2011 PWC Service Repair Manual PDF

2011
Shop Manual
GTS/GTl™/RXT™/GTXtJWAKE™ SERIES
se�·..aaa. �
TABLE OF CONTENTS
SAFETY NOTICE .. ....... .......................................... ... . : ......... . ...... . ....... ....... .... ... ...... . . . XI
INTRODUCTION........................................................................................................ XII
VEHICLE INFORMATION............ ........ .. .......................... ... ......................................... XII
MANUAL INFORMATION.......................................................................................... XIV
FASTENER INFORMATION ...................................................................................... XVIII
01 MAINTENANCE
01 - BREAK-IN INSPECTION ......................................................................................... 5
02 - MAINTENANCE SCHEDULE.................................................................................... 7
03 - STORAGE PROCEDURE....................................................................................... 11
PROCEDURES............................................................................................... 11
PROPULSION SYS TEM................................................................................... 11
FUEL SYSTEM............................................................................................ 11
ENGINE ................................................................................................... 11
ELECTRICAL SYSTEM.................................................................................... 14
ENGINE COMPARTMENT ................................................................................ 14
BODY AND HULL......................................................................................... 14
04 - PRESEASON PREPARATION .. ..... .. . .. . ..... ... ....... . . . .................. . . ... .. . .. .. ......... . . ........ . 15
05 - SPECIAL PROCEDURES....................................................................................... 17
GENERAL ..................... ... .... ................................. .................................... . . . 17
PROCEDURES............................................................................................... 17
TOWING THE WATERCRAFT IN WATER ................................................................. 17
SUBMERGED WATERCRAFT ........................... ............ .............. .... ........ . ........ . . . 17
WATER-FLOODED ENGINE ............................................................. ................. 17
CAPSIZED WATERCRAFT ................................................................................ 19
02 ENGINE
01-ENGINE REMOVAL AND INSTALLATION.................................................................. 21
GENERAL .................................................................................................... 25
PROCEDURES............................................................................................... 25
ENGINE ........ ............................................................... ........... ......... ........ 25
ENGINE MOUNTS ........................................................................................ 30
02-AIR INTAKE SYSTEM (EXCEPT iS AND as MODELS) ................................................... 31
GENERAL .................................................................................................... 33
PROCEDURES............................................................................................... 33
AIR INTAKE SILENCER . . . .. . . . .. . . . . . .. . . . . . . .. . . .. . .. . . . . . . . . . . . . . . .. .. . .. . . . . . .. .. .. . . . . ... . .. . . . . . . . . . 33
AIR INTAKE TUBE ... . .... ......... ... .. . .. ....... . ........ .. .... ...... . ...... ... .... ..... ......... ....... 37
03 - AIR INTAKE SYSTEM (iS AND as MODELS).............................................................. 39
GENERAL ..... ................. ................. ..... .............. ..... ..................................... 40
PROCEDURES.. . ..... .... ..... ......... ....... .......... ... ......... .................................. ... ..
. 40
AIR INTAKE SILENCER COVER............................. ................... ............. . .. ... .. . .... . 40
AIR INTAKE SILENCER BAFFLE.......................................................................... 40
AIR INTAKE TUBE . ..... .... . .... . ......... . ........ . ...... . .. .. . ......... .. ... ..... ...... .. . .. .... .. . .. .. 40
AIR INTAKE SILENCER .................................................. ........... ........ ............. . 41
04 - INTAKE MANIFOLD ............................................................................................ 43
GENERAL ........ ........................................................ ................. ....... ........... . 46
PROCEDURES....... ......................... . .............. .......... ....................................
. . 46
INTAKE MANIFOLD ....................................................................................... 46
FLAME ARRESTER . ......... ....... ..... ....... . ....... .... ............ . .... ..... .. ........ .......... .. .. 49
05 - SUPERCHARGER (215 AND 260 ENGINES)............................................................... 51
GENERAL ........ ....................... .. . ..... .............. ..... .............. ... .... ..... .. .............
. 53
INSPECTION............. ....... ........ ....... .. ...... ....... ................................. ... ..........
. 53
SUPERCHARGER INLET CLEANLINESS ..... . ....... ........... . .... ....... ........ ........ ... ...... ... . 53
SUPERCHARGER CLUTCH SLIPPING MOMENT (ON ENGINE) ............. ....... ..................... 54
TABLE OF CONTENTS
02 ENGINE (cont'd)
05 - SUPERCHARGER (215 AND 260 ENGINES) (cont'd)
INSPECTION (cont'd)
SUPERCHARGER CLUTCH SLIPPING MOMENT (BENCH TESTI 55
.......... ..............................
TROUBLESHOOTING...................................................................................... 56
PROCEDURES............................................................................................... 56
SUPERCHARGER......................................................................................... 56
06 - INTERCOOLER (215 ENGINE)................................................................................ 67
GENERAL .............................. . ....................................................................
. 68
PROCEDURES............ ............................ ....... ...............................................
. 68
INTERCOOLER ............. ....... . .. .... . .. ....... ....... .... . . ...... .. ............ ....... ....... ....... 68
07 - INTERCOOLER (260 ENGINE)................................................................................ 71
GENERAL ............................. ....................................................................... 72
MAINTENANCE............................................................................................. 72
INTERCOOLER FLUSHING ... . .......... .......... ...... .. .... . ... ... . .. .... . ...... ....... . .... ... ...... . 72
PROCEDURES.............. ................... . ............................................................. 72
INTERCOOLER ..... ... .............. ... .... ....... ........ .... ........ ...... . ...... ... .... .............. . 72
INTERCOOLER ATIACHMENTS.................................................... ....... ..... .......... 74
08 - EXHAUST SYSTEM............................................................................................ 77
GENERAL .................................................................................................... 82
SYSTEM DESCRIPTION ... .......... .. ..... .... ... ............ ............ ......... ........... ... ..... ... 82
MAINTENANCE............................................................................................. 83
EXHAUST SYSTEM FLUSHING........................................................................... 83
PROCEDURES.... ................. .......................................... .................... .......... 84
. .
MUFFLER ................................................................................................. 84
EXHAUST HOSES......................................................................................... 86
EXHAUST PIPE ............ .......... ....... ....... . ... ...... .. ..... .............. ....... ....... .......... 88
EXHAUST MANIFOLD .................................................................................... 89
RESONATOR.............................................................................................. 90
09 - PTO HOUSING AND MAGNETO .. .... ........ .... ... ..... ..... .. ..... ....... ....... .................. ... ... 93
GENERAL .... ............ .... ..... ............. ............ ..... ............. ............................... 95
.
PROCEDURES............................................................................................... 95
PTO HOUSING............................................................................................ 95
PTO SEAL................................................................................................. 99
PTO COUPLING ......................................................................................... 100
STARTER DRIVE BEARINGS............................................................................. 101
STATOR .................................................................................................. 101
ROTOR AND TRIGGER WHEEL ................... ........ ............... ... ... ...................... 104
. . .
RING GEAR.............................................................................................. 105

STARTER DRIVE ......................................................................................... 106
10 - LUBRICATION SYSTEM .................. ................................................................... 107
.
GENERAL .......................................... ............................. ............................ 112

MAINTENANCE......................... ..... .... .. ........................... ........................... 112
. .
ENGINE OIL.............................................................................................. 112

OIL FILTER............................................................................................... 114
INSPECTION.. ..................................... ..... ........... . .......... ............................ 115
. .
ENGINE OIL PRESSURE ................................................................................. 115

TROUBLESHOOTING..................................................................................... 116
PROCEDURES ....... ........................................................... ............. ...... ......... 117
OIL PRESSURE SWITCH (OPS).......................................................................... 117
PTO OIL STRAINER...................................................................................... 118
SUCTION PUMP OIL STRAINER .......... .. .. .. ... . ..... .. .......... ....... ................... ..... .. .. 119
ENGINE OIL PRESSURE REGULATOR .................................................................. 120
OIL PRESSURE PUMP................................................................................... 121
ROTARY SEAL ........................................................................................... 123
II
TABLE OF CONTENTS
02 ENGINE (cont'dl
10 - LUBRICATION SYSTEM (cont'd)
PROCEDURES (cont'd)
OIL SUCTION PUMP ............ ........ ....... ........... .... ........ ..................... ........... 124
. .
SUPERCHARGER OIL SPRAY NOZZLE.................................................................. 127

PISTON OIL SPRAY NOZZLES............................... ..... ......... ..... ....... .................. 128
OIL SEPARATOR COVER . .. . .. .. .. . .. . ... . .. .. .. . .. . . .. . .. .. .. ... . . .. . .. . ... . .. . . . . . .. . . .. . . . .. . . .. . .. . . 129
BLOW-BY VALVE ....... .. ................. ... .. . ... .. ..... .. ... .. . ... . .. ......... .. ... ... . ... . .... .. .. . . 131
TOPS SWITCH . .. . . .. ........ .. . . .. . . . .. . . . .. ..... .. . . ... .. .. .. . .. .. .. . .. .... . ... . ... . . . . ... . . .. . . . .. .. .. 133
OIL COOLER....... ........ ........... .......... ....... ...... . . ......... . ...... ................. ...... . . . 135
11 - COOLING SYSTEM . .. ... . . .... . . . .. .. . . . . ...... .. . .. . . . . . . . . . . . .. ... ..... .. .. . .. .. .. . . . .. . . . . .. . .... ... ... . .. 137
GENERAL................................................................................................... 143
SYSTEM DESCRIPTION ... .. .. . . . .. . . . . . . . . . . . . .. ... . . .. .. . .. . . .. . . . . . . . . .. ... .. .. . ..... . ... . . . . ... . ... . 143
MAINTENANCE............................................................................................ 143
ENGINE COOLANT...................................................................................... 143
INSPECTION................................................................................................ 145
COOLING SYSTEM LEAK TEST ..................... ....... . .. .... ..................... ...... ......... 145 . .
PROCEDURES....... .................................................... ........... ................ ........ 146
PRESSURE CAP . . .. . . ... .. .. ... . .. .. ... .... .. . . . .. ...... ... . .. ..... . . . . . . . . . . . . . . .. . . .. . ... . .. . . . ... ... . 146
CLAMPS .. ... ......... .... . ............ ................................................... ...... ........ 146
.
WATER PUMP HOUSING .......... . ...... ....... .............. ....... ........................ .... ...... . 147
WATER PUMP IMPELLER............................................................................... 149
T HERMOSTAT . ... ... .. .. .. .. . .. . . . . . .. . . . .. . . ... .. . ... . . . ... . . .. . .. .. .. .... . ... .. . . ................ ..... 150
ROTARY SEAL .. . . ... .. .. . . ... . . . . . .. . .. . . .. .. . . . . . . .. . . . . . . . . . . . . . . ... .. . ... . . . .. ... . ... . . . .... . . .. . . ... 150
12 - CYLINDER HEAD.............................................................................................. 151
GENERAL . . . .. .. . . . . .. . . .. . . . . . . . .. . .. . . .. . .. . .. . . .. .. . .. ... . . . . . . .. . .. .... . . . . . . .. . . .. .. . .. .. . . ......... . .. 153
INSPECTION............. ... ............... ........... . .................... ............ ........... ....... 153
. . .
ENGINE LEAK TEST . .. . . .. . . . ... .. . . . .. . . ... .. ... . . .. . . .. . .. . ... . . . ... .... ... .. . . . . . .. . . . .. . . . . . . .. . . . . . 153
PROCEDURES .. . .... ................................................. .............................. .. .... 156
. .
CYLINDER HEAD COVER................................................................................ 156

SPARK PLUG TUBES . . . . ... . . .. . . . .. . . . . .... . . . ..... . .. . . ..... ... .. .. . .... .. ... . . ... . . . . .. .. ....... .... 157
.
ROCKER ARMS.......................................................................................... 157

CAMSHAFT TIMING GEAR.............................................................................. 160
CAMSHAFT .. ..... .......... ................................. ..... ...................................... 161
.
CYLINDER HEAD........................................................................................ 163

VALVE SPRINGS .. . .. .. . . . . . . . . .. . . . . . . .. . . ... . . .... . ... . .. . .. . .. .. . . . . . .. ..... . . .. . . . .. .. ..... .. . .. . ... . 165
VALVES... .... . ................ ................. ...... .................... . ........................ ..... 166
. .
VALVE GUIDE............................................................................................ 170

13 - CYLINDER BLOCK............................................................................................. 173
GENERAL................................................................................................... 176
PROCEDURES.............................................................................................. 176
TIMING CHAIN................ . ............................. . ........ . ..................... .............. 176
CHAIN TENSIONER.. .... ............................. ................... ....... ......... ................ 177
PISTONS AND CONNECTING RODS .................................. ........................ . ....... 177 . .
PISTON RINGS........................................................................................... 182

CRANKSHAFT............................................................................................ 184
BALANCER SHAFT . . . . ... . . . . . .. . . . . . . . .. .. .... . . .. .. . .... . . . . . . . . . . . . . . . . ...... .... .. . . .. . .. .. .. . . . .. . . 188
CYLINDER BLOCK.......... .............. .. ..... ................................................. ...... 191
.
Ill
TABLE OF CONTENTS
03 ELECTRONIC MANAGEMENT SYSTEMS

01- ENGINE MANAGEMENT SYSTEM. ....... ........ .... .... ...... ... .. . ................................. ... 197
.
GENERAL................................................................................................... 199
SYSTEM DESCRIPTION .. ....................................................... .............. .......... 199
02 - ICONTROL SYSTEM ..... . .. . .... .... . .. .... ....... . .. . ..... . .... ... . ... . ...... ....... ... . ......... . ... . ..... . 201
GENERAL ... ... . . .. . . .. . .... ....... . ..... . . .. . .. . ... . ... .... ... ........ . ... . . ...... . .... . .. ............ .. ... 201
iTC (INTELLIGENT THROTILE CONTROL) .......... ... .. .. ........ ........... .... .................. ... 201
.
iBR (INTELLIGENT BRAKE AND REVERSE) .. ....... . ... ........ ....... ......... ........................ 201
iS (INTELLIGENT SUSPENSION) .... .. ... . ...... . ... .. ... ....... ........... ... ......... ....... .......... 201
03 - CONTROLLER AREA NETWORK (CAN) . .............. ....... .... . ....... . .. ... . . . ... ........... .. ........ 203
GENERAL .......... ............ .. . .... . ........................... ..... .................. .................. 203
.
SYSTEM DESCRIPTION .. . .... . .. . . .. . .... ... ....... .... ... . ... . . ............ ... ....... .............. ... 203
TROUBLESHOOTING........... ................. .. .. ...................... ..... . . . ............ .... . .... 204
. .
DIAGNOSTIC TIPS....................................................................................... 204

04 - COMMUNICATION TOOLS AND B.U.D.$................................................................. 207
GENERAL .................... ...... ............. ....... ... ................ .................................. 207
TROUBLESHOOTING...... ... .. ...................... .......... ......................................... 207
.
DIAGNOSTIC TIPS . . . . ... . ..... . ..... .... . ... . . ... . . .... . ............ . ..... ...... . ................. ...... 207
PROCEDURES ... ........... ............. ............ . ...................................................... 208
MPl-2..... ....... . ........ ...... .................... ................................. ... . . ......... ...... 208
.
B.U.D.S. SOFTWARE .............. ......... ............ ............ .. .................. ... .............. 210
05 - DIAGNOSTIC AND FAULT CODES ....,, .................................................................... 215
GENERAL ................ ........... .. .................... .................... ............................ . 215
.
MONITORING SYSTEM ................................................................................. 215

FAULT CODES . .. ... ..... .... . . .. . ... ....... . ... . . . . ... . ..... ...... . ....... . .. ... . ....... ... .. ......... .. 220
FAULT CODE DIAGNOSTIC.............................................................................. 223
GUIDELINES TO SOLVE SPECIFIC FAULT CODES...................................................... 227
FAULT CODE TABLE..................................................................................... 228
04 FUEL SYSTEM
01 - INTELLIGENT THROTTLE CONTROL (iTC)................................................................ 253
GENERAL. ... ........ .. . . .. . .. ..... ... .. ..... ....... ............ ..... ... . ... . . .... . .. ............ ....... .... 253
SYSTEM DESCRIPTION ..... ......... . ... .... ... .... ... ..... .... . ....... ....... .. . ...... .... ........... . 253
OPERATING MODES (GTS, GTI AND WAKE SERIES) ................................................... 256
OPERATING MODES (AXT, GTX AND WAKE PRO SERIES)................. ...... . .. . ................. 269 .
PROCEDURES..................... ......... ........................ ........................................ 280

THROTILE ACCELERATOR SENSOR (TASJ .. ... . ... . .... . .. . .. . ..... . ............. ......... ....... .... . 280
CRUISE SWITCH............................. ....... ......................... ... ... .................... .. 284
02 - ELECTRONIC FUEL INJECTION (EFI) ............ . ............. . ........... . .......... .. .. .. . .. . . ... ....... 287
GENERAL... . ... .................................. ........... ..... ....... ............... . . .. . ....... ....... 287
.
SYSTEM DESCRIPTION ................................................................................. 288

ADJUSTMENT............................................................................................. 288
IDLE SPEED . . . . ............. ..... .... . .... .... ... ... .. ... ..... ................ ......... ................. 288
CLOSED T H ROTIL E RESET ............. .... ... .. ....... . ........... ................................... 289
.
TROUBLESHOOTING.. ... ......... ................ ................ ................ . ......... ..... . .... 290
. . .
DIAGNOSTIC TIPS .. ..... . .... .. . ..... ... . . .. . . .. . . .... ... .... . .... .............. .......... .............. 290
PROCEDURES.................................................. . ........ ... ...... . ... . . ............ ... 290
. . . ..
ENGINE CONTROL MODULE (ECM).................................................................... 290

FUEL RAIL ... .. ....... ... .... . . .............. .... .. . . .. .. . ......... . ... ... ..... ... . ... .. ....... .......... 297
FUEL INJECTOR .... .. ... ........ ..... ..... .. ... .. . .... ..... .. ..... ............ ...... . ... . ... .. .......... 299
THROTILE BODY........................................................................................ 304
TPS {THROTILE POSITION SENSOR)................................................................... 307
CRANKSHAFT POSITION SENSOR (CPS) . .. .. . . . .. ... .... .... . ........ ........... . ..... . .. . .. ..... ..... 309
CAMSHAFT POSITION SENSOR (CAPS) ........ .................................. .. . ... ....... ....... . 311 .
MANIFOLD AIR TEMPERATURE SENSOR (MATS) .. .......... ....... .................................. 314
IV
TABLE OF CONTENTS
04 FUEL SYSTEM {cont'd)

02 - ELECTRONIC FUEL INJECTION (EFI) (cont'd)
PROCEDURES (cont'd)
COOLANT TEMPERATURE SENSOR (CTS) ...................................... ...................... 315 .
MANIFOLD ABSOLUTE PRESSURE SENSOR (MAPS).................................................. 317

EXHAUST GAS TEMPERATURE SENSOR (EGTSJ ........................................ ............. . 318 .
KNOCK SENSOR (KS) ................................... ....... .................. ............... . ...... 319

. .
03 - FUEL TANK AND FUEL PUMP .............................................................................. 323

GENERAL .. .. . . ..... .. . . . .. ... .. .. ........ .. .. ... .. ......... ... . . .. . .... ... ...... .. ... ... .. . . .. ... .. .. ...... 328
SYSTEM DESCRIPTION . .. ..... . . . . ........ . ... .. .. . . .. . . . . . . . . . . .... ....... . .. . . . .. . . . .. .. ..... ..... . .. 328
INSPECTION................................................................................................ 330
FUEL TANK LEAK TEST.................................................................................. 330
FUEL SYSTEM HIGH PRESSURE LEAK TEST........................................................... 334
FUEL PUMP PRESSURE TEST .... .... ... . . .. . ... . ... . .. . .. ....... ................. .... .. . ...... . . . .. . . . 334
PROCEDURES ............................................. . ............. .. ................... .............. 336
FUEL HOSES AND OETIKER CLAMPS.................................................................. 336
FUEL PUMP . . .... .. . .... . ...... . ......... .. . . ... ... ...... .. ..... ..... .... . . .. . ....... .. . .. .. . .. .. ... . ... 337
FUEL FILTER............................................................................................. 340
FUEL LEVEL SENSOR . ... ..... .... .... . .. . . ............. . . . . .. . . ..... ....... . . . ......... .. .. ....... .. . . . 341
FUEL TANK ......... . .. .... ..... . . . . . . .. .... . ....... .... .... ... . . . .. ... .... ....... ... .... ... . ............ 347
05 ELECTRICAL SYSTEM
01 -POWER DISTRIBUTION AND GROUNDS................................................................. 351
GENERAL ...................................... ....... ........ . ..... ..... ....................... .......... 351
. .
POWER DISTRIBUTION DIAGRAM ............ ......................................................... 351

FUSE BOX . ... ..... ... . ... .. ... ............ ... .... ....... ...... . . . . . . .... .... . . . . .. . .... . .. . ....... .. . . . . 352
RELAY................. . ... ..... ... ............. . ... . .. ............................. ................... 354
. . .
GROUNDS ............................................................................................... 354

02 -IGNITION SYSTEM .. . . . . .. .. ... ..... .. . . ... .... . .. . . .. ........ .. . . ... . . . . ...... . .. . .. . . . ... . .. . ... . .... . . . . . . 355
GENERAL................................................................................................... 355
SYSTEM DESCRIPTION ... ..... ... .... .. .. . .. .. ............ .. . .. .. . .... ... . . ... . . ... . . . .... . ... . .. ..... . 355
TROUBLESHOOTING ......................... .. ....................................................... 356
. . .
IGNITION SYSTEM TESTING......................................................... . ......... ......... 356

DIAGNOSTIC GUIDELINES.............................................................................. 356
PROCEDURES.. .......................... .......................... ........................................ 357
IGNITION COILS......................................................................................... 357
SPARK PLUGS . ... . . . . . . . .... ... . .. . . . . . . . .. . .. . . .. . ...... . . . .. . .. . . . .... ...... ... ... .... . .... ....... . .. . 360
03 - CHARGING SYSTEM . . .. . .. . . ... ......... ... .... . .. ........... ..... .. . .. ... ...... . .... .. . .. . . . . .. . .. .. ... .. .. 363
GENERAL................................................................................................... 363
SYSTEM DESCRIPTION . . . ... . .... . . .. . . . . .. . ...... ....... ..... .. . . . .. ..... ....... .. . ... . .. ...... . . . . .. . 363
INSPECTION................................................................................................ 364
CHARGING SYSTEM OUTPUT ..................................................................... .... 364 .
TROUBLESHOOTING ........... .................................................... ............. ......... 365

PROCEDURES..... .......... .......................................... ........................ ..... ........ 366
VOLTAGE REGULATOR/RECTIFIER ... .. ... .. .. ... .... . . . . . .. ....... ... ................ .. . ...... . . . ..... 366
BATIERY............. .................................... ................. ............. ................. 368
.
BATIERY VENT CHECK VALVE. .. ..... . . . . . . . ..... .. ....... .. . .. ..... . .. . . . . . . . . ..... . .... . ........ . . .. . 377
04-STARTING SYSTEM .... ................................................. ..... ........................ ........ 381
GENERAL ..... ...... ............ ..... .... ............................................................... 383
. . . .
BASIC STARTING SYSTEM OPERATION................................................................ 383

DIAGNOSTIC TIPS....................................................................................... 383
PROCEDURES. ...... .............. ........................................................................ 384
.
ENGINE START/STOP SWITCH.......................................................................... 384
v
TABLE OF CONTENTS
05 ELECTRICAL SYSTEM (cont'd)

