer wire screen Aluminum Thermoplastic elastomer with polystyrene foam Polyethylene Polyethylene Polyurethane foam STANDARD EQUIPMENT Safety lanyard Tool kit Fuel tank reserve Monitoring beeper Electric fuel gauge / low oil warning light Tachomete
PAGE 300
Section 13 TECHNICAL DATA Sub-Section 01 (SP AND SPI MODELS) TIGHTENING TORQUES SP (5876) Exhaust manifold screw 24 N•m Magneto flywheel nut 145 N•m Flywheel (PTO side) 110 N•m Crankcase screws M8 24 N•m M10 40 N•m Crankcase / engine support nuts 35 N•m Engine support / hull 25 N•m Cylinder head screws 24 N•m Crankcase / cylinder screws 24 N•m Tuned pipe nut 25 N•m Tuned pipe fixation screws 25 N•m Cylinder head cover screws 9 N•m Flame arrester screws 10 N•m Impeller 70 N•m Pump / hull nuts 35 N•m Venturi
PAGE 301
Section 13 TECHNICAL DATA Sub-Section 02 (SPX AND XP MODELS) SPX AND XP MODELS ENGINE Engine type Induction type Exhaust system 2 SPX (5877) Type Water injection fitting (head) Water injection fitting (cone) Water injection fitting (muffler) XP (5858 / 5859) Bombardier-Rotax 717 Bombardier-Rotax 787 Rotary valve Water cooled, water injected Water cooled, water injected with regulator 3.5 mm (.139 in) 3.5 mm (.139 in) Not applicable Not applicable 3.5 mm (.
PAGE 302
Section 13 TECHNICAL DATA Sub-Section 02 (SPX AND XP MODELS) ELECTRICAL Magneto generator output SPX (5877) XP (5858 / 5859) 160 W @ 6000 RPM or 4.0 A @ 2000 RPM 180 W @ 6000 RPM or 5.0 A @ 2000 RPM CDI DC-CDI Ignition system type Spark plug Make and type NGK BR8ES Gap 0.5 - 0.6 mm (.020 - .024 in) Ignition timing mm (in) 2.59 (.102) 3.38 (.
PAGE 303
Section 13 TECHNICAL DATA Sub-Section 02 (SPX AND XP MODELS) PROPULSION SPX (5877) Propulsion system Jet pump type XP (5858 / 5859) Bombardier Formula Pump Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission Coupling type Direct drive Crown splines Oil type Steering nozzle pivoting angle SEA-DOO JET PUMP SYNTHETIC POLYOLESTER OIL 75W90 GL5 26° Trim nozzle pivoting angle Minimum required water level ± 8° 90 cm (35 in) Drive shaft deflection (maximum) Impelle
PAGE 304
Section 13 TECHNICAL DATA Sub-Section 02 (SPX AND XP MODELS) MATERIALS SPX (5877) Hull Inlet grate Impeller housing / venturi / nozzle XP (5858 / 5859) Composite Plastic Plastic / Plastic / Aluminum Air intake silencer Flame arrester Thermoplastic Multi-layer wire screen Exhaust muffler Steering padding Aluminum Thermoplastic elastomer with polystyrene foam Fuel tank Oil injection reservoir Polyethylene Polyethylene Seat ADDITIONAL INFORMATION : STANDARD EQUIPMENT Polyurethane foam SPX (5877)
PAGE 305
Section 13 TECHNICAL DATA Sub-Section 02 (SPX AND XP MODELS) TIGHTENING TORQUES SPX (5877) Exhaust manifold screw Magneto flywheel nut Flywheel (PTO side) ENGINE Crankcase screws PUMP STEERING (3) (4) (1) (81 lbf•ft) 24 N•m 40 N•m (17 lbf•ft) (30 lbf•ft) (3) (4) (3) (4) 35 N•m 25 N•m (26 lbf•ft) (18 lbf•ft) (1) (1) 24 N•m 24 N•m (17 lbf•ft) (1) (4) (17 lbf•ft) 40 N•m (30 lbf•ft) (1) (4) (3) (4) 25 N•m (18 lbf•ft) (1) 25 N•m 40 N•m (30 lbf•ft) (18 lbf•ft) (1) (1) Crankcase / engine suppo
PAGE 306
Section 13 TECHNICAL DATA Sub-Section 03 (GTS AND GTI MODELS) GTS AND GTI MODELS ENGINE GTS (5817) Engine type Induction type Exhaust system 3 GTI (5865 / 5866) Bombardier-Rotax 587 Bombardier-Rotax 717 Rotary valve Type Water injection fitting (head) Water injection fitting (cone) Water cooled, water injected 4.6 mm (.181 in) 3.5 mm (.
PAGE 307
Section 13 TECHNICAL DATA Sub-Section 03 (GTS AND GTI MODELS) ELECTRICAL GTS (5817) Magneto generator output Ignition system type GTI ( 5865 / 5866) 160 W @ 6000 RPM or 4.0 A @ 2000 RPM CDI Spark plug Make and type Ignition timing Gap mm (in) 0.5 - 0.6 mm (.020 - .024 in) 2.41 (.095) 2.59 (.102) Degrees 20° ± 1 ¿ 40 - 76 W (BTDC) Generating coil Battery charging coil Ignition coil NGK BR7ES NGK BR8ES .05 - .