04 - STARTING SYSTEM (cont'd)
PROCEDURES (cont'd)
STARTER SOLENOID .................................................................................... 386
STARTER ................ ..................... ....................................... .... . ............. .. 391 .
05 - DIGITALLY ENCODED SECURITY SYSTEM ID.E.S.S.) ............................................. .... 395 .
GENERAL................................................................................................... 395
SYSTEM DESCRIPTION . ....... . .... .. ....... ....... ....... ..... ....... . ...... ......... . .... ....... . .... 395
PROCEDURES .............................................................................................. 396
D.E.S.S. KEY............................................................................................. 396
BEEPER .... ............................................................................... ............... 398
- FF SWITCH.............................................................................. 398
ENGINE CUTO
06 - INFORMATION CENTER IGAUGEI .... ... .. .. . .. .... ....... ........ .... .......... .... ... .... ... .... ........ 401
GENERAL ...... ............ ............ ....... .. .. ... .......... . ... .. ...... ....... ... ... . .... .. ..... ... . .... 402
INFORMATION CENTER IGTS MODELS) . ....... ................... ................ ... . .. .. ............ 402
INFORMATION CENTER (GD< 155, GTI SERIES AND WAKE MODELS)................................ 404
INFORMATION CENTER (RXT,Gn< (EXCEPT 155) AND WAKE PRO SERIES) .......................... 414
TROUBLESHOOTING ..................................................................................... 427
DI AGNOSTIC TIPS ....................................................................................... 427
TROUBLESHOOTING GU IDELINES ..... ...... ............. .................... ..................... .... 427
PROCEDURES.............................................................................................. 429
INFORMATION CENTER .. .. .. .......... .................. .... ..............
. . . . . ........ ................ 429
G AUGE SUPPORT (RXT, GTX AND WAKE PRO SERIES) .... .. . . ... .. .. ....... ....... .. ..... . ...... .... 441
MODE/SET AND UP/DOWN ARROW BUTTONS .... .................. . ....... . . . .... . . ..... ..... .. ... . 442
WATER TEMPERATURE SENSOR....................................................................... 447
DEPTH SOUNDER ....................................................................................... 447
06 STEERING AND PROPULSION

01 STEERING AND O.T.A.S...................................................................................... 451
-
GENERAL .. . . .. . . . .. . ............ . .... . .......... .. ......... . .... . ... . . ............. . .. ... .. .. ..... ... ...... 456
SYSTEM DESCRIPTION (0.T.A.S.)....................................................................... 456
ADJUSTMENT ............................................................................................. 456
STEERING ALIGNMENT ................................................................................. 456
ERGONOMIC ADJUSTMENTS ..................................................................... .. ... 457
INSPECTION............ . .......... ........ ...... .......... .................. .............................. 458
.
O.T.A.S. OPERATION .. ..... ....... . .. . ................... .. ....... ... ........... ....... . ... . . . ..... . .... 458
TROUBLESHOOTING ..................... ... ... ............................ ... .......... ............... 458
. .
DIAGNOSTIC TIPS....................................................................................... 458

PROCEDURES................................................. ........ .................................... 458
.
HANDLEBAR GRIP ...................................................................................... 458

HANDLEBAR SWITCH COVER (LH OR RH)............................................................. 459
EXTENSION BLOCKS (RXT-X MODELS)................................................................. 461
STEERING COVER....................................................................................... 461
THROTTLE AND iBR LEVERS .... ..... . ..... .. . .... .... . ..... .. . .... ............ .............. ....... ... 463
STEERING CABLE .. ..... . .... .......... ...... . .. ... ... .. ....... .. .......... ..... .. ..... ....... . . ........ 464
STEERING COLUMN .................................................................................... 466
STEERING COLUMN SUPPORT ......................................................................... 468
STEERING TILT RELEASE HANDLE ..................................................................... 469
O.T.A.S. SWITCH ..... .... ... ..... ... . . . .. . ............. ........ .... . .... ....... . ...... . .. .... ..... ... .. . 469
O.T.A.S. MAGNETS ...................................................................................... 471
02 - iBR AND VTS ... . ... .......... .. ... .... . ..... .. . .. . . .. ................. . . . ........ . ........ .. . .. .. ............. 473
GENERAL ................................................................................................... 477
SYSTEM DESCRIPTION (iBR)............................................................................ 477
SYSTEM DESCRIPTION (VTS) .... ..... .... . . . .. . . ... ..... ... . . .. . .. .. ....... . ... ........ ... .... ....... .. 480
VI
TABLE OF CONTENTS
06 STEERING AND PROPULSION (cont'd)

02 - iBR AND VTS (cont'd)
ADJUSTMENT ...................................................................................... . ...... 483
IBR NE UTRAL ADJUSTMENT........................................................................... 483
MAINTEN ANCE............................................................................................ 483
iBR GATE BACKLASH CHECK ........................................................................... 483
FRICTION SLEEVE REPLACEMENT..................................................................... 484
INSPECTION................................................................................................ 485
IBR SYSTEM FUNCTIONAL TEST .................. . ................................... .. ............... 485
VTS FUNCTIONAL TEST................................................................................. 485
TROUBLESHOOTING ....... . ... . ....... . ..... . . ...... . ........... . . . .. ..... . ... ....... ......... . ...... . .. 487
TESTING SEQUENCE ............... .................................................................... 487
.
PROCEDURES ........ ........................................................ ..... ....................... 487

. .
iBR LEVER SENSOR (BRLS)............................................................................. 487

iBR ACTUATOR ...... .. ..... ... . .... .... ....... .... .................... .. ............ ............. .... . .. 492
iBR GATE...... .......................................................................... ................ 500
.
U-ARM ................. ................................................................................. 505

.
iBR GATE SUPPORT PLATES............................................................................ 506

FITIING PLATE ................. .... ................................................................... 509
. .
VTS CONTROL BUTION ................................................................................ 512

03 - JET PUMP ...................................................... ................................................ 515
GENERAL ................................................................................................... 518
JET PUMP MAIN COMPONENTS ......................................... ............... ............ 518
. . .
INSPECTION................................................................................................ 518
IMPELLER CONDITI ON.................................................................................. 518
IMPELLERNVEAR RING CLEARANCE................................................................ .. 518 .
IMPELLER SHAFT RADIAL PLAY........................................................................ 518

LEAK TEST... .. .... . ....... ........ . .. . ............ .... ... .... ... ....... .. .......... ......... .. ..... ..... 519
PROCEDURES .............................................................................................. 520
SACRIFICIAL ANODE.................................................................................... 520
JET PUMP HOUSING .............................................................................. ..... 521 .
VENTURI ................................................................................................. 525

IMPELLER COVER....................................................................................... 526
IMPELLER ............................................................................................... 528
WEAR RING ........... ................................................................................. 530
.
IMPELLER SHAFT AND BEARING ..... ......... .. ..... .......... ............ . . . ...... ............ . . .... 531
NOZZLE (GTS MODELS)................................................................................. 537
04- DRIVE SHAFT .................................................. ... ........... . ................................ 539
.
GENERAL ................................................................................................... 541

PROCEDURES ................................................................ ........................... 541
...
DRIVE SHAFT ....................... . .............. ..................................................... 541

.
DRIVE SHAFT B O O T..... .................................................... .......................... 548

. .
CARBON RING........................................................................................... 548
07 BODY AND HULL

01 SUSPENSION laS) ............ ............................................................................... 549
- .
GENERAL ................................................................................................... 553

SYSTEM DESCRIPTION ........ ............ ........... . ............ ............................ .. .. .. ... 553
PROCEDURES.............................................................................................. 555
SHOCK ABSORBER ....... .. ... .. ..... . .... ... ...... ........ .. ..... .. ..... . ............. ... ............. 555
SPRING .................................................................................................. 557
LINK ARM................................................................................................ 559
LATERAL SUPPORT ......... ..... ... .. . ... .. .. ... . ... .. . ....... .. .. . ........ ... .................. . ...... 559
VII
TABLE OF CONTENTS
07 BODY AND HULL (cont d) '
01 - SUSPENSION (aS) (cont'd)

PROCEDURES (cont'd)
LATERAL BELLOWS..................................................................................... 560
FRONT SUSPENSION ARM .... ....... .......................................... ....... ....... .......... 561
SUSPENSION BASE ..................................................................................... 562
REAR SUSPENSION ARM.............................................. ........................ ......... 564
SUSPENSION ARM SHAFTS .. . ....... ....... ...................... .... ....... ..................... ..... 566
02 - SUSPENSION US)............................................................................................. 569
GENERAL ................................................................................................... 573
SYSTEM DESCRIPTION (COMPONENTS)............................................................... 573
SYSTEM OPERATION ................................................................................... 574
DIAGNOSTIC TIPS....................................................................................... 575
DIAGNOSTIC FLOW CHARTS ... .............. ..... .. ............ ..... ....... . . .............. ........... 578
PROCEDURES.............................................................................................. 580
SHOCK ABSORBER ............. ........ .... ... . ............. . ...................... ....... . ...... ...... 580
SPRINGS............ ........................... ..... ..................................................... 581
SUSPENSION POSITION SENSOR...................................................................... 582
iS MODULE.............................................................................................. 584
iS BUTION............................................................................................... 586
HYDRAULIC PUMP............................................................. ......................... 587
ACTUATOR ..... . . . .................... ............... ................ .............. ....... ....... ....... 591
LATERAL SUPPORT .... ............................. . ............ . ... ....... .... . .. ..................... 593
LATERAL BELLOWS..................................................................................... 594
FRONT SUSPENSION ARM .......... . . ...... ........................ ....... ....... ...... . ....... ....... 595
SUSPENSION BASE ..................................................................................... 596
REAR SUSPENSION ARM............................................................................... 597
SUSPENSION ARM SHAFTS ............ .......... ..... ...... . ................... ....... ....... ......... 599
03 - BODY (GTS/GTl/WAKE) .... ..... ..... ..... ............ ....... ..... .... .............. ....... ........ ......... 603
GENERAL ................................................................................................... 610
PROCEDURES .............................................................................................. 610
GELCOAT ................ ........ . ...................................... ...............................
. . 610
DECALS ............ ................... ..................... ... ........... .. .... ... .................... 610
. . .
CARPETS .......... .. .................................... ................................................ 610

STORAGE COMPARTMENT COVER .......... ........... .... ......................... ................. 610
.
STORAGE COMPARTMENT COVER HINGE . .... ....... ......... . ...... . . ...... .................. . ..... 612
GAUGE TRIM ................ ......... ................................................................... 613
LATERAL TRIM PANEL ........... ................... .. ...... ..... ....... ... .................. ......... 614
. .
MIRROR SUPPORT................................................................................... ... 615

MIRRORS................................................................................................ 616
CONSOLE ... . ............................... ....... ........... ...................... . ............ ...... 616
. .
GLOVE BOX COVER.............................. ....................................................... 617

SEAT ..................... .................................................................... ............ 617
SEAT LATCH ..................................... ...................... ...................... ............ 618
REAR HANDLE ......................................... ...................... . .......................... 618
BUMPER.... ....... ..................... ............. ... .. .......................... ................... 618
. .
VENTILATION DUCT..................................................................................... 619

WAKE PYLON (WAKE) ................................................................................... 620
04 - BODY (AXT/GTX/WAKE PRO)..... ......................................................................... 625
GENERAL ................................................................................................... 638
PROCEDURES.............................................................................................. 638
GE LC OAT .... ..... .......... . .... ................... . ............. .. ......... . .... ... . ........... .... .... 638
DECALS.................................................................... .............................. 641
VIII
TABLE OF CONTENTS
07 BODY AND HULL (cont'd)

04 - BODY (RXT/GTX/WAKE PRO) {cont'd)
PROCEDURES (cont'd)
CARPETS ... ... ..... ...... ............ ... .. .. ... .. .... ............ .. . .... .. ....... .............. . ...... . . 641
STORAGE COMPARTMENT COVER .................................................................... 642
GLOVE BOX COVER..................................................................................... 643
SEAT ..................................................................................................... 643
SEAT LATCH ... ............... ... . . . .. . . . . . . . . . . ....... .. .. . . . ...... . ....... .. . .. ........ . ....... ....... . 644
MIRRORS................................................................................................ 645
BUMPERS ............................................................................................... 646
BODY COVER............... ,............................................................................ 648
FRONT BODY MODULE................................................................................. 649
SPEED-TIE UNIT......................................................................................... 650
BOARDING PLATFORM (iS AND as MODELS) ... ....... ...... ...... .. ..... ....... ....... ....... .. ..... 660
DECK EXTENSION (iS AND as MODELS) ............................................................... 661
MOVING DECK (iS AND as MODELS) ..... .................... ..................... . ................... 662
FRONT GRILLE (iS AND aS MODELS) ..... ....... ... ... . . . ............ ....... ........ ............. ..... 668
SPLASH DEFLECTOR (iS AND as MODELS}............................................................ 669
REAR VENTILATION BOX (iS AND as MODELS)........................................................ 669
FRONT VENTILATION BOX (iS AND as MODELS)...................................................... 669
AIR INTAKE DUCT (iS AND as MODELS) .......... .. ................... ... .. ....... .. ............. . .... 670
REAR ACCESS PANELS (MODELS WITHOUT iS OR aS) . .. . ......... ....... .. . ............ . ... .... . . .. 670
WAKE PYLON (WAKE PRO 215)......................................................................... 671
05 - HULL (GTS/GTl/WAKE)...................................................................................... 675
GENERAL................................................................................................... 678
PROCEDURES.......... ......................................................... . ............... .. ........ 678
.
HULL ..................................................................................................... 678

INLET GRATE ............................................................................................ 679
RIDE PLATE.............................................................................................. 679
JET PUMP SUPPORT.................................................................................... 681
TH RU-HULL FITIING ... ................. ... ....... .... ....... ... ................ ..... ........... . ...... . 682
SPONSONS.............................................................................................. 683
BAILERS ................................................................................................. 683
DRAIN PLUGS . .......... ..... ..... .. . .... .. ..... .. ................. .. ..... .... . .. ......... .... ... ....... 684
BOW AND STERN EYELETS . ... .. ....... ....... .. ... .............. ..... ....... ......... ....... ......... 685
HULL INSERTS .......... ..... ....... . .. ......... ....... .. ..... ..... ... ..... ...... .............. ..... .... 686
06- HULL (GTX/RXT/WAKE PRO).......... ........................... ............................... .. ....... 689 . .
GENERAL .... ..... ..... ........ ..... .... ............ ..... .. ....... ............. ......... ........... ......... 692
PROCEDURES .................................. ... . ............ ................. ......................... 692
. .
HULL ..................................................................................................... 692

INLET GRATE ... ..... ..... .. ..... . ... . .... . ....... .............. ....... .... ........ ....... ......... ...... 692
RIDE PLATE.............................................................................................. 693
JET PUMP SUPPORT.................................................................................... 695
THRU-HULL FITIING ... ...... . .. ...... . ..... ........ .. ............ ............ .... ............ .... ... ... 697
SPONSONS.............................................................................................. 698
BAILERS ........... .............. ..... ... .... ..... .. ........ ................ ........ ...... .. ... .......... 699
DRAIN PLUGS ...... . .. ... .. .......... ... ..... .. ..... ....... ......... ... ..... ...... . . ........ ............ 700
BOW EYELET............................................................................................ 700
STERN EYELETS......................................................................................... 703
HULL INSERTS .... .......... . .... ........ .... ............................... ....... ................ .. ... 703
IX
TABLE OF CONTENTS
08 TECHNICAL SPECIFICATIONS
01 GTS 130 AND GTI 130........................................................................................
- 705
02 GTI 155 AND WAKE 155 .....................................................................................
-
711
03- GTX 155/215/260 ............................................................................................. 717
04- RXT 260 . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .......... . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . 723
05 - WAKE PRO 215................................................................................................ 729
09 WIRING DIAGRAM
01 WIRING DIAGRAM INFORMATION . ......... ...... . ......... ............ ....... ....... ....... ....... ...... 735
-
GENERAL ...... ......... . ...... ... . ... . ..... ...................... .......... ... ...... ...... ..... 735
. . . . . . . . . . . .
WIRING DI AGRAM LOCATION.......................................................................... 735

WIRING DIAGRAM CODES.............................................................................. 735
02 CONNECTOR INFORMATION............................................................................... 737
-
PROCEDURES 737
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . .. . . . . . . . . . .
MAGNETO AND ENGINE CONNECTOR (DEUTSCH) .. .... ..... ..... ....... ............................ 737
ECMCONNECTOR (MOLEX)............................................................................ 739
BRLS, TAS AND STARTER SOLENOID CONNECTORS (DELPHI)... .............. . ... .... ... ... 742 . . . . . . ..
iBR AND iS POWER CONNECTORS (DELPHI).......................................................... 743

SPS CONNECTORS (BOSCH) .. ..... ...... ....... .. .. . .. . . . .. . . .. . . .. . ... .. . . .. . .. .. . . . .. . . .. . .. .. .. . .. 743
•
INFORMATION CENTER CONNECTOR (DELPHI)....................................................... 744

VTS, iS, MODE/SET AND UP/DOWN SWITCH CONNECTORS (DELPHI)... ....... ... ......... ... ... 745 . . .
24 PIN STEERING CONNECTOR (APEX ERGOMATE) .. ...... ......... .. .......... .. .... . .............. 745
VOLTAGE REGUL ATOR/RECTIFIER CONNECTOR (FURUKAWA)....................................... 750
BATTERY CABLES . ............ ....... .................... . 750
. . .. • .. . . . . . . . . .. . . . . . . . . . . . . . . . . • . . . . . . . . . . . •
SAFETY NOTICE
SAFETY NOTICE
This manual has been prepared as a guide to NOTE: Indicates supplementary information re
correct l y service and repair 2011 Sea-Doo® wa quired to fully complete an instruction.
tercraft as described in the model list in the Although the mere reading of such infor mation
INTRODUCTION. does not eliminate the hazard, your understand
This edition was primarily published to be used ing of the information will promote its correct
by technicians who are already tam11tar with all use. Always use common shop safety practice.
service procedures relating to BRP products. It is understood that this manual may be trans
Mechanical technicians should attend training lated into another language. In the event of any
courses given by BRPTI. discrepancy the English version shall prevail.
,
Please note that the instructions will apply only BRP disclai m s liability for all damages and/or in
if proper hand tools and special service tools are juries resulting from the improper use of the con
used. tents. We strongly recommend that any services
The contents of this manual depicts parts and pro be carried out and/or verified by a highly skilled
cedures applicable to the particular product at the professional mechanic.
time of writing. Service and Warranty Bulletins
may be published to update the content of this
manual Dealer modifications that were carried
.
out after manufacturing of the product, whether

or not authorized by BRP. are not included.
In a ddit ion, the sole purpose of the illustrations
throughout the manual, is to assist identification
of the general configuration of the parts. They are
not to be interpreted as technical drawings or ex
act replicas of the parts .
The use of BRP parts is most strongly recom

mended when considering replacement of any
component. Dealer and/or distributor assistance
should be sought in case of doubt .
The engines and the corresponding components

identified in this document should not be utilized
on product(s) other than those mentioned in this
document.
It is understood that certain modifications may
render use of the watercraft illegal under existing
federal, provincial and state regul ations.
This manual emphasizes particular information de
noted by the following wording and symbols:
A WARNING
Indicates a potential hazard that, if not
avoided, could result in serious injury or
death.
A CAUTION Indicates a hazardous situation

which, if not avoided, could result in minor or
moderate injury.
ti+tuilllljIndicates a n instruction which, if not

followed, could result in severe damage to ve
hicle components or other property .
.,,,r2011--002 XI
INTRODUCTION
INTRODUCTION
This shop manual covers the following BRP made VEHICLE INFORMATION
2011 Sea-Doo watercraft models.
MODEL MODEL NUMBER HULL IDENTIFICATION NUMBER

GTI Limited 398A. 3988
(H.l.N.)
24BA, 2488, 248C, 308A, The hull identification number is composed of 12
GTI SE digits:
3088
GTI 238A, 2388 YDV 12345 L 4 95

Model year
GTS 258A, 438A, 4388
Year of production
GTX Limited iS 188A,1888
Month of production
GTXiS 338A
Serial number (a letter may also be used as a digit)
GTX 38BA,3888,428A,4288
Manufacturer
RXTiS 348A. 3488
RXT-X as 41BA It is located on the deck at the rear of watercraft .
RXT-XRS aS 4188
RXTX 318A
AXT XRS 3188
AXT 178A, 1788
WAKE 358A,358B
WAKE PRO 268A, 2688
The information and component/system descrip

tions contained in this manual are correct at time
of wr iti n g. BRP however, maintains a policy of
continuous improvement of its products without
imposing upon itself any obligation to install them
on products previously manufactured.
Due to late changes, there may be some differ smo2�·131 b
ences between the manufactured product and the TYPICAL
description and/or specifications in this document. 1. Hull Identification Number (H.l.N.J-aS and iS models
BRP reserves the right at any time to discontinue

or change specificat i ons, designs, features, mod
els or equipment without incurring obligation.
s m<iO I 0-034� 1.B
TYPICAL
1. Hull Identification Number (H.l.N.J - models without aS and iS
XII srnr2011·002
INTRODUCTION
ENGINE IDENTIFICATION
NUMBER (E.l.N.)
The Engine Identification Number is located on
front end of the engine.
TYPICAL
ENGINE EMISSIONS
INFORMATION
Manufacturer's Responsibility
Since production of the 1999 model year engines,
PWC manufacturers of marine engines are re
quired to determine the exhaust emission levels
for each engine horsepower family and certify
these engines with the United States of Amer
ica ENVIRONMENTAL PROTECTION AGENCY
(EPA). An emissions control information label,
showing emission levels and engine specifica
tions, must be placed on each vehicle at the time
of manufacture.
TYPICAL
1. Engine Identification Number (E.l.N.J Dealer Responsibility
When servicing all 1999 and more recent
HOISTING A WATERCRAFT SEA-000 watercrafts that carry an em1ss1ons
control information label, adjustments must be
To work on a watercraft, you should mount it se kept within published factory specifications.
curely on a stand.
Replacement or repair of any emission related
The LIFTING STRAP (PIN 529 036 171) MUST be component must be executed in a manner that
used to hoist and mount the watercraft on a maintains emission levels within the prescribed
stand. certification standards.
!L!l1)ilfJjj Using any lifting strap kit other t h a n Dealers are not to modify the engine in any man
t h e one recommended m a y cause damage t o ner that would alter the horsepower or allow emis
t h e vehicle. Bumpers c o u l d b e torn off. sion levels to exceed their predetermined factory
specifications.
Exceptions include manufacturers' prescribed
changes, such as altitude adjustments.
Owner Responsibility
The owner/operator is required to have engine
maintenance performed to maintain emission
levels within prescribed certification standards.
smr2011·002 XIII
INTRODUCTION
The owner/operator is not to, and should not al The use of RIGHT (starboard) and LEFT (port) in
low anyone else to modify the engine in any man dications in the text are always referenced to the
ner that would alter the horsepower or allow emis driving position (when sitting on the watercraft).
sions levels to exceed their predetermined factory
specifications.
EPA Emission Regulations

All new 1999 and more recent SEA-DOO water
crafts manufactured by BRP are certified to the
EPA standards as conforming to the requirements 1 2
._. ....
of the regulations for the control of air pollution
emitted from new watercraft engines. This certi
fication is contingent on certain adjustments be
ing set to factory standards. For this reason, the
factory procedure for servicing the product must
be strictly followed and, whenever practicable, re
turned to the original intent of the design. �ll-002_t
1. Left (port)
The responsibilities listed above are general and 2. Right (starboard)
in no way a complete listing of the rules and regu
lations pertaining to the EPA requirements on ex Other common terms used in the marine indus
haust emissions for marine products. For more try are the BOW (front of the watercraft), and the
detailed information on this subject, you may con STERN (rear of the watercraft).
tact: This manual uses technical terms which may be
different from the ones in the PARTS CATALOGS
For All Courier Services:
U.S. Environmental Protection Agency When ordering parts always refer to the specific
Office of Transportation and Air Quality model PARTS CATALOGS
1310 L Street NW
Washington D.C. 20005 MANUAL LAYOUT
This manual is divided into many major sections as
Regular US Postal Mail:
can be seen in the main table of contents at the
U.S. Environmental Protection Agency
beginning of the manual.
Office of Transportation and Air Quality
1200 Pennsylvania Ave. NW Each section is divided into various subsections,
Mail Code 6403J and again, each subsection has one or more divi
Washington D.C. 20460 sions.
INTERNET WEB SITE: http://www.epa.gov/otaq Illustrations and photos show the typical construc
tion of various assemblies and, in all cases, may
E-Mail: otaqpublicweb@epa.gov
not reproduce the full detail or exact shape of the
parts used in a particular model vehicle. However,
MANUAL INFORMATION they represent parts which have the same or a
similar function.
MANUAL PROCEDURES
Many of the procedures in this manual are inter
related. Before undertaking any task, you should
read and thoroughly understand the entire section
or subsection in which the procedure is contained.
A number of procedures throughout the book
require the use of special tools. Before com
mencing any procedure, be sure that you have
on hand all the tools required, or their approved
equivalents.
XIV smr2011.002
INTRODUCTION
TYPICAL PAGE
Section 06 ENGINE Page heading

Subsection 01 I� indi
(MAGNETO cates section
and subsection.
Subsection title-�--·· MAGNETO

Indicates applicable --'-----')lo•Made/s
models.
Locttta 243
Drop represents a
& service product
11
Exploded view assists
you in identifying parts --''-----1>•1 < Model
to be applied.
,
-
and their related Dotted box contains

positions. 1 ' ------- parts applicable to a
'(-
1 - - ,1
l - - - '
specific model.
Bold face number

,,...
•- ----- is used to identify
a part referred to
the text.
NEW indicates that the
part must be replaced --''----'--_.
with a new one.
Illustration number
for publishing process.
Document number for

publishing process. ---''-----1>•-·-.o•
.....,.___ Page number
....��
.
Specific torque applicable to this installation.
Ul111ljj Pay attention to torque specifications.

Some of these are in lbf•ln instead of lbf•ft.
Use appropriate torque wrench.
smr2011·002 xv
INTRODUCTION
TYPICAL PAGE
Section 03 ENGINE
Subsection 09 (MAGNETO SYSTEMI
Tittle in bold
indicates category --'-
--')>•GENERAL
of information to be
carried out. NU It; Ihe to!lowing procedures can be dO'ltl
W1thout removing the en{J ne
Duong asseirblymstalatooo. use the torque val
ues and service produe� es in the exploded
views.
Reference to a 00011 threads before opply1ng a threadlocker. Rt
specific section _
_ _!_
_ ....
·. ...:, ••-l
-- -
)>� .SElF-LOCK!NG rASTENERSand LOC
or subsection. TtrE APPLICATION sec1ions at the beginning of
this manual for complete procedure. "TYPICAL"
6, WARNING indicates a gene r al
Torque w
renc h tig htening sp ecifications
view which may
must be s tri ctl y adhered to. not represent exact
Locking devices ie.g.: l ockin g tabs, elastlc details.
Glop nuts, self-locking fas te ners, etc.) must
be replaced with new ones.
PROCEDURES NOTE: To remove s1011lng pul:ey bolls, hold mag Call-outs pertaining
neto flywheel v111h a socket as shown to above illustration.
Indicates component
procedures apply to. �MAGNETO FLYWHEEL
Magneto Flywheel Cleaning
Clean all metal components in a non-ferrous m etal
cleaner.
CAUTION: Clean magneto llywheol usl11g only

a clean cloth. Illustration always
Indicates specific
procedure to be --..!....-l)o�Magneto Flywheel Removal follows text to which
carried out. nomove muffler. refer to the EXHAUSTSYSTEM
it applies.
S<ICl<l<l
Remove acoustic panel
Remove rewind starter.
Remove starting pulley n o. 2. Italic bold face type
Moders�-------'-- setting indicates a
in procedure applicable
Remove the ooMecting fla,.,ge retain g the
reMnd s.arter 10 the engine hoos<ng. 10 a specific
model(s).
Bold face number following part

name refers to exploded view
at beginning of subsection.
XVI smrZ011--002
INTRODUCTION
TIGHTENING TORQUE
Tighten fasteners to the torque specified in the exploded view(s) and/or in the written procedure. When
a torque is not specified, the torque normally recommended for a specific fastener should be used. Refer
to the following table.
A WARNING
Torque wrench tightening specifications must be strictly adhered to.
Locking devices must be replaced when removed (e.g.: locking tabs, elastic stop nuts, self-lock
ing fasteners, cotter pins, etc.).
In order to avoid a poor assembly, tighten screws, bolts, or nuts in accordance with the following proce
dure:
1. Manually screw all screws, bolts and/or nuts.
2. Apply half the recommended torque value.
WtlitHj Be sure to use the recommended tightening torque for the specified fastener used.
NOTE: Whenever possible, always apply torque on the nut.

3. Tighten fastener to the recommended torque value.
NOTE: Always torque screws, bolts and/or nuts using a crisscross pattern when multiple fasteners are
used to secure a part (e.g. a cylinder head). Some parts must be torqued according to a specific se
quence and torque pattern as detailed in the installation procedure.
4.8 8.8 9.8 10.9 12.9
@ 0 0 0 0 Q@
Property
class and
head
markings
� ��
5 8 10 12
Property
©�© ©�© ©�© ©�©

class and
nut
marki n gs
AOOA8BS
FASTENER FASTENER GRADE/fORQUE

SIZE 5.8 Grade 8.8 Grade 10.9 Grade 12.9 Grade
1.5-2N•m 2.5-3N•m 3.5-4N•m 4-5N•m

M4
(13- 18 lbf•in) (22-27 lbf•in) (31 -35 lbf•ft) (35-44 lbf•ft)
3-3.5 N•m 4.5-5.5N•m 7 -8.5N•m 8-10N•m

M5
(27 - 31 lbf•ft) (40-47 lbf•ft) (62-75 lbf•ft) (71 -89 lbf•ft)
6.5-8.5N•m 8-12N•m 10.5-15N•m

M6 16N•m (142 lbf•in)
(58 - 75 lbf•ft) (71 - 106 lbf•ft) (93 - 133 lbf•in)
M8 15 N•m (133 lbf•in) 25N•m (18 lbf•ft) 32N•m (24 lbf•ft) 40N•m (30 lbf•ft)
M10 29 N•m (21 lbf•ft) 48N•m (35 lbf•ft) 61N•m (45 lbf•ft) 73N•m (54 lbf•ft)
M12 52 N•m (38 lbf•ft) 85N•m (63 lbf•ft) 105N•m (77 lbf•ft) 128N•m (94 lbf•ft)
M14 85 N•m (63 lbf•ft) 135N•m (1001bf•ft) 170 N•m (125 lbf•ft) 200N•m (1481bf•ft)
smr2011·002 XVII
INTRODUCTION
FASTENER INFORMATION 2. Apply LOCTITE PRIMER N (P/N 293 800 041) on

threads and allow to dry.
(+!lui@j Most fasteners are metric. Mis
3. Choose proper strength Loctite threadlocker.
matched o r incorrect fasteners could cause
damage to the vehicle. 4. Fit bolt in the hole.
5. Apply a few drops of threadlocker at proposed
SELF-LOCKING FASTENER tightened nut engagement area.
PROCEDURE 6. Position nut and tighten as required.
Thread locker Application for Blind

Holes
AOOA Ol.A
TYPICAL - SELF-LOCKING FASTENER

The following describes common procedures
used when working with self-locking fasteners.
Use a metal brush or a tap to clean the hole prop
erly, then use a solvent. Allow the solvent time
to act, approximately 30 minutes, then wipe off.
Solvent utilization is to ensure proper adhesion of lmr?007·040.00 4.•
the product used for locking the fastener. 7. On fastener threads

2. On threads and at rhe bottom of hole
LOCTITE® APPLICATION 1. Clean threads (bolt and hole) with solvent.

PROCEDURE 2. Apply LOCTITE PRIMER N (P/N 293 800 041) on
threads (bolt and nut} and allow to dry for 30
The following describes common procedures
seconds.
used when working with Loctite products.
3. Choose proper strength Loctite threadlocker.
NOTE: Always use proper strength Loctite prod
uct as recommended in this Shop Manual. 4. Apply several drops along the threaded hole
and at the bottom of the hole.
Threadlocker Application for 5. Apply several drops on bolt threads.
Uncovered Holes (Bolts and Nuts) 6. lighten as required.
7. Apply here
2. Do not apply
1. Clean threads (bolt and nut) with solvent.
XVIII sm.-2011-002
INTRODUCTION
Threadlocker Application for Stud Threadlocker Application for

Installation in Blind Holes Pre-Assembled Parts
1. On stud threads
2. On threads and in the hole
3. On retaining nut threads
2
AOOA30A
1. Clean threads (stud and hole) with solvent.
1. Apply here
2. Apply LOCTITE PRIMER N (P/N 293 800 041) on 2. Do not apply
threads and allow to dry.
3. Put 2 or 3 drops of proper strength Loctite 1. Clean bolts and nuts with solvent.
threadlocker on female threads and in hole. 2. Assemble components.
NOTE: To avoid a hydro lock situation, do not ap 3. Tighten nuts.
ply too much Loctite .
4. Apply a few drops of proper strength Loctite on

4. Apply several drops of proper strength Loctite bolt/nut contact surfaces.
on stud threads .
5. Avoid touching metal with tip of flask.
5. Install stud.
NOTE: For preventive maintenance on exist
6. Install cover, part, etc. ing equipment, retighten nuts and apply proper
7. Apply a few drops of proper strength Loctite on strength Loctite on bolt/nut contact surfaces.
uncovered stud threads.
Threadlocker Application for an
8. Install and tighten retaining nut(s) as required. Adjustment Screw
1. Apply here
2. Plunger
1. Adjust screw to proper setting.

2. Apply a few drops of proper strength Loctite
threadlocker on screw/body contact surfaces.
3. Avoid touching metal with tip of flask.
srnr2011-002 XIX
INTRODUCTION
NOTE: If it is difficult to readjust, heat screw with Gasket Compound Application

a soldering iron (232°C (450°F)).
Application for Stripped Thread Repair
1. Release agent
2. Strp
i ped threads 1 3
3. Form-A-Thread
4. Tape
5. Cleaned bolt 1. Proper strength Loctite
6. Plate 2. Loctite Primer N (PIN 293 800 041) and Gasket Eliminator 518
7. New threads (P/N 293 800 038) on both sides of gasket
8. Threadlocker 3. Loctite Primer N only
Standard Thread Repair 1. Remove old gasket and other contaminants us
Follow instructions on Loctite FORM-A-THREAD ing LOCTITE CHISEL (GASKET REMOVER) (P/N 413
81668 package. 708 500). Use a mechanical means only if nec
essary.
If a plate is used to align bolt:
NOTE: Avoid grinding.
1 . Apply release agent on mating surfaces.
2. Clean both mating surfaces with solvent.
2. Put waxed paper or similar film on the surfaces.
3. Spray Loctite Primer N on both mating surfaces
3. Twist bolt when inserting it to improve thread
and on both sides of gasket and allow to dry 1
conformation.
or 2 minutes.
NOTE: NOT intended for engine stud repairs.
4. Apply LOCTITE 518 (P/N 293 800 038) on both
Repair of Small Holes/Fine Threads sides of gasket, using a clean applicator.
Option 1: Enlarge damaged hole, then follow 5. Place gasket on mating surfaces and assemble
STANDARD THREAD REPAIR procedure. parts immediately.
Option 2: Apply FORM-A-THREAD on the screw NOTE: If the cover is bolted to blind holes, apply
and insert in damaged hole. proper strength Loctite in the hole and on threads.
Permanent Stud Installation (Light Duty) lighten fastener.
1. Use a stud of the desired thread length. If holes are sunken, apply proper strength Loctite
on bolt threads.
2. DO NOT apply release agent on stud.
6. lighten as usual.
3. Follow Standard Thread Repair procedure.
4. Allow 30 minutes for Loctite FORM-A-THREAD Threadlocker Application for Mounting
to cure. on a Shaft
5. Complete part assembly. Mounting with a Press
xx smr2011-002
INTRODUCTION
3. Apply a strip of proper strength Loctite on lead-

ing edge of outer metallic gasket diameter.
NOTE: Any Loctite product can be used here. A
low strength liquid is recommended as normal
strength and gap are required.
4. Install according to standard procedure.
5. Wipe off excess product .
6. Allow 30 minutes for product to cure.

AOOA3UA NOTE: Normally used on worn-out housin gs to
prevent leaking or sliding.
1. Bearing
2. Proper strength Loctite It is generally not necessary to remove gasket
3. Shaft
compound applied on outer gasket diameter.
1. Clean shaft external contact surface.
2. Clean internal contact surface of part to be in
stalled on shaft.
3. Apply a strip of proper strength Loctite on cir
cumference of shaft contact surface at inser
tion or engagement point.
NOTE: Retaining compound is always forced out
when applied on shaft.
4. DO NOT use antiseize Loctite or any similar
product.
5. No curing period is required.
Mounting in Tandem
1. Apply retaining compound on internal contact
surface (bore) of parts to be installed.
2. Continue parts assembly as per previous illus
tration.
Threadlocker Application for Case-In

Components (Metallic Gaskets)
- t
AOOA3VA 1
1. Proper strength Loctite
1. Clean inner housing diameter and outer gasket

diameter.
2. Spray housing and gasket with LOCTITE PRIMER
N (P/N 293 800 041).
smr2011·002 XXI
XXll smr201 1·002
SERVICE TOOLS INDEX
3-PIN MAGNETO HARNESS BEARING SUPPORT/PUSHER DIAGNOSTIC HARNESS

ADAPTER (P/N 529 035 950) (P/N 529 036 188)
(P/N 529 036 016}
Page: 280, 342, 385, 399-400, 433,

Page: 101-102 Page: 61-62
436-437, 470, 489-491, 746
4-PIN SOCKET BLIND HOLE BEARING PULLER SET DIGITAL INDUCTION TACHOMETER
{P/N 529 035 948) (P/N 529 036 117) (P/N 529 014 500)
Page: 59, 62 Page: 288

Page: 101
ADAPTER HOSE DRIVE SHAFT ADAPTER

CAMSHAFT LOCKING TOOL
(P/N 529 035 652) (P/N 529 035 985)
(P/N 529 035 839)
Page: 54. 161
CRANKSHAFT LOCKING TOOL

(P/N 529 035 821)
Page: 115 Page: 154
ALIGNMENT SHAFT ADAPTER

===·-==--
DRIVE SHAFT C-CLIP REMOVER
(P/N 529 035 719) (P/N 529 036 026)
Page: 184, 188, 190, 195
CRIMPING TOOL (HEAVY GAUGE

WIRE)
(P/N 529 035 730)
Page: 26-28
ALIGNMENT SHAFT SUPPORT Page: 542

(P/N 529 035 506)
Page: 751 ECM ADAPTER TOOL
(P/N 529 036 166)
D.E.S.S. POST REMOVER
(P/N 529 035 943)
Page: 26
ALIGNMENT SHAFT
(P/N 295 000 141)
Page: 117, 134, 205, 292, 302, 310,

Page: 26-29 314,316,318,320,338,358,384,388,
400, 741
Page: 461
SERVICE TOOLS INDEX
ECM TERMINAL REMOVER 2.25 FLUKE 115 MULTIMETER HANDLE

(P/N 529 036 175) (P/N 529 035 868) (P/N 420 877 650)
Page: 101, 193
IMPELLER REMOVER/INSTALLER
Page: 741 (P/N 529 035 820)
Page: 117, 134, 205, 280, 285, 292,
ECM TERMINAL REMOVER 3.36 301-303,308, 310,312,314,317-318,
(P/N 529 036 174) 337, 342-343, 357-358, 384-385,
387-388, 399-400, 432, 434, 436,
438, 443, 470, 489, 494-495, 513,
582-585, 587
Page: 100. 529-531, 533. 536
FLUSHING CONNECTOR ADAPTER

(P/N 295 500 473)
(P/N 529 035 956)
Page: 741
ENGINE ALIGNMENT TOOL

(P/N 529 036 197)
Page: 529-531, 533. 536
Page: 83
IMPELLER SHAFT BEARING TOOL
FUEL HOSE ADAPTER (P/N 529 036 168)
(P/N 529 036 023)
Page: 27
ENGINE LEAK DOWN TEST KIT

(P/N 529 035 661) Page: 533-534
Page: 335
IMPELLER SHAFT PUSHER
FUEL HOSE DISCONNECT TOOL (P/N 529 035 955)
(P/N 529 036 037)
Page: 297
Page: 154
FUEL PUMP MODULE SOCKET
Page: 533-534
FLOATING RING TOOL (TYPE I) (P/N 529 036 125)
(P/N 529 035 841 l LARGE HOSE PINCHER
(P /N 529 032 500)
Page: 542, 547

Page: 339
Page: 19. 73
2
SERVICE TOOLS INDEX
MAGNETO HARNESS 6 PINS PISTON CIRCLIP INSTALLER SEAUBEARING PUSHER

(P/N 295 000 136) (P/N 529 035 765) (P/N 529 035 8191
Page: 181
Page: 582 Page: 535
PRESSURE CAP
MPl-2 DIAGNOSTIC CABLE (P/N 529 036 172)
SMALL HOSE PINCHER
(P/N 710 000 851)
(P/N 295 000 076)
Page: 519
PRESSURE GAUGE
Page: 209 (P/N 529 035 709) Page: 332-333
MPl-2 INTERFACE CARD

STARTER DRIVE SEAL PUSHER
!P/N 529 036 018)
(P/N 420 876 502)
Page: 101. 193
Page: 115, 335

STEERING CABLE TOOL
(P/N 295 000 145)
Page: 210 PTO SUPPORT TOOL
(P/N 529 035 842) co --
--IE
OETIKER PLIERS
(P/N 295 000 070) Page: 465
SUCTION PUMP
(P/N 529 035 880)
Page: 543, 546
Page: 100, 146, 336

PUMP PLATE
(P/N 529 036 224)
OIL SEAL GUIDE
(P/N 529 035 822) Page: 18, 95, 113
SUPERCHARGER GEAR HOLDER

(P/N 529 036 025)
Page: 123
Page: 26, 521-522
Page: 55
3
SERVICE TOOLS INDEX
SUPERCHARGER OIL SPRAY NOZZLE THAU-HULL ADAPTER VALVE SPRING COMPRESSOR CUP
TOOL (P/N 529 036 193) (P/N 529 036 073)
(P/N 529 036 134)
Page: 165
Page: 128
VALVE SPRING COMPRESSOR
SUPERCHARGER RETAINING KEY (P/N 529 035 724)
(PIN 529 036 027) Page: 28
TORX ADAPTER
(P/N 529 035 938)
. -
- .
Page: 165
Page: 58-59, 64 Page: 57, 65

WATER PUMP SEAL PUSHER
SUPERTANIUM DRILL BIT 3/16' VACUUM/PRESSURE PUMP (P/N 529 035 823)
(P/N 529 031 800) (P/N 529 021 800)
Page: 560, 594, 615-616, 619, 650
SUPPORT PLATE
(P/N 529 035 947) Page: 123-124
Page: 68, 73, 146, 331, 378, 519
VALVE GUIDE PUSHER (6 MM)

(P/N 529 036 087)
Page: 55, 58, 61-62 •...._,

I .- .•
\ ,� .... '! - "
' .. '
TEST CAP
-----.c.-----....__..IL..I_...� - -
(P/N 529 035 991)
Page: 170
VALVE GUIDE REMOVER (6 MM)

(P/N 529 036 086)
Page: 145
Page: 170
4
Section 01 MAINTENANCE
Subsection 01 (BREAK-IN INSPECTION)
BREAK-IN INSPECTION
BRP recommends that the maintenance or inspection items listed in the following table be carried out
immediately after the first 1 O hours of operation (break-in period).
NOTE: Some maintenance or inspection items listed in the following maintenance schedule may not be
applicable to every watercraft model (iS. aS. iBR and supercharger components). Follow maintenance
schedule as applicable to watercraft model.
REPLACE
ADJUST
BREAK-IN INSPECTION CHART LUBRICATE
CLEAN
INSPECT
ENGINE
Engine oil and filter x

Rubber mounts x
Corrosion prote c tion x
Supercharger clutch x
EXHAUST SYSTEM
Exhaust system fasteners, hoses and components condition. Also inspect for leaks x
'"
COOLING SYSTEM
Hose and fasteners x

Coolant x
--
FUEL SYSTEM
Fuel cap, filler neck, fuel tank, fuel tank straps, fuel lines and connecti ons x
Fuel system leak test x
Throttle body x
- ··- � --- --·
·-
AIR INTAKE SYSTEM

-·
Air in take si lenc er x

ELECTRONIC MANAGEMENT SYSTEM
EMS sensors x
Fault codes (ECM, iBR, iS, cluster) x
ELECTRICAL SYSTEM
Spark pl ug s x
Electrical connections and fastening (ignition system, starting system, fuel injectors, fuse boxes etc.) x
Engine cut-off switch x
Monitoring beeper x
Battery and fasteners x
STEERING SYSTEM
Steering cable and connections x

Steering nozzle bushings x
O.T.A.S. (see NOTE 1 after break-in inspection chart) x
smr2011-046 5
Subsection 01 (BREAK-IN INSPECTION)
REPLACE
ADJUST
BREAK-IN INSPECTION CHART LUBRICATE
CLEAN
INSPECT
PROPULSION SYSTEM
Carhnn ring and rubber boot (drive shaft) x

Impeller boot x
Sacrificial anode (if so equipped) x
Impeller and impeller wear ring clearance x
Pump mounts x
iBR SYSTEM (intelligent Brake and Reverse)
iBR gate backlash x
iBR support plates x
iBR friction sleeves x
iBR connecting arms, sleeves and bushings x
iBR U lever, VTS trim ring, iBR gate and bushings x

iBR U a r m to actuator shaft retaining screw torque (see NOTE 2 after break-in inspection chart) x
iBR protective guard x

iS SYSTEM (intelligent Suspension)
iS oil x
iS position sensor x
aS SYSTEM (adjustable Suspension)

-
Nitrogen remote reservoir (adjustment knob, mounts) x

HULL/BODY
_,
Hull x
Ride plate and water intake grate x
(1) Inspect operation.