PAGE 308
Section 13 TECHNICAL DATA Sub-Section 03 (GTS AND GTI MODELS) GTS (5817) PROPULSION Propulsion system Jet pump type GTI (5865 / 5866) Bombardier Formula Pump Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission Coupling type Direct drive Crown splines Oil type SEA-DOO JET PUMP SYNTHETIC POLYOLESTER OIL 75W90 GL5 26° Steering nozzle pivoting angle Trim nozzle pivoting angle Minimum required water level Not applicable 90 cm (35 in) 0.5 mm 139.5 mm (.
PAGE 309
Section 13 TECHNICAL DATA Sub-Section 03 (GTS AND GTI MODELS) MATERIALS GTS (5817) GTI (5865 / 5866) Hull Inlet grate Composite Plastic Air intake silencer Thermoplastic Flame arrester Exhaust muffler Multi-layer wire screen Aluminum Steering padding Fuel tank Thermoplastic elastomer with polystyrene foam Polyethylene Oil injection reservoir Seat Polyethylene Polyurethane foam ADDITIONAL INFORMATION : STANDARD EQUIPMENT GTS (5817) GTI (5865 / 5866) Safety lanyard Tool kit Standard Standar
PAGE 310
Section 13 TECHNICAL DATA Sub-Section 03 (GTS AND GTI MODELS) GTS (5817) TIGHTENING TORQUES Exhaust manifold screws Magneto flywheel nut Flywheel (PTO side) ENGINE PUMP STEERING (17 lbf•ft) (107 lbf•ft) (4) (1) 110 N•m (81 lbf•ft) (5) 24 N•m 40 N•m (17 lbf•ft) (30 lbf•ft) (3)* (4) (3)* (4) Crankcase / engine support nuts Engine support / hull 35 N•m 25 N•m (26 lbf•ft) (18 lbf•ft) (1) (1) Cylinder head screws Cylinder head cover screws (GTS) 24 N•m 9 N•m (17 lbf•ft) (80 lbf•in) (1)* (4) C
PAGE 311
Section 13 TECHNICAL DATA Sub-Section 04 (HX MODEL) HX MODEL 4 ENGINE HX (5881) Engine type Induction type Exhaust system Bombardier-Rotax 717 Rotary valve Type Water injection fitting (head) Water cooled, water injected 3.5 mm (.139 in) Water injection fitting (cone) 3.5 mm (.
PAGE 312
Section 13 TECHNICAL DATA Sub-Section 04 (HX MODEL) ELECTRICAL HX ( 5881) Magneto generator output Ignition system type Spark plug Ignition timing (BTDC) 160 W @ 6000 RPM or 4.0 A @ 2000 RPM CDI Make and type NGK BR8ES Gap mm (in) 0.5 - 0.6 mm (.020 - .024 in) 2.59 (.102) Degrees 20ø ñ 1 ? 40 - 76 y Generating coil Battery charging coil Ignition coil .05 - .
PAGE 313
Section 13 TECHNICAL DATA Sub-Section 04 (HX MODEL) PROPULSION HX (5881) Propulsion system Jet pump type Bombardier Formula Pump Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission Coupling type Direct drive / split FR and RR Driving claw with rubber cushion Oil type SEA-DOO JET PUMP SYNTHETIC POLYOLESTER OIL 75W90 GL5 26ø Steering nozzle pivoting angle Trim nozzle pivoting angle ñ10ø Minimum required water level 90 cm Drive shaft deflection (maximum) Impe
PAGE 314
Section 13 TECHNICAL DATA Sub-Section 00 (TABLE OF CONTENTS) MATERIALS HX (5881) Hull Inlet grate Composite Aluminum Impeller housing Plastic Air intake silencer Flame arrester Thermoplastic Multi-layer wire screen Exhaust muffler Steering padding Aluminum Thermoplastic elastomer with polystyrene foam Fuel tank Oil injection reservoir Polyethylene Polyethylene Seat ADDITIONAL INFORMATION : Polyurethane foam STANDARD EQUIPMENT HX (5881) Safety lanyard Tool kit Standard Standard Fuel tank r
PAGE 315
Section 13 TECHNICAL DATA Sub-Section 04 (HX MODEL) TIGHTENING TORQUES HX (5881) Exhaust manifold screw Magneto flywheel nut 24 N•m 145 N•m (17 lbf•ft) (107 lbf•ft) 110 N•m (81 lbf•ft) 24 N•m 40 N•m (17 lbf•ft) (30 lbf•ft) (3) (4) (3) (4) Crankcase / engine support nuts Engine support / hull 35 N•m 25 N•m (26 lbf•ft) (18 lbf•ft) (1) (1) Cylinder head screws Crankcase / cylinder screws 24 N•m 24 N•m (17 lbf•ft) (17 lbf•ft) (1) (4) (1) (4) Tuned pipe nut Tuned pipe fixation screws 25 N•m 2
PAGE 316
www.SeaDooManuals.