(2) Ensure proper torque of screws retaining iBR U arm to iBR actuator shaft. If retaining screws found loose. do not re-torque them.
Replace them with new ones.
6 smr2011-048
Subsection 02 (MAINTENANCE SCHEDULE)
MAINTENANCE SCHEDULE
The maintenance schedule should be adjusted according to operating conditions and use.
NOTE: The schedule provides an equivalence between number of hours and months/year. Maintenance
operations should be carried out following whichever time frame comes due first.
IMPORTANT: Watercraft rental operations or intensive use of watercraft, will require greater frequency
of inspection and maintenance.
When m;:iintP.n;:ince is completed, the maintenance reminders must be cleared using B.U.D.S. Refer to
the (INFORMATION CENTER GAUGE} subsection.
NOTE: Some maintenance or inspection items listed in the following maintenance schedule may not be
applicable to every watercraft model (iS, aS. iBR and supercharger components}. Follow maintenance
schedule as applicable to watercraft model.
A: ADJUST 25 HOURS OR 3 MONTHS
C: CLEAN
50 HOURS OR 6 MONTHS
I: INSPECT
L: LUBRICATE 100 HOURS OR 1 YEAR
R: REPLACE 200 HOURS OR 2 YEAR
0: OPERATOR TO BE PERFORMED BY
D: DEALER
PART/TASK NOTE
ENGINE
Engine oil and filter R D
Rubber mounts I D
(1) See NOTE 1 afte r maintenance schedule.
Corrosion protection L 0
Supercharger clutch R t11 0
EXHAUST SYSTEM
I, C (2) Daily fl ushi ng in salt water or foul
Exhaust system 0/D
(21 water use .
COOLING SYSTEM
Coolant R D -
FUEL SYSTEM
iTC lever t3J I, L 0/0 (3) See NOTE 2 after maintenance schedule.
Fuel cap, filler neck, fuel tank, fuel tank straps, fuel lines and
I !4l 0
connections (4) At stora g e period or after 100 hours of
Fuel system leak test I 0 use whi cheve r comes first.
Throttle body I 0
- � -
AIR INTAKE SYSTEM

Air intake silencer I. c 0
-
Blow-by valve hose I, c 0

ELECTRONIC MANAGEMENT SYSTEMS
EMS sensors I 0
-
Fault codes (ECM. iBR, iS. Cluster) I 0
smf.?011-003 7

C: CLEAN
I: INSPECT
D: DEALER
PAR T/TASK NOTE
ELECTRICAL SYSTEM
Spark plu g s I A D
Ign it ion coils I, L 0
Electrical connections and fastening (ignition system, start ing
I 0 (5) Inspect on ce a month. Add electrolyte
system. fuel injectors, fuse boxes etc.)
as required.
Engine cut-off switch I 0
Mo n i toring be e pe r I 0
Battery an d fasten ers I ISl 0
STEERING SYSTEM
Steering cable and connections I 0
Steering nozzle bu shing s I D (6) Inspect operation.
O.T.A.S. (61 I 0
PROPULSION SYSTEM
Carbon ring and rubber boot (drive shaft) I 0
Impeller boot I 0
(4) At storage period or after 100 hours
Impeller shaft seal, sleeve and 0-ring I !4l D of use whichever comes first.
D rive shaft/i mpeller splines I, L 0 (7) Inspect each month (more often
I 171 in salt water use) and change whe n
Sacrificial anode (if so equipped) 0
necessary.
Impeller and impeller wear ring cle arance I 0
Pump mounts I D
-
iBR SYSTEM (intelligent Brake and Reverse)
iBR control lever 131 I, l 0/0
iBR gate backlash I D
iBR support plates I D
(3) See NOTE 2 after maintenance cha rt.
iBR friction sleeves R 0
(4) At s torage period or after 100 hours
iBR connecting arms. sleeves and bushings I 0 of use whichever comes first.
iBR U lever, VTS trim ring, iBR gate and bushings I D (8) See NOTE 3 after maintenance
s chedule.
I
iBR U arm to actuator shaft retaining screw torque (4) D
(8)
iBR prot ecti ve g uard I 0

i S SYSTEM (intelligen t Su sp ensio n)
iS oil (9l I D (9) Check pump reservoir oil level and for
iS position sensor I D system leaks.
8 smr2011-000

C: CLEAN
I: INSPECT
D: DEALER
PART/TASK NOTE
aS SYSTEM (adjustable Suspension)

Nitrogen remote reservoir (adjustment knob, mounts) D
HULL AND BODY
Hull 0
Ride plate and water intake grate 0
(1) The supercharg er clutch requires replacement when the SUPERCHARGER MAINTENANCE REQUIRED message is displayed on the
information center every 100 hours of operation or earlier depending on the riding style (speed. engine's RPM. water conditions). This
is determined by the engine management system. The supercharger clutch will need to be replaced within 5 hours of the message
display. The supercharger maintenance reminder must be reset using B.U.D.S. in order to reset the supercharger maintenance hour
counter, even i f the maintenance was carried out before the reminder appeared in the information center.
(2) The iTC and i BR levers should be inspected by depressi ng and releasing the levers to check for freedom of movement . If any friction
is felt, the lever must be taken apart, cleaned, inspected for wear and lubricated.
(3) Ensure proper torque of screws retaining iBR U arm to iBR actuator shaft. If retaining screws are found loose, do not re torque
-
them. Replace them with new ones.
smr2011-003 9
10
Subsection 03 (STORAGE PROCEDURE)
STORAGE PROCEDURE
SERVICE PRODUCTS
Description Part Number Page
DOW CORNING 111 .................................................................... . 413 707 000 ........................................... 14
LOCTITE 767 (ANTISEIZE LUBRICANT) ...................................... . 293 800 070 ........................................... 13
XPS FUEL STABILIZER................................................................ .. 413 408 601 . .............. ........... .............. . . . 11
XPS LUBE . . . . . . . . . . . . . . ...... .............................. .................................... 293 600 016 ............................... 11, 13-14
PROCEDURES A WARNING
Always stop the engine before refueling.
PROPULSION SYSTEM Fuel is inflammable and explosive under
certain conditions. Always work in a well
XPS Lube Cleaning ventilated area. Do not smoke or allow open
Clean jet pump by spraying water in its inlet flames or sparks in the vicinity. Fuel tank may
and outlet and then apply a coating of XPS LUBE be pressurized, slowly turn cap when open
(P/N 293 600 016) or equivalent. ing. When fueling, keep watercraft level.
Do not overfill or top off the fuel tank and
A WARNING leave watercraft in the sun. As temperature
Always remove tether cord from the engine increases, fuel expands and might overflow.
cut-off switch to prevent unexpected engine Always wipe off any fuel spillage from the
starting before cleaning the jet pump area. watercraft. Periodically inspect fuel system.
Engine must not be running for this opera
tion.
l!ff1Jitij Should any water be trapped inside
fuel tank, severe internal damage will occur to
Jet Pump Inspection
the fuel injection system.
Remove impeller cover and check if jet pump is
water contaminated; if so, refer to JET PUMPsub
ENGINE
section for the repair procedure.
Engine Oil and Filter Replacement
FUEL SYSTEM Change engine oil and filter. Refer to LUBRICA
TION SYSTEM subsection.
Fuel System Inspection
Verify fuel system. Check fuel hoses for leaks. Exhaust System Flushing
Replace damaged hoses or clamps if necessary.
Flush the exhaust system. Refer to EXHAUST
SYSTEM subsection.
Fuel System Protection
XPS FUEL STABILIZER (P/N 413 408 601) (or equiva lntercooler Draining (260 Engine)
lent) should be added in the fuel tank to prevent
It is important to expel any trapped water that may
fuel deterioration and fuel system gumming. Fol
have accumulated from condensation in the exter
low manufacturer's instructions for proper use.
nal intercooler.
llft•Jllill Fuel stabilizer should be added ti+ttJitij Failure to drain the intercooler may
prior to engine lubrication to ensure fuel sys
cause severe damage to this component.
tem component protection against varnish
deposits. Proceed as follows:
Fill up fuel tank completely Ensure there is no wa

. iS and aS Models
ter inside fuel tank. 1. Open the boarding platform and remove the RH
storage bin.
smr2011-004 11
2. Ensure there is an alignment line drawn on the 2. Ensure there is an alignment line drawn on the
intercooler outlet hose. This will ensure the throttle body inlet hose. This will ensure the
hose is not twisted or kinked on reinstallation. hose is not twisted or kinked on reinstallation.
3. Loosen the clamp retaining the intercooler out 3. Loosen the clamp retaining the hose to the
let hose. throttle body.
4. Remove the intercooler outlet hose from the in- 4. Remove the hose from the throttle body and
tercooler. direct it away from the throttle body and other
components.
NOTE: This hose feeds the inlet of the throttle
body. 5. Start engine and rev up to 4000 RPM several
times. Water will be expelled from the inter
1S Models
cooler.
5. Drape a couple of shop rags over the iS module NOTE: Prevent air intake system from aspirating
to protect it from any expelled water from the
foreign objects which may cause severe engine or
intercooler.
damage.
6. Stop engine.
7. Properly align and reinstall hose on throttle
body.
8. Torque intercooler hose clamp as specified.
INTERCOOLER HOSE CLAMP TORQUE

4 N•m (35 lbf•in)
Exhaust System Protection

The exhaust system is self draining, but the ex
haust manifold and intercooler (215 engine) need
to be drained to avoid damages should the water
craft be stored in an area where the temperature
attains the freezing point of water.
TYPICAL
1. Hose altgnment lines
Using the flushing connector located at the rear of
2. Hose clamp vehicle, inject pressurized air (at 380 kPa (55 PSI))
3. lntercooler outlet hose
4. iS module
in the system until there is no more water flowing
from jet pump.
All Models
6. Start engine and rev up to 4000 RPM several
times. Water will be expelled from the inter
cooler.
NOTE: Prevent air intake system from aspirating
damage.
7. Stop engine.
8. Properly align and reinstall hose on intercooler.
9. Torque intercooler hose clamp as specified.
INTERCOOLER HOSE CLAMP TORQUE

4 N•m (35 lbf•in) 1. Flushmg connector
The following hose can be fabricated to ease

Models Without iS or aS
draining procedure.
1 . Open the seat.
12 smr2011-0Q.d
Su bse c tion 03 (STORAGE PROCEDURE)
A WARNING
When disconnecting coil from spark plug, al
ways disconnect coil from main harness first.
Never check for engine ignition spark from
an open coil and/or spark plug in the engine
TYPICAL compartment as the spark may cause fuel va
1. Flushing adaptor (PIN 295 500 473)
2. Hose
13mm (1/2in) pors to ignite.
3. Air hose male adapter
l.U•>itiii Failureto drain the exhaust mani

IN.Jililj Never cut the locking ties of ignition
fold may cause severe damage to components.
coil connectors. This would allow mixing of
the wires between cylinders.
Engine Coolant Replacement
Antifreeze should be replaced every 200 hours or 4. Clean the area around the ignition coils to avoid
every two years to prevent antifreeze deteriora dirt falling into a cylinder.
tion .
5. Remove ignition coils.
IW•Jifilj Failure to replace the antifreeze as 6. Unscrew spark plugs.

recommended may allow its degradation that 7. Using an ignition coil as a puller. remove spark
·
could result in poor engine cooling. plugs.
If coolant is not replaced, test the coolant density

using an antifreeze hydrometer.
Replace coolant if necessary. For the coolant re
placement procedure, refer to COOLING SYSTEM
subsection.
IWuit11#1 1mproper antifreeze density may

result in coolant freezing should the vehicle
be stored in area where the freezing point
is attained. This could seriously damage the
engine.
Engine Internal Lubrication

Engine must be lubricated to prevent corrosion on
internal parts.
Lubrication of the engine is recommended at the 1. Igni tion coil
end of the season and before any extended stor 2. Spark plug
age period to provide additional corrosion protec
8. Spray XPS LUBE (P/N 293 600 016) into each
tion. This will lubricate the engine intake valves,
spark plug hole.
the cylinders and the exhaust valves.
9. Crank the engine a few turns to distribute the
To lubricate the engine, proceed as follows:
oil on cylinder wall.
1 Open seat.
.
NOTE: To crank engine, use the drowned mode

iS and aS Models to avoid injecting fuel. Fully depress throttle lever
2. Remove the rear ventilation box. and hold for cranking engine.
10. Apply LOCTITE 767 (ANTI SEIZE LUBRICANT)
All Models
(P/N 293 800 070) on spark plug threads then
3. Disconnect ignition coil connectors. reinstall them.
NOTE: Refer to IGNITION SYSTEM subsection
for details on installing the spark plugs and igni
tion coils.
smr201Hl04 13
11. Prior to inserting the ignition coil onto its spark Hull Repair
plug, apply some DOW CORNING 111 (P/N 413 If any repair is required, refer to appropriate HULL
707 000) around the seal area that touches the subsection.
spark plug hole.
12. Reinstall ignition coils. Body and Hull Protection
13. Ensure the seal seats properly with the engine Apply a good quality marine wax on body and hull.
top surface. If the watercraft is to be stored outside, cover it
14. Reconnect ignition coil connectors. with an opaque tarpaulin to prevent sun rays and
grime from affecting the plastic components, wa
15. Install all other removed parts.
tercraft finish as well as preventing dust accumu
lation.
ELECTRICAL SYSTEM
IN1)iliJj The watercraft should never be left
Battery Removal in water for storage, stored in direct sunlight
For battery removal, cleaning and storage, refer to or stored in a plastic bag.
CHARGING SYSTEM subsection.
ENGINE COMPARTMENT
Engine Compartment Cleaning
1 . Clean the bilge with hot water and a mild deter
gent, or using bilge cleaner.
2. Rinse thoroughly.
3. Lift front end of watercraft to completely drain
bilge. Refer to appropriate HULL subsection for
bilge drain plug removal.
Anticorrosion Treatment
Wipe off any residual water in the engine compart
ment.
Spray XPS LUBE (P/N 293 600 016) over all metallic
components in engine compartment.
NOTE: The seat should be left partially open
during storage. This will prevent engine compart
ment condensation and possible corrosion.
BODY AND HULL

Body and Hull Cleaning
Wash the body with a soap and water solution
(only use a mild detergent). Rinse thoroughly with
fresh water. Remove marine organisms from the
hull.
W1JiliJj Never clean body parts or hull with

strong detergent, degreasing agent, paint thin
ner, acetone, etc.
Replace damaged labels/decals.
Body Repair
If any repair is required, refer to BODYsubsection.
14 smr2011-004
SE�DD. �
WATERCRAFT
SERVICE
Bulletin
October 29, 2010 Subject: Storage Procedure No. 2010-7
YEAR MODEL MODEL NUMBER SERIAL NUMBER
2010 All All All
NOTE: Carry out the following tasks in the same Fuel System Protection
order as detailed in this bulletin. The BRP FUEL STABILIZER (P/N 413 408 600) or
equivalent should be added in fuel tank to pre
PROCEDURES vent fuel deterioration and fuel system gumming.
Follow manufacturer's instructions for proper
Propulsion System use.
Jet Pump Cleaning fW1Jilijj Fuel stabilizer should be added prior

to engine lubrication to ensure fuel system
Clean jet pump by spraying water in its inlet
components protection against varnish de
and outlet and then apply a coating of XPS LUBE
posits.
(P/N 293 600 016) or equivalent.
A WARNING Engine
Always remove safety lanyard cap from post Engine Oil and Filter Replacement
to prevent unexpected engine starting before Change engine oil and filter. Refer to LUBRI
cleaning the jet pump area. Engine must not CATION SYSTEM subsection in the appropriate
be running for this operation. SHOP MANUAL.
Jet Pump Inspection lntercooler Draining

Remove impeller cover and check if jet pump is It is important to expel any trapped water that may
water contaminated; if so, refer to JET PUMPsub have accumulated from condensation in the exter
section in the appropriate SHOP MANUAL for the nal intercooler.
repair procedure.
ffl•Jm:Jj Failure to drain the intercooler may
Drive Shaft Corrosion Protection cause severe damage to this components.
No protection against corrosion is required since All 255 Engine Models except iS Series
the drive shaft is rubber-coated.
1 . Removed the intake hose from throttle body.
Fuel System
Fuel System Inspection
Verify fuel system. Check fuel hoses for leaks.
Replace damaged hoses or clamps if necessary.
1i![1Jilijj Salt water use

may cause clamps to
prematurely corrode. Therefore, they would
require a closer look and a more frequent pre
ventive replacement.
Printed in Canada. (sbs201 Q..005 en AP) 1 I 4

©2010 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved.
®™ and the BRP logo are trademarks of Bombardier Recreational Products. Inc. or its affiliates.
1. Intake hose
2. Throttle body
1. Hose alignment lines
2. Hose clamp
2. Start engine and rev up to 4000 RPMs several 3. lntercooler outlet hose
4. iS module
times. Water will be expelled from intercooler.
4. Start engine and rev up to 4000 RPMs several

times. Water will be expelled from intercooler.
NOTE: Prevent air intake system from aspirating
damage.
5. Stop engine.
6. Install intercooler outlet hose.
Exhaust System Protection

The exhaust system is self draining, but the ex
haust manifold needs to be drained to avoid dam
ages if watercraft is stored in area where freezing
weather is present.
Using the flushing connector located at the rear
3. Stop engine. of vehicle, inject pressurized air into system until
there is no more water flowing from jet pump.
4. Liberally lubricate throttle body inside and out.
5. Clean off any lubrication on the throttle body MODEL AIR PRESSURE
intake hose flange. iS Series 380 kPa (55 PSI)
6. Install air intake hose to the throttle body. All other models 689 kPa (100 PSI)
iS Series
Proceed as follows:
1 . Loosen the clamp retaining the intercooler out
let hose.
2. Remove the intercooler outlet hose from the in-

tercooler.
NOTE: This hose feeds the inlet of the throttle
body.
3. Drape a couple of shop rags over the iS module
to protect it from any expelled water from the
intercooler. smi1009-021-004.'
TYPICAL - IS SERIES
1. Flushing connector
2I 4 2010-7 SERVICE
Lubrication of the engine is recommended at the
end of the season and before any extended stor
age period to provide additional corrosion protec
tion. This will lubricate the engine intake valves,
the cylinders and the exhaust valves.
To lubricate the engine, proceed as follows:
1. Open seat and remove the rear ventilation box.

2. On iS series, remove the rear ventilation box.
For all other models, pull engine cover upward
and remove it.
3. Disconnect ignition coil connectors.
smo 2008 -00 1 -054
TYPICAL
_ a
ALL OTHER MODELS

-
A WARNING
1. Flushing connector - location may differ When disconnecting coil from spark plug, al
ways disconnect coil from main harness first.
The following hose can be fabricated to ease
draining procedure.
compartment as spark may cause fuel vapor
to ignite.
IW1)@jj Never cut the locking ties of ignition

coil connectors. This would allow mixing the
TYPICAL wires between cylinders.
7. Flushing adaptor (PIN 295 500 473)
2. Hose 73mm (1/2in)
3. Air hose male adapter 4. Clean ignition coil areas to avoid falling dirt into
cylinder.
li!t•Ji@j
Failure to drain the exhaust manifold
5. Remove ignition coils.
may cause severe damage to this components.
6. Unscrew spark plugs.
Engine Coolant Replacement 7. Using an ignition coil as a puller, remove spark
Antifreeze should be replaced every 200 hours or plugs.
every two years to prevent antifreeze deteriora
tion.
£![1)@jj Failure to replace the antifreeze a s

recommended m a y allow its degradation that
could result in poor engine cooling.
If coolant is not replaced, test the coolant density

using an antifreeze hydrometer.
Replace coolant if necessary. For the coolant re

placement procedure. refer to COOLING SYSTEM
subsection in the appropriate SHOP MANUAL
fift.Ji@j Improper antifreeze density might

lead coolant to freeze if vehicle is stored in
area where freezing point is reached. This
would seriously damage the engine.
1. Ignition coil
2. Spark plug
Engine Internal Lubrication
Engine must be lubricated to prevent corrosion on 8. Spray XPS LUBE (P/N 293 600 016) into each
internal parts. spark plug hole.
9. Crank the engine a few turns to distribute the

oil on cylinder wall.
SERVICE 2010-7 3I 4
NOTE: To crank engine, use the drowned mode Vehicle Protection
to avoid injecting fuel. Fully depress throttle lever Apply a good quality marine wax on body and hull.
and hold for cranking engine.
The seat should be left partially open during stor
10. Apply LOCTITE 767 (ANTISEIZE LUBRICANT)
age. This will prevent engine compartment con
(P/N 293 800 070) on spark plug threads then
densation and possible corrosion.
reinstall them.
If the watercraft is to be stored outside, cover it
11. Prior to inserting the ignition coil to its loca with an opaque tarpaulin to prevent sun rays and
tion, apply some DOW CORNING 111 (P/N 413
grime from affecting the plastic components, wa
707 000) around the seal area that touches the
tercraft finish as well as preventing dust accumu
spark plug hole. lation.
12. Reinstall ignition coils.
iW.JmJj The watercraft should never be left in
13. Ensure the seal seats properly with the engine water for storage, stored in direct sunlight or
top surface.
stored in a pl astic bag.
14. Reconnect ignition coil connectors.
Electrical System
Battery Removal
For battery removal, cleaning and storage, refer to
CHARGING SYSTEM subsection in the appropri
ate SHOP MANUAL.
Vehicle
Bilge Cleaning
Clean the bilge with hot water and mild detergent
or with bilge cleaner.
Rinse thoroughly.
Lift front end of watercraft to completely drain
bilge.
Body and Hull Cleaning

Wash the body with soap and water solution {only
use mild detergent). Rinse thoroughly with fresh
water. Remove marine organisms from the hull.
g+t.Ji[iJjNever clean body parts or hull with

strong detergent, degreasing agent, paint thin
ner, acetone, etc.
Replace damaged labels/decals.
Body Repair
If any repair is needed, refer to BODY subsection
in the appropriate SHOP MANUAL.
Anticorrosion Treatment
Wipe off any residual water in the engine compart
ment.
Spray XPS LUBE (P/N 293 600 016) over all metallic
components in engine compartment.
4I 4 2010-7 SERVICE
Subsection 04 (PRESEASON PREPARATION)
PRESEASON PREPARATION
Proper vehicle preparation is necessary after the
winter months or when a watercraft has not been
used during 4 months.
Any worn, broken or damaged parts found during
the storage procedure should have been replaced.
If not, proceed with the replacement.
Referring to the maintenance schedule, carry out
the maintenance procedures for every item spec
ified in the columns 100 HOURS OR 1 YEAR, and
TO BE PERFORMED BY.
A llOJUSl
C: CIIAll 1 --,....:.----1
l INSPECT
I,; LUBRJCAlE
R: REPlACI:
0: OPEAAIOR
0; DEAi.ER
ENGIN E
E)(HAUSf.SYS TEM
0 fl! Doily1""'°9iniltw;�"
JO �Wl:UU•
1. Use rhasa columns
Furthermore, proceed with the following:

Watercraft Prepared as per Storage Procedure
- Ensure battery is fully charged.
- Reinstall the battery.
- Test ride watercraft to confirm proper opera-
tion.
Watercraft Not Prepared as per Storage Proce
dure
- Ensure battery is fully charged.
- Replace engine oil and filter.
- Drain fuel tank and fill with fresh fuel.
- Reinstall the battery.
- Test ride watercraft to confirm proper opera-
tion.
smr2011-005 15
16
Subsect io n 05 (SPECIAL PROCEDURES)
SPECIAL PROCEDURES
SERVICE TOOLS
.
LARGE HOSE PINCHER................................................................ 529 032 500 .... ... . ............ .......... . ......... . . 19
SUCTION PUMP ........... .......... ............................. ......................... 529 035 880 ........................................... 18
GENERAL Engine Lubrication
Refer to the following special procedures accord Refer to WATER-FLOODED ENGINE in this sub
ing to the specific event. Procedures described section.
may not be applicable to every watercraft model.
Fuel Inspection
PROCEDURES Check fuel tank for water contamination. If nec
essary, siphon and refill with fresh fuel.
TOWING THE WATERCRAFT IN

WATER WATER-FLOODED ENGINE
If the engine is flooded with water, it must be ser
Special precautions should be taken when towing
viced within a few hours after the event. Other
a Sea-Doo watercraft in water.
wise, the engine will have to be overhauled.
The maximum recommended towing speed is
24 km/h (15 MPH). IM•Ji&i
- Never try to crank or start the engine. Water
This will prevent the exhaust system from fill
trapped in the intake manifold would enter
ing with water, which may lead to water being
the combustion chamber through the intake
injected into and filling the engine. Without the
valves and may cause damage to the engine.
engine running, there isn't any exhaust pressure
to push the water out the exhaust outlet. - An engine flooded with water must be prop
erly drained, lubricant replaced (oil change),
*•!l•>lliJi Failureto follow these instructions operated (boil out procedure), then lubricant
may result in damage to the engine. If you replaced again, otherwise parts will be se ri
must tow a stranded watercraft i n water, be ously damaged.
sure n ot to exceed the maximum towing speed
of 24 km/h (15MPH). Exhaust System Draining
If water is suspected to be in the exhaust system,
SUBMERGED WATERCRAFT remove the exhaust pipe and the muffler. Drain
them or siphon the water out of them. Refer to
IW.JftlJj Never try to crank or start engine. EXHAUST SYSTEM subsection.
Water trapped in the intake manifold would
flow towards the engine and possible cause Intake System Draining
severe engine damage. 1. I f water is present in the air intake silencer,
empty it. Refer to AIR INTAKE SYSTEM sub
1. Drain bilge.
section.
2. If the watercraft was submerged in salt water,
2. Remove the air intake silencer and check for
rinse the bilge and all components thoroughly
water in the supercharger inlet hose. Remove
with fresh water using a garden hose to stop
hose to empty it.
the salt corroding effect.
3. Remove the water from blow-by valve hose.
3. Check for water in the intake system. If wa
ter found in the intake system, refer to WA 4. If water is suspected in the intake manifold,
TER-FLOODED ENGINE in this subsection. remove the intake manifold and drain it. Then
siphon the water out from the intake valve
ports. Refer to INTAKE MANIFOLD subsec
tion.
SITlf201 l-006 17
Subsection 05 (SPECIAL PROCEl;>URES)
Throttle Body Lubrication

The throttle body should be lubricated to flush out
any water infiltration and to prevent corrosion.
Supercharger Servicing
215 and 260 Engines
If there is water in the oil or in the supercharger in
TYPICAL
let hose, the supt:m;lioryer should be taken apart, 1. Valve cover
all the components dried, and the slip clutch nee
dle bearings and shaft ball bearings replaced. Re 8. Wrap a piece of tape around the suction pump
fer to SUPERCHARGER subsection. tube 400 mm (16 in) from the end of the tube.
9. Insert the tube in the PTO area until the tape is
Engine Oil and Filter Replacement even with the cylinder-block edge.
If the engine oil is contaminated with water (oil will 10. Siphon contaminated oil out.
be milky), change the engine oil and filter as per
following procedure.
iS and as Models
Remove the deck extension. Refer to BODY sub
section.
All Models
1. Using the SUCTION PUMP (P/N 529 035 880).
siphon the contaminated oil from the engine
reservoir through the dipstick hole.
TYPICAL
1. Suction pump tube with tape
2. Edge of cylinder-block
11. Remove the suction pump tube.

12. Reinstall valve cover.
13. Install a NEW oil filter and reinstall the oil filter
cap.
14. Replenish the engine with appropriate amount
of the recommended engine oil. Refer to LU
ici'tJitflJj Never crank or start engine when BRICATION SYSTEM subsection.
siphon tube is i n dipstick hole. Never start
engine when there is no oil in eng ine. 15. Proceed with the BOIL OUT PROCEDURE
that follows.
2. Remove the suction pump tube from the dip
NOTE: The boil out procedure is intended to evap
stick hole.
orate a small quantity of water contained in the oil
3. Fully depress throttle lever and HOLD it for system.
cranking.
Boil Out Procedure in a Test Tank or Tied to a
4. Crank the engine for 5 seconds. Trailer with Watercraft in Water
5. Remove the oil filter cap and the oil filter. Refer 1. Connect the vehicle to latest applicable
to LUBRICATION SYSTEM subsection. B.U.D.S. version to monitor the coolant tem
6. Again, siphon the contaminated oil from the oil perature. Coolant temperature must exceed
filter reservoir. 100°C (212°F) in order for the water to boil out.
Once the boiling point is attained, the water
7. Remove valve cover. Refer to CYLINDER
will evaporate quickly.
HEAD subsection.
2. Run the engine for 5 minutes at 3500 RPM.
18 smr201 l-006
Subsection 05 (SPECIAL PROCEDURES)
CAPSIZED WATERCRAFT
Be sure to safely secure the watercraft. Capsized for More than 5 Minutes
Refer to WATER-FLOODED ENGINE in this sub
3. With the engine still running at 3500 RPM, in section.
stall a LARGE HOSE PINCHER (P/N 529 032 500)
on the coolant line going to the oil cooler.
529032500
A WARNING
Certain components in the engine compart
ment may be very hot. Direct contact may re
sult in skin burn. Do not touch any electri
cal parts or jet pump area when the engine
is running.
•mr2009·0 1 6-00 1 _a
TYPICAL
1. Oil cooler coolant inlet hose
4. Continue to run the engine at 3500 RPM for 15

more minutes (20 minute total run time).
5. Shut the engine off.
6. Remove the hose pincher from coolant line go-
ing to the oil cooler.
li!f.Jili1j Hose pincher must be removed prior

to operating the watercraft. Failure to do this
will result in damage to the engine.
7. Change the oil and filter again.

8. Procedure is now complete.
Slllf2011.()()6 19
20
Section 02 ENGINE
Subsection 01 (ENGINE REMOVAL AND INSTALLATION)
ENGINE REMOVAL AND INSTALLATION

SERVICE TOOLS
ALIGNMENT SHAFT ADAPTER ................................................... 529 035 719 . ..................................... 26-28
ALIGNMENT SHAFT SUPPORT .................................................... 529 035 506 ........................................... 26
ALIGNMENT SHAFT .................................................................... 295 000 141 . .... ..... . .. .... .. ....... .. 26-29
.. . . .. .. . .
ENGINE ALIGNMENT TOOL......................................................... 529 036197 ........................................... 27

PUMP PLATE 529 036 224
...................................... . . . ...................... ................. . ........................................... 26
TH RU-HULL ADAPTER ................................................................. 529 036193 ........................................... 28
SERVICE PRODUCTS
Descrp
i tion Part Number Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ..................................... 26, 30
PULLEY FLANGE CLEANER ...... ... ... .. ....
. ... ..... .. .. .
. .. ... . .. .
. . ... ..... ..
. .. 413 711 809 ........................................... 26
smr2011-007 21
Section 02 ENGINE
ENGINE SUPPORTS
GTS 130, GT/ 130, GT/ 155 and WAKE 155
mm
25 N•m
Maximum
(18 lbt-ft) thickness:

5mm
(13/64 in)
v-rmm(f� ,�;�)
'.f i
��
IDi!l.I 5l
� Maximum thicknes8'
(13/64 in}
;rft)
5 mm
25 N•m
.
(18 1bf.tt)i i
mm
·�! j 25 N•m
Q
\___
mtm "' Component must be replaced when removed.

cmr2011.007-001.a
22 smr2011-007
Section 02 ENGINE
GTX 155
25 N•m
(18 lbfoft)
25 N•m
(18 lbfeft)
25N•m
(18 lbfoft)
{ Maximum
thickness:
5mm
Imm-! nr.nn 25N•m
loM:Uil ( 18 I bf.ft)
(13/64 in)
mm
Imm = Component must be replaced when removed.

tmt2011�7-002_a
smr201Hl07 23
Section 02 ENGINE
RXT Series, GTX Series (except GTX 155) and WAKE PRO 215
mtm --=------IJ
25 N•m
25 N•m
(18 lbMt) "l
}
(18 lbfoft)
I
Maximum
thickness:
Smm
(13/64 in)
Maximum
thickness:
5mm
(13/64 in)
25 N·m r:.r.rm
Imm = Component must be replaced when removed. (18 1 bfeft)�
smr2011-007-003_•
24 smr2011-007
Section 02 ENGINE
GENERAL COMMON PROCEDURE FOR ALL MODELS
During assembly/installation, use torque values - Remove the seat. Refer to BODY.
and service products from exploded views in the - Disconnect the battery. Refer to CHARGING
appropriate subsections. SYSTEM.
Clean threads before applying a threadlocker. Re - Unplug fuel hose from fuel rail. Refer to
fer to SELF-LOCKING FASTENER and LOCTITE ELECTRONIC FUEL INJECTION (EFI).
APPLICATION at the beginning of this manual for - Drain coolant. Refer to COOLING SYSTEM
complete procedure. - Disconnect the "B' conne ctor from the ECM.
- Disconnect the engine connector.
A WARNING - Disconnect the knock sensor and magneto
Torque wrench tightening specifications connectors (remove connector housings from
must be strictly adhered to. the ECM support).
Locking devices when removed (e.g.: locking - Disconnect the EGTS sensor from the muffler.
tabs, elastic stop nuts, self-locking fasteners, - Disconnect the three ground cables on the front
cotter pin, etc.) must be replaced. end of engine.
- Unplug the front exhaust hose from the muffler.
- Unplug the blow-by valve hose.
lrt'oi[;Jj Hoses, cables or locking ties re - Unplug the ride plate hoses from water pump
moved during a procedure must be reinstalled housing.
as per factory standards. - Move muffler backward. Refer to EXHAUST
SYSTEM.
PROCEDURES - Remove the drive shaft. Refer to DRIVE SHAFT.
- Remove the engine mounting screws .
ENGINE - Cut any locking ties from hoses or wiring
harness that prevent engine removal.
Engine Removal Guideline - Slightly lift the engine using a suitable
lifting device.
PROCEDURES ACCORDING TO MODEL
ALL iS AND aS
- Remove moving deck and deck extension. Refer

to BODY.
- Remove the air intake silencer and its support.
Refer t o AIR INTAKE SILENCER (IS AND aS
models).
RXT SERIES AND GTX LTD iS 260
- Unplug air intake hose from the throttle body.
AXT 260, AXT X 260, AXT XRS 260,

GTX 215 AND WAKE PRO 215
- Remove the supercharger. Refer to

SUPERCHARGER.
GTX 215, GTX iS 215 AND WAKE PRO 215
- Unplug both hoses from the supercharger.
ALL EXCEPT iS AND as Rt•lmJj Be ca r eful not to scratch body or

to hit any engine component during engine
- Disconnect all fuel injector connectors and the
removal.
following sensors (CTS. CPS. TOPS, CAPS and
OPS).
Engine Installation
- Remove the intake manifold. Refer to INTAKE
MANIFOLD. Installation of engine in watercraft is essentially
the reverse of removal procedures. However pay
particular attention to the following.
smr2011-007 25
Section 02 ENGINE
l!!lni@j Whenever engine is removed from Engine Alignment

watercraft, engine alignment must be per
GTS, GT/ and WAKE 155
formed at reinstallation.
REQUIRED TOOLS
Wipe off any spillage in bilge. Clean with the PUL
LEY FLANGE CLEANER (P/N 413 711 809). PUMP PLATE
Check tightness and condition of engine rubber (P/N 529 036 224)
mounts. Refer to ENGINE MOUNTS in this sub
ALIGNMENT SHAFT SUPPORT
section.
(P/N 529 035 506)
Before completely lowering engine, install ground
ALIGNMENT SHAFT ADAPTER
cable, starter cable and water hoses on exhaust
[P/N 529 035 719)
manifold. Follow these guide lines.
- Ensure contact surface is perfectly clean then ALIGNMENT SHAFT
(P/N 295 000 141)
reconnect ground cable to engine.
- Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on To verify alignment of engine proceed as follows:
threads of ground cable screw or use a new
screw with self-locking product. 1. Remove jet pump and drive shaft. Refer to
STEERING AND PROPULSION section.
- Tighten ground cable screw to 23 N•m
(17 lbf•ft). 2. Remove drive shaft boot.
- Torque starter cable nut to 7 N •m (62 lbf•in). 3. Assemble alignment tool.
- Install protective cap over the starter cable end. 3. 1 Install the alignment shaft support on
- Connect exhaust manifold water inlet and pump plate.
outlet hoses. Tighten clamps to 1.7 N•m 3.2 Secure using M8 x 25 x 1.25 hexagonal
(15 lbf•in).
screws.
Place engine into vehicle.
Install engine support screws. Do not apply
threadlocker to engine support screws and do
not torque yet.
Align engine. Refer to ENGINE ALIGNMENT in
this subsection for complete procedure.
lfi!ltJi@j The engine alignment must be com

pleted before finalizing the engine installation.
Install and properly align exhaust pipe. Refer to

EXHAUST SYSTEM subsection. smt 201 1 -007-006.•
Reinstall all other removed parts. 1. Alignment shaft support (P/N 529 035 506}
2. Support plate (P/N 529 036 224}
Check hose condition and pressure test fuel sys 3. MB x 25 x 1.25 hexagonal screws
tem, refer to FUEL SYSTEM
TORQUE
A WARNING Alignment tool screws I 24 N•m (18 lbf•ft)
Whenever doing any type of repair on wa
tercraft or if any components of the fuel sys 4. Install the alignment tool as follows.
tem are disconnected, a pressure test must 4.1 Position the alignment tool against the
be done before starting engine. pump support.
4.2 Push the alignment tool upward and hold
Verify all electrical connections (ground wires and it in this position.
battery).
Run engine and ensure there is no leakage.
11lttJmJj If watercraft is out of water, exhaust

system must be cooled using the flush kit.
26 smr2011 ·0t>7
Section 02 ENGINE
smr2009-01 S-02 9_1
1. Alignment shaff adapter
emr2009 0 1 6-0St_a
5. Install the THRU-HULL ADAPTER (P/N 529 036
1. Jet pump socket screws
193) into the thru-hull fitting. Ensure the adapter
Install the ALIGNMENT SHAFT ADAPTER (P/N 529 is properly seated against the fitting.
035 719) on the end of the ALIGNMENT SHAFT
(P/N 295 000 141).
��
. ·�,�
, �'..;·· ;. ·
52900 571 9
!2900 6 193
Trace two thin lines on alignment shaft.
- - ·- -J
E
B
- ---
I
- - A -
----- -
=�--=r
1mr2009-0t6-053_o
1. Thru-hul/ fitting
2. Thru-hul/ adapter
smr2009-<ll S.200_ 1
NOTE: On some occasions, the thru-hull adapter

LINES DISTANCE must be retained in the fitting using a hose clamp.
Line A at 607 .5 mm (23.917 in)
Line B at 610.5mm (24.035in)
4. Remove the ALIGNMENT SHAFT ADAPTER

(P/N 529 035 719) from the end of the alignment
shaft and install it in engine PTO housing.
M•Ji@j Ensure alignment shaft adapter is

fully inserted into the engine PTO housing.
28 smr2011-007
Section 02 ENGINE
7. Insert alignment shaft end into alignment

shaft adapter. If the alignment is correct, the
alignment shaft end should slide through the
adapter.
NOTE: A small resistance during shaft insertion is
normal.
8. If the alignment is incorrect, loosen engine
mount retaining screws (Allen socket screws).
9. Add or remove shims as required.
NOTE: Shims location is between engine mount
smrl01 1·001-006 _a
Step 7: Place alignment tool against pump support

and engine mount plate.
Step 2: Push alignment tool upward
l+t[tli[iljj Whenevershims are used to cor
TORQUE rect alignment, never install more than 5 mm
(13/64 in) of shims.
Alignment tool nuts I 24 N•m (18 fbf•ft)
5. Install the ALIGNMENT SHAFT ADAPTER (P/N 529

035 719) in the engine PTO housing.
RtomJj Ensure alignment shaft adapter is

fully inserted into the engine PTO housing.
'""20 11.()07 -00ll.,a
REAR STARBOARD ENGINE MOUNT SHOWN

1. Engine mounting screw
2. Engme mount retaining screws
3. Shim(s)
omr200 9 -0 1 6-0Z9_1 When alignment of engine is correct, tighten

TYPICAL all engine mount screws. Refer to ENGINE
1. Alignment shaft adapter MOUNTS in this subsection.
6. Carefully slide the ALIGNMENT SHAFT (P/N 295 Recheck engine alignment.
ooo 141) through the engine alignment tool.
RXT, GTX and WAKE PRO 215
To verify alignment proceed as follows:
1. Remove jet pump and drive shaft. Refer to
2. Remove the sealing ring and the drive shaft
boot. Refer to DRIVE SHAFTsubsection.
3. Secure the ENGINE ALIGNMENT TOOL (P/N 529
036 197) on ride plate using jet pump socket
screws.
sm-2011.(1()7.00 7_1
7. Alignment shaft (P/N 295 000 147)

2. Alignment tool
smr2011-007 27
Section 02 ENGINE
6. Carefully slide the ALIGNMENT SHAFT (P/N 295

000 141 l through the engine alignment tool and
the thru-hull adapter.
1. Alignment shaft
2. Alignment shaft adapter
NOTE: A small resistance during shaft insertion is

normal.
8. If the alignment is correct, check the longitudi
nal position of engine. See procedure further.
9. If the alignment is incorrect, loosen engine
mount screws to align engine.
10. Add or remove shims as required.
NOTE: Use shim(s) (P/N 270 000 770) for the
front engine mount and shim(s) (P/N 270 000
1 m r2009 · 0 16-0S2_a
762) for the rear engine mounts. Shims location
1. Alignment shaft
2. Engine alignment tool is between engine mount and engine mount
plate.
l.![tJi@j Whenever shims are used to correct

alignment, never install more than 5 shims.
s m r 2 00tl-01 8 - 054_o
1. Alignment shaft
2. Thru-hul/ adapter
7. Insert alignment shaft end into alignment

REAR STARBOARD ENGINE MOUNT SHOWN
shaft adapter. If the alignment is correct, the 1. Engine mount
alignment shaft end should slide through the 2. Engine mount screws
3. Shim
adapter. 4. Engine mount plate
11 . When engine alignment is correct, check the

longitudinal position of engine.
smr2011·007 29
Section 02 ENGINE
Engine Longitudinal Position Verification

With alignment shaft installed, check the location
of the marks (previously drawn at the beginning of
the engine alignment procedure).
Engine is properly positioned longitudinally when
the engine alignment tool is between both shaft
marks.
- If one mark is visible, the engine is properly po
sitioned.
- If both marks are visible, the engine must be
moved forward.
- If n o mark is visible, the engine must be moved
rearward. tmr2011.0J7-00 4_a
1. T mark
PROPER POSITION
I. Engine alignment tool
2. Mark at 610.5 mm 124.035in)
When alignment and longitudinal position of en

gine are correct, tighten engine mount screws.
Refer to ENGINE MOUNTS in this subsection.
Recheck engine alignment.
ENGINE MOUNTS
If engine mounts have been removed, apply LOC
TITE 243 (BLUE) (P/N 293 800 060) on screw threads
or use new screws with self-locking product.
Torque all engine mount screws to 25 N•m
(18 lbf•ft).
NOTE: Position conical spring washer with the ·r·
mark upwards.
30 smr2011-007
Section 02 ENGINE
Subsection 02 (AIR INTAKE SYSTEM (EXCEPT iS AND aS MODELS))
AIR INTAKE SYSTEM (EXCEPT iS AND

aS MODELS)
130 and 155 engines
Hand tight
730 engines
r------------------
---
-
1.7N•m
'
I.
'
>
)15 lbf•in)
��
"' 155 engines
smt2011 00&001.•
srnt2011-008 31
Section 02 ENGINE
215 and 260 Engines
Hand tight
1.7 N•m
(15 lbfein)
4 N•m
(35 lbfein)
cmr2011 ·008·002...
a
32 smr2011-008
Section 02 ENGINE
GENERAL
During assembly/installation, use torque values
and service products as in the exploded views.
Clean threads before applying a threadlocker. Re
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.
A WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed (e.g.: locking smr2 0 1 1-008-004,.a
tabs, elastic stop nuts, self-locking fasteners, 1. Gauge connector

cotter pins, etc.) must be replaced. 2. OTAS connector
4. Cut locking tie retaining fuel hose on body.

W1Jil11j Hoses, cables or locking ties re
moved during a procedure must be reinstalled
as per factory standards.
PROCEDURES
AIR INTAKE SILENCER

Air Intake Silencer Access
GTS and GT/ Models
1. Open the front storage compartment cover.
2. Remove partitions. Refer to BODYsubsection. smr201 H
J<J S-013_•
1. Cut this locking tie
5. Remove plastic darts securing the top of the

ventilation tubes.
6. Unplug ventilations tubes and place them lower
in hull.
RXT and GTX Models

2. Remove the storage bin.
3. Unplug the top of ventilations tubes and place
them lower in hull.
s mr20 t t -008-00 3_•
1. Partitions
2. Retaining strap
3. Plastic rivets
3. Disconnect gauge and OTAS connectors.
s mr201 Hl08-014_a
1. Ventilation tubes
smr2011-008 33
Section 02 ENGINE
4. Cut locking ties securing winng harness and

fuel hoses to air intake silencer.
smr20 1 l -008.(I05...a
TYPICAL - GTS AND GT/

omr20 11--00&016_a 1. Cut this locking tie
1. Cut these locking ties
5. Cut locking ties securing fuel hoses and wiring

harness to upper bracket
6. Disconnect gauge and OTAS connectors.
$mr2011·008-01 l _a
TYPICAL - RXT AND GTX

1. Cut this lockii1g tie
3. Detach rear retaining strap retaining air intake

silencer and fuel tank.
smr2011-008'0 1 s_o

2. Disconnect the OTAS connector
3. Disconnect the gauge connector
Air Intake Silencer Removal

1 . Open or remove the seat.
2. From seat opening, cut locking tie securing the
wiring harness and the fuel supply hose to air
intake silencer.
TYPICAL - GTS AND GT/

1. Rear retaining strap
34 smr2011-008
Section 02 ENGINE
TYPICAL - RXT AND GTX

1. Rear retaining strap - under glove box
smr2011·008 -00 7_0
4. Loosen clamp securing the air intake silencer THROUGH FRONT STORAGE COMPARTMENT OPENING
1. Cut this locking rie
outlet hose to throttle body. 2. Front of air intake silencer
7. Detach the fron t retainin g straps .
sm'2011 .()()6.()0 9J
TYPICAL - GT/ SHOWN 1. Front retaining straps

7. Air intake silencer outlet hose
2. Loosen this clamp
8. Carefully pull the air intake silencer forward to
5. Detach the breather hose from the air intake remove it from the vehicle .
silencer outlet hose.

Air Intake Silencer Disassembly
1. Remove screws retaining both parts of air in
take silencer together.
smr2011-008-01 o_a
TYPICAL - GT/ SHOWN

1. Breather hose
2. Breather hose clamp
6. From the front storage compartment, cut lock

ing tie securing the wiring harness an d the fuel smt2011-008-017_ a
hose to air intake silencer. 1. Retaining screws (5x)
2. Unlatch air intake silen cer and remove the up

per section.
smr2011-008 35
Section 02 ENGINE
smr 2011-000-02 3_a
TYPICAL GTX SHO WN

-
1. Baffle mark
2. Outlet hose mark
$mr2 011 -000-01 8 _a
1. RBmov8 upper section of air intake silencer

Install the assembly in the air intake silencer.
3. Remove the inlet tube (2 inlet tubes on 215

and 260 models), the baffle and the outlet hose
from the air intake silencer.
s.rrr201 i -008.Q 2 1 _•
TYPICAL GT/ SHOWN-
1. Baffle tab into air intake silencer slot

2. Air intake sil8ncer rib into th8 outlet hose groove
Install the inlet tube. Ensure each end is properly

s m 1 201 l .()()8-0 1 9_ a attach.
1. Inlet tube NOTE: On 215 and 260 models, both inlet tubes
2. Baff/8
3. Outlet hose are attached as shown.
Air Intake Silencer Assembly

Install the baffle into the outlet hose. Ensure
marks are aligned.
""'2011-008-022.. •
1. Retaining tabs
Press both halves of the air intake silencer to

gether until all tabs are locked. Do not force,
make sure all tubes are properly installed.
TYPICAL GT/ SHOWN
-
1. Baffle mark
2. Outlet hose mark
36 smt2011-008
Section 02 ENGINE
TORQUE
Air intake silencer screws I Hand tight
Air Intake Silencer Installation

The installation is the reverse of the removal pro
cedure. However, pay attention to the following.
Ensure wiring harness and fuel hoses are properly
route.
lighten all gear clamp as specified in exploded
views.
smr2011-00B·025_n
AT THE FRONT OF ENGINE

AIR INTAKE TUBE 1. Air intake tube
2. Retaining clamp
Air Intake Tube Removal
215 and 260 Models 4. Detach the air intake tube from both hoses.
1 . Open seat. 5. Open the front compartment storage cover and

remove the storage bin.
2. Detach the seat bridge from the body and move
it aside to make room. 6. Slide the air intake tube over the air intake
silencer and through the front compartment
3. Loosen clamps retaining the air intake tube to
opening.
supercharger inlet hose and air intake silencer
outlet hose.
Air Intake Tube Installation
cedure. However pay attention to the following.
Make sure hoses are perfectly inserted into air in
take tube before tightening the clamps.
TORQUE
Retaining clamps l 4 N•m (35 lbf•in)
.
smr 201 1 -0 0 8·02A_ a
AT THE REAR OF ENGINE

1. Air intake tube
2. Retaining clamp
3. Supercharger inlet hose
smr2011·008 37
38
Section 02 ENGINE
Subsection 03 (AIR INTAKE SYSTEM OS AND aS MODELS))
AIR INTAKE SYSTEM (iS AND aS

MODELS)
1.7 N•m
(15 lbf-in)
Blow-by
valve
Imm= Component must be replaced when removed.
'm'20 09-01 7-001 _ b
smr2011-009 39
Section 02 ENGINE
Subsection 03 (AIR INTAKE SYSTEM (iS AND aS MODELS))
GENERAL TORQUE
During assembly/installation, use torque values Blow-by hose clamp I 1.7 N•m (15 lbf•in)
and service products as in the exploded view.
Refer to BODYsubsection for the proper installa
tion procedure.
complete procedure. AIR INTAKE SILENCER BAFFLE
Air Intake Silencer Baffle Removal
A WARNING
Remove AIR INTAKE SILENCER COVER, see pro
cedure in this subsection.
Locking devices {e.g.: locking tabs, elastic Pull the baffle out of the air intake silencer.
stop nuts, self-locking fasteners, cotter pins,
etc.) must be replaced with new ones.
l4'[11iliJIHoses, cables or locking ties re

moved during a procedure must be reinstal led
PROCEDURES
AIR INTAKE SILENCER COVER

Air Intake Silencer Cover Removal o mr2009-017-00
5 _o
1. Air intake silencer baffle
Remove the deck extension. Refer to BODYsub
section for procedure.
Air Intake Silencer Baffle Installation
Release retaining latches.
Insert the end of the baffle into supercharger air
Loosen clamp securing blow-by hose to cover. inlet hose. Using hose ears to retain hose, push
the baffle into supercharger air inlet hose.
smr2009-0 l 7-005_ o
smr2009·017-00<_a 1. Baffle
2. Air intake hose
1. Retaining latches
Install air intake silencer cover and all other re
Remove the cover. moved parts.
Air Intake Silencer Cover Installation AIR INTAKE TUBE

Air Intake Tube Removal
Remove the AIR INTAKE SILENCER COVER and
Check the condition of the seal cover. Replace
the AIR INTAKE SILENCER BAFFLE, see proce
seal as required.
dure in this subsection.
Tighten blow-by hose clamp.
40 smr201Hl09
Section 02 ENGINE
Subsection 03 (AIR INTAKE SYSTEM OS AND aS MODELS))
Release the three rubber latches securing the air Install the air intake silencer into hose groove.
intake tube.
""'2009--01 7-00 9_•
1. Air intake silencer

2. Outlet hose groove
omr20 09-01 7 ·007-a
1. Rubber latches Secure air intake silencer using NEW screws.
Remove air intake tube from vehicle. TORQUE
Air intake silencer screw I 6 N•m (53 lbf•in)

Air Intake Tube Installation
The installation is the reverse of the removal pro Install all other removed parts.
cedure.
AIR INTAKE SILENCER

Air Intake Silencer Removal
Remove:
- Deck extension, see BODYsubsection for pro-
cedure
- Air intake cover
- Air intake tube.
Remove and discard both screws securing air in
take silencer.
1. Air intake silencer screws
Inside air intake silencer, squeeze the top of its

outlet hose and move hose out of air intake si
lencer.
Air Intake Silencer Installation

Squeeze the top of the air intake silencer outlet
hose and move it in the air intake silencer.
smr2011-009 41
42
Section 02 ENGINE
Subsection 04 (INTAKE MANIFOLD)
INTAKE MANIFOLD
SERVICE PRODUCTS
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 49
130 and 155 Engines
5.5 N•m
(49 lbfoin)
17 N•m 9 N•m
(150 lbfoin) (80 lbfoinl
5.5 N•m
See
(49 lbfoin) ELECTRONIC FUEL
INJECTION (EFIJ
mim = Component must be replaced when removed.

•m'2011-010-00l_a
smr'2011-010 43
Section 02 ENGINE
215 Engine
See
ELECTRONIC FUEL
INJECTION (EFI}
9 N•m
(80 lbf•in)
See
ELECTRONIC FUEL
17 N•m
INJECTION (EFI} (150 lbf•in)
-
5.5 N•m - --
� -- -- - -- - - ----- --
- ----------
(49 lbfoin
/
'
\
'"""
See
INTERCOOLER
(215 ENGINE}

•mr20 1 l .() 10.00 3 •
44 sm'2011-010
Section 02 ENGINE
260 Engine
See
ELECTRONIC FUEL
INJECTION (EFI) See
ELECTRONIC FUEL
INJECTION (EFI)
9 N•m
(80 lbf.in)
l
9 N•m
(80 lbfoin)
5.5 N·m
(49 lbfoin)
See
ELECTRONIC FUEL
5.5 N•m INJECTION (EFI)
(49 lbf.in)
mJ:m =Component must be replaced when removed.

snv2011-01e>-002_a
smr2011-010 45
Section 02 ENGINE
GENERAL Disconnect fuel hose connector at fuel rail. Refer

to ELECTRONIC FUEL INJECTION (EFI) subsec
During assembly/installation, use torque values tion.
and service products as in the exploded views .
Unplug the "B' connector from the ECM by pulling

Clean threads before applying a threadlocker. Re the lock . Refer to CONNECTOR INFORMATION
fer to SELF-LOCKING FASTENERS and LOCTITE subsection for procedure.
APPLICATION at the be g in ning of this manual for
complete procedure. Cut all locking ties securing the wiring harnesses
to the intake m an ifold .
A WARNING
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, self-locking fasteners,
cotter pins, etc.) must be replaced.
IM1)i@j Hoses, cables or locking ties re

PROCEDURES
•mr200B·O t &-00 2 .•
INTAKE MANIFOLD 1. Cuc these locking ties to release harness
Intake Manifold Removal

On iS models, remove the moving deck and the
deck extension. Refer to BODYsubsection.
Remove the air intake silencer. Refer to the ap
propriate subsection according to model:
- AIR INTAKE SYSTEM (EXCEPT tS AND as
MODELS)
- AIR INTAKE SYSTEM (tS AND as MODELS).
Disconnect the intake hose at intake manifold.
1. Cur these locking ties to release harness
sml?OO&-O ! 8-020. •
TYPICAL - SUPERCHARGED ENGINE SHOWN

1. Intake hose
Move the coolan t expansion tank aside to make

room.
Remove the oil dipstick .
• m r 20()(1.0 11J.OO�.•
1. Cut these locking ties ro release harness
46 smr2011-010
Section 02 ENGINE
Unplug the ignition coil and fuel injector connec

tors.
1. Engine connector
2. ECM support
Unplug the knock sensor (KS), the magneto and

srnt200!Hl l &-006 I
the throttle actuator connectors.
I. Ignition cot/ connectors
2. Fuel injector connectors
Unplug the manifold air pressure sensor (MAPS),

the engine connector and the manifold air temper
ature sensor (MATS).
smr 2 009.() 1 8-00 9_e
7. KS connector
2. Magneto connector location
3. Throttle actuator connector
Detach the knock sensor (KS) and magneto con

nector housings from the ECM support. For
TYPICAL more details, refer to CONNECTOR INFORMA
1. MAPS connector TION subsection.
2. Engine connector location
3. MATS connector
Detach the engine connector housing from the

ECM support.
smr2011-010 47
Section 02 ENGINE
Subsection 04 {INTAKE MANIFOLD)
On 215 engine, disconnect both hoses at the

front end of intercooler.
Remove manifold retaining screws and push the
oil dipstick tube out of the manifold slot.
1r rn2009.018·010_a
1. KS connector
2. Magneto connecror
3. ECM support
Unplug the oil pressure switch (OPS).
R 1603molr59A
Lift intake manifold up to pull it out of the mount
ing brackets.
smr�009-019-011Jl
1. Oil pressure switch (OPS)
Unscrew ECM retaining screws and remov e ECM

from its support.
Rl503motr61A 1
1. Mounting brackets
Pull intake manifold out.
Intake Manifold Inspection

Check intake manifold for cracks, warping at
flanges or any other visible damage.
Check if intake manifold gaskets are cracked, brit
tle or otherwise damaged.
Replace damaged parts as necessary.
....,, 2009-010-01 2_.

Intake Manifold Installation
1. ECM retaining screws
For installation, reverse the removal procedure.
Pull the engine wiring harness with the ECM Pay attention to following details.
plugged away from intake manifold .
48 SITV2011·010
Section 02 ENGINE
Ensure that all gaskets are properly installed and

in good condition.
i; n-12009-018-01 3,_a
Ensure to properly route and secure wiring har

ness with locking ties.
Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on t he
R1503mou62A
ECM retaining screws and t ighten them to speci
INTAKE MANIFOLD fication.
1. Gaskers
TORQUE
First, position intake manifold on front mounting
bracket then push manifold toward engine to then ECM retaining screws \ 9 N•m (80 lbf•in)
proceed with rear mounting bracket.
Install all other removed parts.
When installing the intake manifold, lift up the oil
dipstick tube a little bit to fit in the slot of the man NOTE: Make sure the outlet hose of the inter
ifold. cooler is installed in its holding device {located on
the oil filler tube) otherwise the hose will scuff on
1 the engine block.
A1503mou598
1. Oil dipstick tube
1. lntercooler outlet hose holdu1g device

Apply LOCTITE 243 {BLUE) (P/N 293 800 060) on the
intake manifold screws.
FLAME ARRESTER
lighten intake manifold to specification using the
following sequence. Flame Arrester Location
TORQUE The flame arrester is integrated in the intake man
ifold.
Intake manifold screws l 9 N•m (80 lbf•in)
smr2011-010 49
Section 02 ENGINE
"""2009-0 1 8 -0 1 •_a
1. Flame arrester
Flame Arrester Inspection

The flame arrester in the intake manifold is main
tenance free.
Flame Arrester Replacement

NOTE: The flame arrester can not be removed
from the intake manifold.
Replace intake manifold if necessary. Refer to IN
TAKE MANIFOLD in this subsection.
50 smr2011·010
Section 02 ENGINE
Subsection 05 (SUPERCHARGER (215 AND 260 ENGINES))
SUPERCHARGER
(215 AND 260 ENGINES)
SERVICE TOOLS
4-PIN SOCKET................................... .. ... .. ..

. . . . . . . . . . . . . . . .... . .. .... 529 035 948 ..................................... 59, 62
BEARING SUPPORT/PUSHER ..................................................... . 529 035 950 ..................................... 61-62
CAMSHAFT LOCKING TOOL ....................................................... . 529 035 839 ........................................... 54
SUPERCHARGER GEAR HOLDER .............................................. .. 529 036 025 ........................................... 55
SUPERCHARGER RETAINING KEY.............................................. . 529 036 027 ............................... 58-59, 64
SUPPORT PLATE.......................................................................... . 529 035 947 ......................... 55, 58, 61-62
TORX ADAPTER ........................................................................... . 529 035 938 ..................................... 57' 65
SERVICE PRODUCTS
ISOFLEX GREASE TOPAS NB 52 ................................................. 293 550 021 ........................................... 63

LOCTITE 243 (BLUE) ..................................................................... 293 800 060 ..................................... 62-65
LOCTITE 5910 ............ . . . . . . . . .......... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293 800 081 ........................................... 64
SUPER LUBE GREASE .............................................. ................. . . 293 550 030 ........................................... 64
smr2011·011 51
Section 02 ENGINE
Loctite 243
�
9 N•m /
(80 lbf.in) �
29 N•m
(21 lbf.ft)
� (Left-hand
Loctite threads)
5910
--- ------ ---

/'
( -- - -- - --
'
\
\ Loctite
-, 243 9 N•m
_ /&/(80 lbfoin)
"'-. /
Q
grease
&
lsoflex grease
29 N•m
Topas NB 52
(21 lbfoft)
mi\!J =Component must be replaced when removed.
smr2010-019-001_b
52 sm12011-011
Section 02 ENGINE
GENERAL
During assembly/installation, use the torque val
ues and service products as in the exploded view.
complete procedure.
A WARNING
must be strictly adhered to. smc
2009 020.01 1 •
Locking devices when removed (e.g.: locking MANY PARTS REMOVED FOR CLARITY PURPOSE
1. Support screws
tabs, elastic stop nuts, cotter pins, etc.) must
be replaced. Remove the air inlet hose from supercharger.
fi+ZoillJj Hoses, cables or locking ties re

INSPECTION
SUPERCHARGER INLET
CLEANLINESS
NOTE: A lower than usual maximum RPM at full srnr2009.0 20-0 1 2
_1
throttle might be caused by a dirty supercharger 1. Air inlet hose
inlet. 2. Hose clamp
Remove the air intake silencer. Refer to the ap Visually inspect supercharger inlet side for oil, salt
propriate subsection according to model: or any other deposits.
- AIR INTAKE SYSTEM (EXCEPT 15 AND aS
MODELS)
- AIR INTAKE SYSTEM (15 AND as MODELS).
Remove the air intake silencer support.
•m(.1009-020-010_•
7. Air intake silencer support
smr2006-C l 2 .01 O_e
1. Dirt here
If dirt is found, proceed as follows.
smr2011-011 53
Section 02 ENGINE
Remove supercharger and perform the clutch slip Remove the air inlet hose from supercharger.
ping moment test. Inspect bearings and friction
clutch. Replace bearings and clutch components
as necessary.
Separate supercharger housing.
NOTE: Since supercharger is disassembled, it is
recommended to completely inspect it.
Cleon internal housing and turbine using a brush
and cleaning solvent to get rid of oil deposits.
Blow dry with compressed air.
*•U•Vfil Do not let turbine spin when using

compressed air. 1. Air in/er hose
2. Hose clamp
Complete usual assembly procedures as de
scribed in this subsection. Remove cylinder head cover, refer to CYLINDER
HEAD subsection.
SUPERCHARGER CLUTCH Remove spark plugs.
SLIPPING MOMENT Turn engine by rotating the supercharger nut
(ON ENGINE) counterclockwise until the position lines on oil
separator cover are lined up as shown in the
Remove the air intake silencer. Refer to the ap following illustration.
- AIR INTAKE SYSTEM (EXCEPT JS AND as
MODELS)
- AIR INTAKE SYSTEM (IS AND as MODELS).
Remove the air intake silencer support.
1. Position lines
sm
.1' 2009-020-0 1 0.1 Lock camshaft to prevent camshaft rotation while
1. Air intake silencer support checking slipping moment of supercharger.
REQUIRED TOOL
CAMSHAFT LOCKING TOOL

(P/N 529 035 839)
snv 2009-02 0--0 IIo
MANY PARTS REMOVED FOR CLARITY PURPOSE

1. Support screws
54 smr2011-011
Section 02 ENGINE
Subs ection 05 (SUPERCHARGER (215 AND 260 ENGINES))
SUPERCHARGER CLUTCH
SLIPPING MOMENT
(BENCH TEST)
Mount supercharger on support plate.
Hold supercharger gear with supercharger gear
holder.
REQUIRCD TOOLS
�
SUPPORT PLATE
(P/N 529 035 947)
omr 2009-02&-007_b
SUPERCHARGER GEAR HOLDER
1. Camshaft locking roof
(P/N 529 036 025) �
Check slipping moment counterclockwise by us
ing a torque wrench with actual torque viewer. A
mirror is useful to see the viewer.
Check slipping moment counterclockwise by us

1. Torque wrench ing a torque wrench with a viewer.
NOTE: Before checking the supercharger slipping

moment on a new or rebuilt supercharger. it is rec
ommended to turn the clutch for a minimum of 3
complete revolutions. This will dissipate grease or
oil on the friction shims for a precise reading.
Supercharger should start to turn at a torque
within the specified values.
SLIPPING MOMENT (NEW SUPERCHARGER)
9 N•m to 14 N•m (80 lbf•in to 124 lbf•in)
SLIPPING MOMENT (BREAK-IN SUPERCHARGER)

ornr2000-074 -I OO •
1. Torque wrench
If the torque is not within specifications, repair 2. Gear holder
supercharger clutch. Verify supercharger clutch
components as per SUPERCHARGER INSPEC NOTE: Before checking the supercharger slipping
T/ON in this subsection. moment on a new or rebuilt supercharger, it is rec
ommended to turn the clutch for a minimum of 3
complete revolutions. This will dissipate grease or
oil on the friction shims for a proper reading.
smr20n.011 55
Section 02 ENGINE
Supercharger should start to turn at a torque Remove the air intake silencer support.
within the specified values.
SLIPPING MOMENT (NEW SUPERCHARGER)
SLIPPING MOMENT (BREAK-IN SUPERCHARGER)
8 N•m to 12 N•m (71 lbf•in to 106 lbf•inl
If the torque is not within specification. repair

supercharger clutch. Verify supercharger clutch
components as per SUPERCHARGER INSPEC
TION in this subsection. s m r2C09-020.0 1 0_ a
1. Air intake silencer support
TROUBLESHOOTING
The following is provided to help in diagnosing the
probable source of troubles. It is a guideline and
it should not be assumed to list all possible prob
lems.
Always check for fault codes. If a fault code is de
tected, service the fault code first. Refer to DIAG
NOSTIC AND FAULT CODES subsection.
ENGINE WILL NOT START (ENGINE DOES

NOT TURN OVER)
1. Supercharger seized or obstructed

- Inspect and repair supercharger. 1. Support screws
ENGINE LACKS ACCELERATION OR Remove the air inlet hose from supercharger.
POWER (DOES NOT REACH MAXIMUM
RPM)
1. Supercharger inlet is dirty

- Check and clean supercharger inlet.
- Check engine oil. Siphon excess of oil.
2. Supercharger slipping clutch defective

- Check slipping clutch moment.
- Repair supercharger if out of specification.
PROCEDURES
1. Air inlet hose
2. Hose clamp
SUPERCHARGER
Remove air outlet hose from supercharger.
Supercharger Removal
On iS models, remove the moving deck. Refer to
BODY (RXT, GTX AND WAKE PRO) subsection for
proper procedure.
Remove the air intake silencer. Refer to appropri
ate subsection according to model:
- AIR INTAKE SYSTEM (EXCEPT tS AND as
MODELS)
- AIR INTAKE SYSTEM (iS AND as MODELS).
56 smr2011 ·011
Section 02 ENGINE
Remove retaining screws and pull out the super

charger.
1. Air outlet hose

2. Hose clamp
Unscrew blow-by valve screws and move it aside

to make room.
1. Retaining screws
2. Upper retaining screw (hidden behind the supercharger)
NOTE: Use the following tool to remove the up

per retaining screw.
REQUIRED TOOL
TORX ADAPTER
(P/N 529 035 938)
smr200S-012-01 0 ...a
1. Blow-by valve
2. Supercharger
Using a marker, trace a mark on rubber adapter

and exhaust pipe.
l. Upper retaining screw
Supercharger Disassembly
ffltli@j Be scrupulous when working on

supercharger parts. Supercharger rotation
smr2008-01 2 · 011_ • reaches 45 000 RPM. Any modification, im
1. Rubber adapter proper repair, assembly or damage on the
2. Exhaust pipe
parts, may result in damage of the super
Loosen clamp securing rubber adapter to exhaust charger. Strictly follow the described proce
pipe. dures.
Detach muffler strap. 1. Secure the supercharger on its support plate.

Move muffler back (± 5 cm (2 in)).
smr2011-01 I 57
Section 02 ENGINE
REQUIRED TOOL
SUPPORT PLATE
(P/N 529 035 947)
2. Take apart supercharger housing.
•""2009-0 2 0-006 _
•
1. Cap nut {left-hand thread)
4. Remove washer, turbine, 0-ring and step collar

from supercharger shaft.
FOOB28A 3 1
1. Retaining screws
2. Housing half (intake side)
3. Housmg half (engine side)
1. Washer
2. Turbine
3. 0-ring
4. Step collar
5. Loosen nut on supercharger shaft engine side

(turn counterclockwise).
REQUIRED TOOL
FOOB29A SUPERCHARGER RETAINING KEY

(P/N 529 036 027)
PLASTIC HAMMER
3. Loosen cap nut (turn clockwise) on super

charger shaft turbine side.
REQUIRED TOOL
SUPERCHARGER RETAINING KEY

(P/N 529 036 027)
58 smr2011-011
Section 02 ENGINE
FOOB2CA
1. Supercharger shaft
8. Press out ball bearing from supercharger shaft

1
FOOB2BA
by using a press.
1. Nut
2. Retaining key REQUIRED TOOL
6. Remove L-ring, spring washers, lock washer, SUPERCHARGER RETAINING KEY

drive gear and needle pins by turning the super (P/N 529 036 027)
charger upside down. Discard all needle pins.
smr 2006-01 2-00 8_o
1. Nut
2. L-ring
3. Spring washers (5x)
4. Lock washer FOOB2DA 2 3
5. Friction shims
6. Drive gear 1. Supercharger shaft
7. Needle pins {discard all) 2. Ball bearing
3. Retaining key
7. Carefully push out supercharger shaft towards
engine side by using a press. 9. Remove retaining disc with seal from housing
half (engine side).
REQUIRED TOOL
•
4-PIN SOCKET
(P/N 529 035 948)
NOTE: I t may be necessary to heat the housing

with a heat gun to release the retaining disc.
smr2011·01 I 59
Section 02 ENGINE
A. Driven plate journal depth

B. Drive gear thickness
C. Lock washer thickness
FOOB2AA
DRIVEN PLATE JOURNAL DEPTH
1. 4-pin socket
14.460mm to 14.500 mm
10. Disc ard the oil seal. NEW
(.5693in to .5709in)
11. Remove and discard ball bearing from super
SERVICE LIMIT 14.600 mm (.57 48 in)
charger housing half (engine side) by using a
press and a suitable bearing pusher.
DRIVE GEAR THICKNESS
11.000 mm to 11.050mm
NEW
(.4331 in to .435in)
SERVICE LIMIT 10.900 mm (.4291in)
LOCK WASHER THICKNESS
4.050 mm to 41
. 50 mm
NEW
(.1594in to .1634in)
SERVICE LIMIT 3.950 mm (.1555 in)
Spring Washer
1. Supercharger housing half (engine side) Put spring washer package together as it is as
2. Bearing pusher
sembled on the supercharger shaft. Measure the
height of the unloaded spring washer package.
Supercharger Inspection
Supercharger Clutch Components and Gear
Check the wear limit on drive gear, lock washer
and driven plate on supercharger shaft. Check
drive gear for cracks .
NOTE: If parts are worn out or damaged repair,
supercharger only by using supercharger repair

kit .
R 1 l503moir2'8A
A Spring washer package height
60 sm<2011·011
Section 02 ENGINE
SPRING WASHER PACKAGE HEIGHT 1 4
10.7mm to 10.9mm
NEW
(.4213in to .4291 in)
Supercharger Assembly
IAAllij Every time when supercharger shaft
has been removed, both ball bearings have to
be replaced.
1itl1Ji{jj Both ball bearings have to be in

stalled with cages facing turbine side.
1. Install ball bearing on supercharger shaft. Hold

bearing using the following tool.
1.1 Apply enough engine oil on NEW ball bear FOOB2FA 2 3
ing.
1. Supercharger shaft
1 .2 Press the bearing. Use the following tool 2. Ball bearing
3. Bearing support plate
to hold the bearing. 4. Protrusion of support plate on this side (underneath inner race)
REQUIRED TOOL 2. Press in the ball bearing in supercharger hous

ing half (engine side).
SUPPORT PLATE
(P/N 529 035 947) 2.1 Apply enough engine oil on NEW ball bear
ing .
2.2 Press the bearing using the following tool.

IW1JmJj Ensure to position ball bearing
against protrusion of support plate for the in REQUIRED TOOL
stallation. This way, the installation pressure
will be applied to the inner race and will not be BEARING SUPPORT/PUSHER
transmitted to the bearing balls which would (P/N 529 035 950)
otherwise shorten the bearing life.
W1JmJj To install ball bearings and super

charger shaft always use a press, never use
any beating force like a hammer.
FOOB2EA
1. Bearing support/pusher
3. Secure the supercharger housing plate (engine

side) in a vice.
smr'l011·011 61
Section 02 ENGINE
REQUIRED TOOL 2 3
SUPPORT PLATE
(P/N 529 035 947)
4. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on

retaining disc. If a new retaining disc is used,
the threads are coated with a self-locking prod
uct.
5. Install the retaining disc in supercharger hous
ing half. F 00 82GA 1
1. Support plate
2. Bearing support/pusher
1 2 3. Protrusion here
ffl.Ji&j Before pressing in the super

charger shaft, be sure to properly support
the inner race of ball bearin g in super
charger housing half with the recom
mended tool. This way, the installation
pressure will be applied to the inner race
and will not be transmitted to the bearing
balls which would otherwise shorten the
bearing life.
6.2 Apply heat outside of the housing w ith a

heat gun to expand its diameter prior to in
serting the shaft. Ensure there is no 0-ring
1. Retaining disc
on the housing half prior to heating.
2. 4-pin socket
6.3 Apply engine oil on supercharger shaft.
REQUIRED TOOL Press shaft with thrust washer and dis
tance sleeve together in supercharger
4-PIN SOCKET housing half.
(P/N 529 035 948) •
TORQUE
Retaining disc
I 40 N•m (30 lbf•ft)
6. Press supercharger shaft in housing half (en

gine side ) .
6.1 Properly support bearing using the follow
ing tools under supercharger housing half.
REQUIRED TOOLS
SUPPORT P LATE
(P/N 529 035 947)
BEARING
SUPPORT/PUSHER 7. Compressor shaft
(P/N 529 035 950) b
2. Ball earing
3. Supercharger housing half
4. Thrust washer
5. Distance sleeve
62 smt201 l-01 I
Section 02 ENGINE
2 1
tr
sm12009-020-007 _b
1. Step collar
2. 0-ring
FOOB2HA 3. Turbine
4. Washer
1. Supercharger shaft 5 Cap nut
2. Distance sleeve
Complete installation of supercharger shaft, en
7. Apply engine oil on seal and push into retaining gine side as follows:
disc by hand.
NOTE: Always use a NEW oil seal when assem
IN1VCIJlj It is of the utmost importance that
bling the supercharger. all parts be absolutely clean. The compressor
shaft spins at up to 45 000 RPM and any debris
could cause a failure.
9. Install the first friction shim.

NOTE: The friction shims have the same inner di
ameter.
IMtJillJlj Manipulate friction shims with care,

those parts are sensitive.
10. IMPORTANT: Apply ISO FLEX GREASE TOPAS

NB 52 (P/N 293 550 021) to the inner diameter
1. Oil seal
of the gear thrust surface on the shaft, friction
8. Install step collar, 0-ring, turbine and washer on shims, needle bearing, shaft surface and lock
washer.
supercharger shaft. Apply LOCTITE 243 (BLUE)
(P/N 293 800 060) on cap nut and temporary fin
IW.Ji@j No other grease can be used, other
ger tight cap nut. wise damage to bearings will occur.
NOTE: The cap nut on the supercharger shaft has
11. Install the NEW needle bearing on the com-
a left-handed thread. The Loctite has to be applied
in a small dose into the nut. pressor shaft.
NOTE: The new needle bearing contains 40 nee
dle pins trapped in a wax strip with an adhesive
backing.
12. Remove the adhesive backing.
13. Install the drive gear over the needle bearing.
14. Install the second friction shim.
15. Install the lock washer.
16. Apply engine oil to the spring washers.
17. Position the spring washers as per i11 ustration.
smr2011-011 63
Section 02 ENGINE
WZ•>i$1 When installing the spring washers,

take care of the exact installation direction of
the washers.
1. Apply Loctite 5910 on sealing surface
o
smr2006-0 12.00 9_
22. Assemble supercharger housing halves.
1. Spong washers
22.1 Apply LOCTITE 243 {BLUE) (P/N 293 800
18. Install the L-ring on the compressor shaft. 060) on retaining screws.
19. Apply LOCTITE 243 (B LUE) (P/N 293 800 060) on 22.2 Tighten supercharger housing halves
the hexagonal nut threads. screws according to the following se
TORQUE
quence.
Hexagonal nut
I 29 N•m (21 lbf•ft) TORQUE
Supercharger housing
halves screws
I 9 N•m (80 lbf•in)
1. Nut
2. L-rmg
3. Spring washers
4. Lock washer
5. Friction shims
6. Drive gear
SUPERCHARGER TIGHTENING SEQUENCE
7. Needle bearing
NOTE: The L-ring will preload the spring washers. 23. Verify the clutch slipping moment. Refer to
SUPERCHARGER CLUTCH SLIPPING MO
20. Hold the lock washer of the supercharger MENT (BENCH TEST) in this subsection.
shaft (engine side) and tighten the cap nut.
REQUIRED TOOL Supercharger Installation

1. Grease sealing surface between supercharger
SUPERCHARGER RETAINING KEY
and PTO housing with SUPER LUBE GREASE
(P/N 529 036 027)
(P/N 293 550 030).
NOTE: Ensure 0-rings are installed.

TORQUE
Cap nut
21. Apply LOCTITE 5910 (P/N 293 800 081) on super

charger housing sealing surface.
64 SllV201 1-011
Section 02 ENGINE
Subsection 05 (SUPERCHARGER (215 AND 260 ENGINES}}
5. After complete installation of the supercharger,

the slipping moment has to be rechecked.
Refer to SUPERCHARGER CLUTCH SLIPPING
MOMENT (ON ENGINE) at the beginning of
this subsection.
R1503motr247A 1
1. Super Lube grease
2. Install supercharger on PTO housing.

the retaining screws.
4. Tighten supercharger retaining screws to spec
ifications.
TORQUE
Supercharger retaining
screws
I 9 N•m (SO lbf•in)
NOTE: For the upper retaining screw the follow

ing tool must be used mounted 90° to torque
wrench.
REQUIRED TOOL
TORX ADAPTER
(P/N 529 035 938)
FOOBIUA 1
1. Torx adapter perpendicular to torque wrench
A. 90°
i!ll•Ji@jNot installing the tool as shown will

change the torque applied to the screw.
smr2011-01 I 65
66
ENGINE Section 02
Subsection 06 (INTERCOOLER (215 ENGINE))
INTERCOOLER (215 ENGINE)

SERVICE TOOLS
VACUUM/PRESSURE PUMP . . . . . . ................................. . . . . . . . . . . . . . . . . . 529 021 800 . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 68

s mr201 i -045-00 1 _a
smr2011·045 67
Section 02 ENGINE
GENERAL
During assembly/installation use torque values
.
and service prod ucts as in the exploded view.

APPLICATIONat the beginning of this manual for
complete procedure.
A WARNING
Torque wrench tightening sp ecificatio ns
tabs, elastic stop nuts, self - locking fasteners,
cotter pins etc.) must be replaced.
,
•mr2 006-0t 2�7-•
INTERCOOLER PULLED OUT FOR CLARITY PURPOSE ONLY

IN.Ji@j Hoses, cables or locking ties re 1. lntercooler
2. Outlet hose
moved during a procedure must be reinsta lled
3. Inlet nipple
Plug intercooler inlet nipp le.
PROCEDURES Install an adapter on the outlet hose to connect a
pressure pump .
INTERCOOLER REQUIRED TOOL

lntercooler Leak Test
Perform intercooler leak test when engine looses VACUUM/PRESSURE PUMP
performance, when there is white exhaust smoke (P/N 529 021 800)
or when temperature in exhaust system is to high.
AwARNING Pressurize the intercooler as follows:
Let engine cool down prior to perform leak PRESSURE TEST

test. Direct contact with hot engine may re 69 kPa (10 PSI) for 10 minutes minimum
sult in skin burn.
If there is a p ressure drop, first spray hoses and
NOTE: The inspection can be done while inter adapters with a soapy solution to ensure they are
cooler remains installed in intake manifold . not leaking .
Remove: Otherwise. remove intercooler from manifold to
- Outlet hose from exhaust manifold spray soapy water on it. If air bubbles are present.
- Inlet hose from intercooler. replace the intercooler. Refer to procedures fur
ther in this subsection .
Properly re install removed parts.

Make sure the intercooler outlet hose is installed
in the holding device (located on the oil filler tube)
otherwise the hose will scuff on the e ngine block.
68 smr2011-045
Section 02 ENGINE
s mf2006-012-002_a
1. lntercooler outlet hose holding device

s mr2006-0> 2-007 _•
1. lntercooler
lntercooler Removal 2. Profile ring
3. Collar
Remove intake manifold. Refer to INTAKE MAN
IFOLD subsection.
lntercooler Installation
Remove collar from intercooler.
Installation is essentially the reverse of removal
procedures. However pay particular attention to
the following.
Ensure profile rings are properly installed on inter
cooler and apply engine oil on them to ease instal
lation.
While properly aligning the inner end of intercooler
in intake manifold, gently push intercooler until it
bottoms.
Rotate intercooler to position nipples as shown.
F1900DB 1 2
TYPICAL
1. lntercooler
2. Collar
Carefully pull intercooler out of intake manifold.
1. Intake manifold flange

2. Nipple parallel with manifold flange
NOTE: If intercooler is hard to push in, a clamp

can be used to press intercooler in.
srnr2011-045 69
Section 02 ENGINE
Subsection 06 (INTERCOOLER (215 ENGINE})
F1900 FA
1. Clamp
2. Plastic block berween nipples
3. Plastic block
Reinstall collar.
Reinstall intake manifold.
70 smr2011-045
Section 02 ENGINE
INTERCOOLER (260 ENGINE)

SERVICE TOOLS
LARGE HOSE PINCHER................................................................ 529 032 500 ........................................... 73

VACUUM/PRESSURE PUMP .............................................. ......... 529 021 800 ........................................... 73
m:DJ = Component must be replaced when removed.
s m r 2 0 1 1 -01 2 -00 1 . a
smr201 l·012 71
Section 02 ENGINE
GENERAL lntercooler Cleaning

If temperature in intake manifold is too high or if
During assembly/installation. use torque values
engine is down in performance, intercooler may
require to be cleaned.
The exhaust system should be flushed first, as it
may unclogged the intercooler. If not, then pro
ceed with the intercooler cleaning procedure as
complete procedure.
detailed here.
A WARNING NOTE: The exhaust temperature will decrease
Torque wrench tightening specifications when the intercooler is clogged because more
must be strictly adhered to. water is rerouted through the exhaust system.
Locking devices when removed (e.g.: locking To clean the intercooler, do the following:
tabs, elastic stop nuts, cotter pins, etc.) must
be replaced .
lillumJj Never try to clean the intercooler
with chemical products. Only use fresh water.
Chemical products will permanently damage
l.TZ.Ji@j Hose, cables or locking ties removed the internal parts of intercooler.
during a procedure must be reinstalled as per
1 . Remove the intercooler from the watercraft.
factory standards.
See procedure further in this subsection.
2. Pour fresh water into the water outlet fitting.
MAINTENANCE
INTERCOOLER FLUSHING
Flushing the intercooler with fresh water is essen
tial 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 in
tercooler.
NOTE: lntercooler is flushed with the exhaust
system, as they are on the same circuit.
Exhaust system and intercooler should be flushed
each time: om'2009 0 1 9·008_11
1. lnrercooler water outlet fitting

- Watercraft is used in salt water and is not ex- 2. lntercooler water inlet fitting
pected to be used further the same day.
- Watercraft is used in foul water. 3. Let water into intercooler for many hours. Oc
casionally, shake the intercooler to soak off de
- Watercraft is stored for any extended time.
posits.
Refer to EXHAUST SYSTEM subsection for flush
4. Rinse the intercooler using a garden hose in
ing procedure.
stalled on water outlet.
IM'11$j Failure to flush the system, when 5. Let water flows out of intercooler a few min
necessary, will severely d amage engine inter utes to evacuate internal deposits.
cooler and/or exhaust system .
6. Check water flow.
PROCEDURES WATER FLOW
LOW OR 1. Repeat cleaning p rocedure .

INTERCOOLER ERRATIC 2. Replace the intercooler.
HIGH AND
lntercooler is not clogged.
Let engi ne cool down prior to work on or near REGULAR
intercooler.
72 smr2011-012
Section 02 ENGINE
sm r 2009-0 >9-00 9_a
1. Garden hose installed on water outlet

2. High and regular water flow 52902>800
BLEED HOSE FITTING

7. Perform a leak test before installing the inter
cooler in the watercraft. Pressurize the intercooler.
PRESSURE TEST
lntercooler Leak Test
69 kPa (10 PSI) for 10 minutes minimum
Block intercooler water outlet hose.
REQUIRED TOOL If there is a pressure drop, first spray tool, hoses

and adapters with a soapy water solution t o en
LARGE HOSE PINCHER sure they are not leaking.
{P/N 529 032 500)
Otherwise, replace the intercooler.
lntercooler Removal
On iS and aS models, open the boarding platform
and remove both storage baskets.
On mod e l s without iS and aS, open the seat and
remove both rear access panels.
From the LH opening, disconnect the intercooler
water hoses.

1. lntercooler
2. lntercooler water outlet hose
3. lntercooler water inlet hose
Unplug the intercooler water inlet hose from the

intercooler.
Install the VACUUM/PRESSURE PUMP (P/N 529 021
800) on intercooler water inlet fitting.

1. lntercooler
2. lntercooler water outlet hose
3. lotercooler water inlet hose
Disconnect both air hoses.
smr201 H)12 73
Section 02 ENGINE
sm r 20 l 1-01 2 003.l> FIXED DECK REMOVED FOR CLARITY PURPOSE

1. lntercooler air inle t hose 1. iS module
2. lntercooler air outlet hose 2. Retaining latch
Detach both intercooler straps. Cut locking ties securing wiring harnesses to iS
module support and front attachment.
7. lntercooler straps
Remove the i BR actuator. Refer to 1BR AND VTS

Models Without IS and as
subsection.
Cut locking ties securing the iBR harness and the
Remove the intercooler from vehicle by the LH
battery harness.
opening.
lntercooler Installation
cedure.
NOTE: Ensure hoses are routed correctly and
locking ties are positioned at proper locations.
INTERCOOLER ATTACHMENTS
Front Attachment Replacement
Remove the INTERCOOLER, see procedure in
this subsection.
DECK REMOVED FOR CLARITY PURPOSE
7. Locking tie retaining the iBR harness
iS Models 2. Locking tie retaining the batlery harness
Detach iS module from its support and move the

All Models
module aside to make room.
Remove screws securing the front attachment to
the hull.
74 smr2011·012
Section 02 ENGINE
-imr2009-019- 00 7_ a
1. Retaining screws
THROUGH THE LH REAR OPENING
Remove the front attachment from vehicle. 1. Retaining screw
2. Washer
NOTE: On iS models, the front attachment and 3. LH rea r attachment
the iS module support are attached together with

Install a new attachment using a NEW screw.
rivets.
Tighten rear attachment screw to specification.
When reinstalling, tighten front attachment
screws to specification. TORQUE
TORQUE Rear attachment screw I 8 N•m (71 lbf•in)
Front attachment screw J 8 N•m (71 lbf•in)

Rear Attachment Replacement

Remove the intercooler, see procedure in this sub
section.
Remove darts and rubber pad.
s mr2009-019-050_a
THROUGH THE LH REAR OPENING

1. Dart
2. Rubber pad
Remove and discard screw securing the attach

ment to the hull.
smr2011-012 75
76
Section 02 ENGINE
Subsection 08 (EXHAUST SYSTEM)
EXHAUST SYSTEM
SERVICE TOOLS
FLUSHING CONNECTOR ADAPTER ............................................ 295 500 473 ......................................... 83 . .
SERVICE PRODUCTS
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 90
smr2011-013 77
Section 02 ENGINE
11 N•m
(97 lbfein) 16 N•m
(142 lbfein)
·h 8 N•m
(71 lbf•in)
--
--
---�
--
--
- ·-
-�
--
8 N•m
(71 lbf•in)
4 N·m
(35 lbfoin)
'
---------------------- r --------------
GTS/GTl/WAKE 155 I RXT!GTX/WAKE PRO :
28 N•m
(21 lbfeft)
12 N•m
(106 lbf•in) I
_____________________ J ______________ ,
78 smf2011-013
Section 02 ENGINE
IED = Component must be replaced when removed.

1mr201l-013-IQQ.JI
smr2011-013 79
Section 02 ENGINE
1.7 N•m
(15 lbf•in)
1.7N•m ---a
(15 lbMnl 1
------------------------------------------------------------- '
RXTSERIES
GTX LTD iS 260
IEm =Component must be replaced when removed.

1m12 0 l 1 .()I3-00 2_ 1
80 smr2011-013
Section 02 ENGINE
r ------------------------------------------------------------�
GTS 130
GT/ 130
1.7 N•m GT/ 155
(15 lbf.ln) WAKE 155 I
'
\
\
\ '
\ '
\
\ '
'
\
'
\
\
\
'
\
'
\
\
GTX 155
smr2011-013 81
Section 02 ENGINE
GENERAL
APPLICATION a t the beginning of this manual for
complete procedure. 1
A WARNING
Torque wrench t ig htening specifications snw2009-021-002..a
must be strictly adhered to. 130, 155 AND 260 ENGINES
Locking devices when removed (e.g.: locking 1. Exhaust manifold water inlet
2. Exhaust manifold
tabs, elastic stop nuts, cotter pins, etc.) must 3. Exhaust manifold water outlet (to pump support)
be replaced. 4. Exhaust mamfold water out/er (to exhaust pipe and muffler}
Water from the exhaust manifold jacket is di

ijf[1Jil1JjHoses, cables or locking ties re rected to the exhaust pipe via 2 hoses.
moved d ur i ng a procedure must be reinstalled
SYSTEM DESCRIPTION
The exhaust system is cooled by water provided
by a pressurized area in the jet pump (open loop
system).
The same water is also used to cool the in
tercooler (supercharged engines) and the iBR
actuator (models with iBR).
3 Water exits exhaust pipe water jacket through

holes to inject water in muffler and resonator.
s m r21)!)8- 0 1 3-007_a
215 ENGINE
1. /ntercooler
2. /ntercooler water inlet
3. lntercooler water outlet
4 Exhaust manifold water inlet
5. Exhaust manifold � i 3-00 9_ a
6. Exhaust manifold water outlet (to pum p support)
7. Exhaust manifold water outlet (to exhaust pipe and muffler) 1. Water packet holes
Water is evacuated through the exhaust outlet in

transom area.
82 smr2011-013
Section 02 ENGINE
Exhaust System Technical

Specifications
Total Loss Cooling System
TYPE
(T LCS)
Flow from jet pump
WATER FLOW
(no water pump)
TEMPERATURE Calibrated outlet fittings

CONTROL {no thermostat)
SYSTEM
Self-bleed type
BLEEDING
smr2009-021 -00 4 ... a
SYSTEM 1. Water inlet connector
Self-drain type
DRAINING
NOTE: The follo wing tool is recommended when
a quick connect adapter is used to ease garden
MAINTENANCE hose installation.
RECOMMENDED TOOL
EXHAUST SYSTEM FLUSHING
FLUSHING CONNECTOR
Flushing the exhaust system with fresh water is
ADAPTER (P/N 295 500 473)
essential to neutralize corroding effects of s alt or
other chemical products present in water. It will
help to clean up sand, salt. shells or other parti
cles in water jackets (exhaust system, interco oler
(supercharged eng i nes ) and hoses).
Exhaust system f lushi ng should be performed
when the watercraft is not expected t o be used
further the same day or when the watercraft is
stored for any extended time.
fOOE0 5A 1 2
IW,Ji@j Failure to flush the system, when
1. Quick connect adapter
necessary, will severely damage intercooler 2. Flushing connector adapter
(supercharged engines) and exhaust system.
Make sure engine operates during entire pro To flush the exhaust system, start the engine then
cedure. immediately open the water tap.
A WARNING Olui@fj Always start the engine before

opening the water tap. Open water tap im
Perform these operations in a well ventilated mediately after engine is started to prevent
area. Certain components in the engine overheating. Never run engine without sup
compartment may be very hot. Direct con plying water to the exhaust system when
tact may result in skin burn. Do not touch watercraft is out of water.
any electrical part or jet pump area when
engine is running. Run the engine about 20 seconds at a fast i dle
between 4000 - 5000 RPM.
A WARNING
IMoitljj Never run engine longer than 2 min
When operating the engine while t h e water utes. Drive line seal has no cooling when wa
craft is out of the water, the heat exchanger tercraft is out of water.
in the ride plate may become very hot. Avoid
any contact with ride plate as burns may oc Ensure water flows out of jet pump whil e flushing.
cur. Close the water tap, then stop the engine.
Connect a garden hose to connector located at the W111lflJj Always close the water tap before
rear of watercraft. Do not open water tap yet. stopping the engine.
Disconnect the garden h ose.
smr20l1·013 83
Section 02 ENGINE
IN•JmJI Remove flushing connector adapter

after operation (if used).
PROCEDURES
MUFFLER
A CAUTION Certa in components in the
engine compartment may be very hot. Let
exh aust system cool down prior to removing
parts. smr20D9-01 6-00 7 -•
TYPICAL
Muffler Access I. Exhaust clamp
iS and aS Models 5. Unplug the exhaust gas temperature sensor

Open seat. (EGTS).
Remove the air intake silencer. Refer to AIR IN

TAKE SILENCER (IS AND aS MODELS) subsec
tion.
All Other Models

Remove seat.
Muffler Removal
1 . Cut locking tie securing water outlet hose (ex
haust system) and blow-by hose.
2. Disconnect the water outlet hose from the ex •m< 2009-011l.()04 _1
haust manifold. TYPICAL
1. EGTS sensor
3. Gen tly disconnect the hose from blow-by valve. 2. Exhaust hose
6. Disconnect the exhaust hose from muffler.
r. mr2009-01 6-00J_a
TYPICAL •mr2009-01 6 -005o

1. Cut this lockmg tie
2. Water our/er hose (exhaust system) TYPICAL
3. Blow-by hose 1. Exhaust hose clamp
4. Blow-by valve
5. Exhaust manifold 7. Detach retain ing strap.
4. Unscrew exhaust clamp.
IAU'1i(IJ!jj Do not use pneumatic or electrical

tools as seizure may occur.
84 smr2011-013
Section 02ENGINE
•mr2009-0 1 6-00G_•
TYPICAL '"1'd 2008.0 1 �026_•

1. Muffler retaining strap
Step 1: Lift adjuster tab
Step 2: Move adjuster outward
8. Remove the muffler.
- On iS and aS m odels, remove the LH rear Insert the muffler in hull.
storage basket then move the muffler back Align the exhaust pipe flange to the exhaust mani
wards and slide it through the rear opening. fold. Rotate and move muffler so that the exhaust
- On models without iS and aS, move the pipe flange makes perfect contact with exhaust
muffler back then slide it forward through the manifold.
deck opening.
Slide both adjuster blocks against muffler to sup
port it in position .
Muffler Inspection
NOTE: Ensure muffler is in contact with both ad
Check muffler for:
juster blocks. Readjust as required.
- Cracks
Install exhaust clamp with the nut upward.
- Corrosion
- Other damages. Tighten clamp loosely.
Check if exhaust hose is: Using a 50 mm (2 in) spacer (in th is case a bolt),
position the exhaust pipe.
- Brittle
- Hard
- Cracked
- Otherwise damaged.
Replace any defective part.
Muffler Installation
With a new muffler, in stall the EGTS sensor. Re
fer to ELECTRONIC FUEL INJECTION (EF/) sub
section.
Open muffler adjusters by sliding adjuster blocks.
1. Engine fdting ring

2. Spacer
3. Exhaust pipe fitting
Confirm that the exhaust pipe mark is aligned with

the mark on the exhaust manifold.
smr2011-013 85
Section 02 ENGINE
1. Exhaust manifold mark sm1 2000-02 1-01 0_.

2. Exhaust pipe mark
1. Retaining clamp
2. Exhaust hose
Tighten exhaust clamp.
Remove the deck extension. Refer to BODYsub
TORQUE
section.
Exhaust clamp
Move the coolant expansion tank aside and cut
locking tie retaining the starter cable (RED) to ex
IW.Ji@j Do not use pneumatic or electric
haust hose.
tools as seizure may occur.
Remove exhaust hose from resonator.
Install the muffler strap.
Cut locking tie retaining bailer hose elbow fittings
@tJl[iJ#I E nsure not to rotate muffler during to exhaust hose.
strap installation. The use of a soapy water so
Models Without iS and aS
lution on inner side of muffler strap is recom
mended. Cut locking tie securing bailers on the top of the
front exhaust hose.
After installation, ensure there is no water or ex
haust gas leak when engine is running.
Test run the engine while supplying water to the
exhaust system.
IM'1)j[iJj Never run engine without supplying

water to the exhaust system when watercraft is
out of water.
EXHAUST HOSES
Front Exhaust Hose Replacement
TYPICAL
iS and aS Models
Remove the LH rear storage basket. On GTS and GTI models, cut locking ties secur
ing wiring harness to exhaust hose.
Remove exhaust hose from muffler outlet.
Remove exhaust hose from the muffler outlet.
86 smr2011-013
Section 02 ENGINE
TORQUE
Front exhaust hose clamp I 4 N•m (35 lbf•in)

After installation, ensure there is no water or ex
haust gas leak when the engine is running. Test
run the engine while supplying water to the ex
haust system.
RttJi@j Never run engine without supplying

sm•201 0.021-00 4_ •
TYPICAL
1. Front exhaust hose out of water.
2. Muffler outlet
Rear Exhaust Hose Replacement

Cut the locking tie securing the electrical harness
to the front exhaust hose. iS and aS Models
Remove battery and battery holder. Refer to
Loosen clamps securing rear exhaust hose to res
onator and iBR support plate.
TYPICAL
1. Cur this locking tie
Detach the end of the hose from the resonator.
1. Retaining clamps
Remove the rear exhaust hose from vehicle.

Remove the resonator. See procedure in this sub
section.
Loosen clamp securing the rear exhaust hose to
RH fixing plate.
vn 120l<>02l<I06_a
TYPICAL
1. Front exhaust hose
2. Resonator
All Models
Remove front exhaust hose from vehicle.
When reinstalling exhaust hose, make sure to at
tach elbow fittings at the highest position that you
can on the exhaust hose.
Tighten retaining clamps to specification.
smr2011-013 87
Section 02 ENGINE
Loosen rubber adapter clamps.
3
2
DECK REMOVED FOR CLARITY

1. Rear exhaust hose
2. Hose clamp
1. Muffler
3. RH fixing plate
2. Rubber adapter
3. Clamps
All Models 4. Exhaust pipe
When reinstalling rear exhaust hose, tighten

Remove exhaust pipe and the rubber adapter .
clamps to specificatio n .
TORQUE Exhaust Pipe Inspection

Inspect exhaust pipe for:
Rear exhaust hose clamp I 4 N•m (35 lbf•in)
- Cracks
Reinstall all other removed parts. - Flange damages
After installation, ensure there is no water or ex - Other damages.
haust gas leak when the engine is running. Test Replace exhaust pipe as required.
run the engine while supplying water to the ex
Check i f the rubber adapter is:
haust system.
- Brittle
l!lZumJj N eve r run engine without supplying - Hard
- Otherwise damaged.
out of water.
Replace rubber adapter if necessary .
EXHAUST PIPE Exhaust Pipe Installation

Exhaust Pipe Removal Trace a mark to locate the middle of the muffler
Remove MUFFLER, see pro cedure in this subsec bulge opening.
tion.
Disconnect water inlet hose from exhaust pipe fit
ting.
1. Bulge
2. Middle of the opening
Install the rubber adapter on exhaust pipe. Ensure

stru2008-01 3·033.... o
rubber adapter is properly seats against exhaust
1. Water inlet hose
2. Exhaust pipe pipe shoulder.
88 sm12011-013
Section 02 ENGINE
1. Exhaust pipe shoulder

2. Rubber adapter
Center the rubber adapter strip of the rubber

adapter between both exhaust pipe marks.
1. Middle of rubber adapter strip
lighten retaining clamp. 2. Center of the muffler bulge opening
TORQUE Using a caliper, measure the distance between
I
Rubber adapter the exhaust pipe shoulder and the outside of the
8 N•m (71 lbf•in) muffler bulge.
retaining clamp
Position the muffler to 95mm± 2mm

(3.74 in± .079 in). Check the distance in
several places.
smr2008-0 1 3"°38. a
1. Rubber adapter strip

2. Retaining clamp
3. Exhaust pipe marks
Slide the other clamp on the rubber adapter. 1. Rubber adapter end
2. Outside of the muffler bulge
Insert the exhaust pipe into the muffler.
A. 95mm ± 2mm (3.74in ± .079in)
Align the center of the rubber adapter strip with
the mark previously traced on muffler. lighten retaining clamp.
TORQUE
Rubber adapter
retaining clamp
Install muffler in vehicle. Refer to MUFFLER /N

STALLATIONin this subsection for complete pro
cedure.
EXHAUST MANIFOLD
Exhaust Manifold Removal
1. On iS a n d aS models. remove the moving
deck and the deck extension. Refer to BODY
subsection.
smt2011-013 89
Section 02 ENGINE
2. Move muffler rearwards to make room. Refer Clean all metal components in a solvent.
to MUFFLER REMOVAL in this subsection to
know how separate muffler from exhaust man Exhaust Manifold Installation
ifold. Installation is essentially the reverse of removal
3. Di sconnect the exhaust manifold water outlet procedures. However, pay particular attention to
hose. the following.
NOTE: There is no gasket between cylinder block
and exhaust manifold.
Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on
t hreads of screws.
To help holding the manifold while installing
screws, first insert the exhaust manifold into the
exhaust pipe then, install the upper front screw.
Continue with the remaining screws.
Torque screws to specificati on as per following il
lustrated sequence. Repeat the procedure twice.
cmf1009-0 1 6 ·02J_
a
1. Water outlet nose TORQUE

2. Exhausr manifold
Exhaust manifold screws I 9 N•m (80 lbf•in)
4. Disconnect exhaust manifold water inlet hose
from e x haust manifold .
tmr 2 009-0 1&024JI
TYPICAL iS MODEL SHOWN

-
1 Exhaust manifold water inlet hose
5. U nscrew the exhaust manifold beginning with

the bottom screws. This will help holding the
manifold while you remove the screws. After installation, ensure there is no water or ex
haust gas leak when the engine is running. Test
6. Remove the exhaust manifold from vehicle.
run the engine while supplying water to the flush
- On iS and as models, move the exhaust
ing connector.
manifold rearwards to remove it.
- On models without iS and as. lift up the fi!l•)ilflJj Never run engi ne without supplying
exhaust manifold to remove it. water to the exhaust system when watercraft is
out of water.
Exhaust Manifold Inspection
Inspect exhaust manifold condition paying atten RESONATOR
tion for cracks or other damage. Check contact
Resonator Removal
surfaces and hose. Replace any defective part.
Inspect plane surfaces for warpage. Small defor iS and aS Models
mation can be corrected by grinding surface with 1. Remove engine from vehicle. Refer to ENGINE
a fine sand paper. Install sand paper on a surface REMOVAL AND INSTALLATION subsection.
plate and rub part against oiled sand paper.
90 smr2011·013
Section 02 ENGINE
Subsection 08 {EXHAUST SYSTEM)
2. Remove battery and battery holder. Refer to

3. Loosen clamp securing rear exhaust hose to
resonator.
4. Remove the screw securing the front of the res
onator.
:smr2011·013·006_
o
1. Resonator retaining screw
5. Loosen clamp securing the rear exhaust hose

to resonator.
a
snv2010-021-00a_
TYPICAL MODEL WITHOUT iS SHOWN

-
1. Resonator retaining screw
5. Remove the front exhaust hose from resonator.

6. Remove resonator from vehicle.

1 Remove seat.
.
2. Cut locking tie securing wiring harness to front

exhaust hose.
1. Resonator
6. Slide resonator by the deck opening.
Resonator Inspection
Inspect parts condition paying attention for defor
mation, cracks or other damage. Check hoses.
Replace any defective part.
Resonator Installation
Installation is the reverse of the removal proce
dures. However, pay attention to the following.
smr2011-013-005_ a TORQUE
1. Front exhaust hose
2. Cut this locking tie Resonator retaining screw I 7 . 5 N•m (66 lbf•in)
3. Detach the front exhaust hose from the res After installation, ensure there is no water or ex
onator. haust gas leak when the engine is running. Test
4. Remove screw and washer securing the front run the engine while supplying water to the ex
of the resonator. haust system.
fi¥[1Jitl}jNever run engine without supplying

out of water.
smr2011·013 91
92
Section 02 ENGINE
Subsection 09 (PTO HOUSING AND MAGNETO)
PTO HOUSING AND MAGNETO

SERVICE TOOLS
3-PIN MAGNETO HARNESS ADAPTER ....................................... . 529 036 016 ................................. 101-102
BLIND HOLE BEARING PULLER SET .......................................... . 529 036 117 ......................................... 101
. .. . ...... 420 877 650 ......................................... 101
HANDLE............................................................... .... .
IMPELLER REMOVER/INSTALLER ............................................... 529 035 820 ......................................... 100

OETIKER PLIERS......................................................................... .. 295 000 070 ......................................... 1 00
STARTER DRIVE SEAL PUSHER ................................................... 420 876 502 ......................................... 101
SUCTION PUMP .... ....................................................................... 529 035 880 . .................. .. ...... ..... .. . . 95
. . . . .. .
SERVICE PRODUCTS
ISOFLEX GREASE TOPAS NB 52 ................................................. 293 550 021 ................................. 101, 106
LOCTITE 243 (BLUE) ..................................................................... 293 800 060 ................................... 99, 104
LOCTITE 648 (GREEN) ................................................................. . 413 711 400 ......................................... 101
PULLEY FLANGE CLEANER ............... ......................................... 413 711 809 ..................................... 96, 99
snv2011-014 93
Section 02 ENGINE
9 N•m
(80 lbf•in)
J Loctite
��243
'O
ra:-
15 N•m
Engine
& oil Loctite
648
(133lbf-in)
�
+50°
250N•m / •
(184
lbfoft)
Im = Component must be replaced when removed.

amf.!01<>022-001_b
94 smr201 l-014
Section 02 ENGINE
GENERAL
NOTE: It is good practice to check for fault
codes using the B.U.D.S. software as a first trou
bleshooting step. Refer to the DIAGN OSTIC AND
FAULT CODES subsection.
Always carry out electrical tests on components
before removing or installing them.
During assembly, use torque values and service
products as in the exploded view.
Clean threads before applying a threadlocker. Re s m r2 000-00 G-0 03_a
fer to SELF-LOCKING FASTENERS and LOCTITE 1. Suction pump cube

2. Edge of cylinder block
complete procedure.
6. Syphon remaining oil out of the lower timing
chain case.
A WARNING
7. Dra in engine coolant, refer to the COOLING
SYSTEM subsection.
Locking devices when removed (e.g.: locking 8. Remove the air intake silencer. Refer to appro
tabs, elastic stop nuts, self-locking fasteners, priate AIR INTAKE SYSTEM subsection.
cotter pins, etc.) must be replaced. 9. Disconnect at throttle body the air intake h ose.
10. Move muffler rearwards. Refer to EXHAUST
SYSTEM subsection.
fl![1)i(IJjHoses, cables or locking ties re
moved during a procedure must be reinstalled 11. On 215 and 260 engines, remove the su
as per factory standards. percharger, refer to the SUPERCHARGER
subsection.
A WARNING
Before carrying out any inspection or main
tenance procedure on the vehicle, wait until
the engine and exhaust have cooled down to
avoid potential burns.
PROCEDURES
PTO HOUSING
PTO Housing Removal
1. Disconnect the battery. Refer to STARTING
SYSTEM subsection.
2. On iS models, remove the moving deck and sml2009-020-00 S_b
the deck extension. Refer to BODY subsection. 1. Supercharger
3. Drain the engine oil. Refer to LUBRICATION

12. Refer to STEERING AND PROPULSION and
SYSTEM subsection.
remove the following:
4. Remove the cylinder head cover. Refer to
- Jet pump
CYLINDER HEAD subsection.
- Drive shaft
5. Insert the tube of the SUCTION PUMP (PIN 529
- Drive shaft bellows.
035 880) in the lower area of the timing chain.
13. Disconnect CPS connector from wiring har
ness.
smr2011-014 95
Section 02 ENGINE
NOTE: Up to 250 ml (8 U.S. oz) of oil could flow

out when removing PTO housing. If spillage oc
curs, clean immediately with the PULLEY FLANGE
CLEANER (P/N 413 711 809) to prevent oil stains.
16. Remove both rear engine support screws.
CPS CONNECTOR
14. Disconnect the magneto connector, located

beside the ECM.
RIGHT SIDE OF VEHICLE

1. Rear engine support screw
-2011-01 4-002_•
130/155 ENGINES
1. Magneto connector
2. ECM support
3. ECM
LEFT SIDE OF VEHICLE

1. Rear engine support screw
17. Slightly lift aft end of engine and insert a safely

block under the engine to secure it in this po
sition.
18. Remove LH rear engine support.
s m r2DI l -O l «Xl3_o
2151260 ENGINES
1. Magneto connector
2. Throttle body
3. ECM support
4 ECM
15. Place rags under PTO housing to prevent oil

spillage.
96 smr2011·014
Section 02 ENGINE
Subsection 09 (P T O HOUSING AND MAGNETO)
NOTE: Note position of the CPS harness retaining

clamp position as illustrated above for reinstalla
tion.
21. Remove PTO housing from engine.
1.UtJitij To prevent damaging contact sur

faces, be sure to use prying lugs to separate
PTO housing from engine.
NOTE: Carefully separate PTO housing from en

gine using two flat screwdrivers prying equally on
opposite sides of the housing and at the same
time. Proceed slowly to prevent starter drive disc
springs and thrust washer from falling down into
bilge area.
TYPICAL
1. Engine support
19. Remove water pump housing, refer to COOL

ING SYSTEM subsection.
smr200J-01&003_c
1. Water pump housing

smt2005-034-00 2.a
20. Remove PTO housing retaining screws. 1. Disc springs

2. Thrust washer
3. Starter drive
22. Remove PTO housing gasket and discard it.
PTO Housing Inspection

Inspect PTO housing for cracks or any other dam
ages. Replace if necessary.
Inspect the needle bearing in the PTO housing
used to support the starter drive shaft.
NOTE: Clean all disassembled metal components
in a non-ferrous metal cleaner.
Inspect oil strainer for contaminants, debris or
other particles. Clean as required.
sm r2009-022-001 _a
1. PTO housing
2. CPS harness retaining clamp
3. CPS
smr2011-014 97
Section 02 ENGINE
IN'1i(ijj Pay particular attention to the PTO

housing gasket alignment to ensure that it
does not get pinched, o r slide out of its sur
face contact area. Never force housing when
installing it. If there is a strong resistance, re
move housing and check oil/water pump shaft
a lignment and starter drive gear alignment.
IN•)mJj Ensure the starter drive shaft is well

a ligned when engaging it in the PTO housing
needle bearing.
R1503motr117A
1. PTO oil strainer
PTO Housing Installation

However, pay attention to the following.
Apply lubricants, sealers or threadlocker as speci
fied in exploded view.
Apply torques as specified in exploded view
Position the disc springs and thrust washer onto
the starter drive shaft as per following illustration.
1. Pay attention that gasket remains properly pos1t1oned
on this surface
Refer to the following illustration to identify the

locations of the various housing screws.
smr2 00S-O J 4. 100_•
TYPICAL
1. Thrust washer
2. Disc springs
3. Starter drive
NOTE: When installing a NEW starter drive, oil

the shaft and gear splines with engine oil.
Install a NEW PTO housing gasket.
NOTE: When installing the PTO housing, you will
smr2009-022.()()I b
need to rotate the oil/water pump shaft slightly to 1. Screws M6 x 35
align it with the balance shaft for proper insertion. 2. Screws M6 x 85
NOTE: Install the CPS harness retaining clamp

at the position noted during the PTO housing
removal.
98 smr2011-014
Section 02 ENGINE
IN.Ji@j An engine a l i gnment procedure

must be carried out to ensure proper engine
alignment or severe component damage may
occur.
Install all remaining parts, reconnect hoses and

electrical connectors. Refer to applicable subsec
tions for procedures and specific details (torques,
service products or special instructions).
Refill engine with oil and cooling system with
coolant. Refer to LUBRICATION SYSTEM and
COOLING SYSTEM subsections.
smr2009·022· 004 -
�
PTO SEAL
1. CPS harness retaining clamp
PTO Seal Inspection
Install the PTO housing screws finger tight, then Inspect the PTO seal on the PTO housing. If brit
torque them to specification as per sequence tle, hard or damaged, or if you see a sign of oil
numbered in the following illustration. leakage, replace it.
Inspect ball bearing within PTO seal for excessive
play and smooth operation.
Replace PTO seal if oil seal or ball bearing is dam
aged.
omr200 9-022-00 1 _c
PTO HOUSING SCREWS TORQUE
Reinstall LH engine support.

1. PTO seal
Apply LOCTITE 243 (BLUE) (PIN 293 800 060) on en
gine support screw threads then torque them to PTO Seal Removal
specification.
Place rags under PTO housing to prevent spillage.
ENGINE SUPPORT SCREWS TORQUE If spillage occurs, clean immediately with PULLEY
FLANGE CLEANER (PIN 413 711 809) to prevent oil
23 N•m (17 lbf•ft)
stains.
Remove block under engine. NOTE: Note position of seal and orientation of
Install both rear engine support screws loosely. Oetiker clamp for installation.
Remove the Oetiker clamp retaining the seal to
Carry out an engine alignment,
refer to the
ENGINE REMOVAL AND INSTALLATION subsec the PTO housing.
tion.
smr2011-014 99
Section 02 ENGINE
PTO COUPLING
sm.-.?009-()22-00 7_1
TYPICAL
1. Oetiker clsmps
2. PTO seal omr201 0-022-00 2 _
a
J. PTO coupling
Pull seal from PTO housing. 2. Seal
3. Stop sleeve
PTO Seal Installation

PTO Coupling Removal
Insert a NEW Oetiker clamp over the seal.
Lock crankshaft. Refer to CYLINDER BLOCKsub
Push seal onto PTO housing. Be sure to align seal section for the procedure.
and clamp as noted at removal.
Remove PTO seal as described in previous proce
W•JmJj When installing PTO seal on super dure.
charged engines, make sure to position the Unscrew coupling from crankshaft.
Oetiker clamps a s illustrated.
REQUIRED TOOL
IMPELLER
REMOVER/INSTALLER
(P/N 529 035 820)
lruuiliil Apply engine oil to the removal tool

to protect the seal located within the PTO cou
pling.
1. Oettker clamps
Crimp Oetiker clamp using OETIKER PLIERS

(P/N 295 000 070).
""''2009-02 2 -00 S_b
TYPICAL - TURN COUNTERCLOCKWISE TO REMOVE

1. Impeller removal tool
100 smr2011-014
Section 02 ENGINE
PTO Coupling Inspection Starter Drive Bearing Removal

Inspect seal within coupling, if it is brittle, cracked Remove PTO housing, see procedure in this sub
or hard, replace it. section.
Check coupling for worn or damaged splines. Re Remove starter drive bearing from PTO housing
place as required. or cylinder block.
REQUIRED TOOL
PTO Coupling Installation
II
BLIND HOLE BEARING PULLER
SET (P/N 529 036 117)
Apply LOCTITE 648 (GREEN) (P/N 413 711 400) on
threads and torque PTO coupling to specification.
PTO COUPLING TORQUE Starter Drive Bearing Installation

250 N•m (184 lbf•ft) Prior to assembly grease starter drive bearing with
ISOFLEX GREASE TOPAS NB 52 (P/N 293 550 021 ).
Install starter drive bearing in the PTO housing or
STARTER DRIVE BEARINGS
in the cylinder block.
REQUIRED TOOLS
STARTER DRIVE SEAL

PUSHER (P/N 420 876 502) CC@D
HAND LE
(P/N 420 877 650) •
STATOR
Stator Output Voltage Test
Disconnect the magneto connector, located be
side the ECM.
Install this following harness adapter onto the
magneto connector.
smr2009-022- 009_
a
PTO HOUSING NOTE: Do not connect the magneto harness

1. Starter drive bearing adapter to the vehicle harness connector.
REQUIRED TOOL
3-PIN MAGNETO HARNESS

ADAPTER (P/N 529 036 016)
1 Set multimeter to Vac scale.

Start engine.
Connect multimeter between each pair of YEL
LOW wires as per following table. Measure volt
age between each pair of wires.
CYLINDER BLOCK
1. Starter drive bearing
smr2011-014 101
Section 02 ENGINE
smr7009-02'·101_e sm12009022-1 0 1_b
STATOR OUTPUT VOLTAGE TEST STATOR CONTINUITY TEST

1. Connect adapter lo magneto connector 1. Connect adapter to magneto connector
2. Leave vehicle harness disconnected 2. Leave vehicle harness disconnected
Read voltage as per following table. Read resistance.
STATOR OUTPUT VOLTAGE TEST STATOR CONTINUITY TEST
TEST ENGINE RESISTANCE @

TERMINAL VOLTAGE (AC) TERM I N AL
SPEED 20°c (68°F)
1 and 2 1 and 2
4000 RPM 1 and 3 Approx. 50 Vac 1 and 3 0.1 - 1 n
2 and 3 2 and 3
If voltage is lower than specification, carry out a If any result is out of specification, replace stator.
Si'i1TOR CONTINUITY TESTand a STATOR INSU
LATION TEST See procedures in this subsection. Stator Insulation Test
Disconnect the magneto connector, located be
Stator Continuity Test side the ECM.
Disconnect the magneto connector, located be Install the 3-PIN MAGNETO HARNESS ADAPTER
side the ECM. (P/N 529 036 016) onto the magneto connector.
Install the 3-PIN MAGNETO HARNESS ADAPTER NOTE: Do not connect the magneto harness
(P/N 529 036 016) onto the magneto connector. adapter to the vehicle harness connector.
NOTE: Do not connect the magneto harness Set multimeter ton.
adapter to the vehicle harness connector.
Connect multimeter between any YELLOW wire
Set multimeter to n. and engine ground.
Connect multimeter between each pair of YEL
LOW wires.
102 smr2011-014
Section 02 ENGINE
Subsection 09 ( PTO HOUSING AND MAGNETO)
smr2009-022·101 _r;
STATOR INSULATION TEST

1. Connect adapter to magneto connector
2. Leave vehicle harness disconnected 1. Stator screws
2. Stator
Read resistance.
Stator Installation
STATOR INSULATION TEST
RESISTANCE @ However, pay attention to the following.
TERMINAL
20°c (68°F)
NOTE: The position of the stator in the PTO hous
Any YELLOW wire and ing is determined by a key on the stator and a
Infinity (open circuit)
engine ground notch in the magneto housing.
If there is a resistance or continuity to engine

ground, the stator coils and/or the wiring is
grounded and need to be repaired or replaced.
Stator Removal
Remove PTO housing, see procedure in this sub
section.
Remove stator cable holding plate from PTO hous
ing.
1. Notch for stator
Place the stator cable rubber grommet in the

notch provided in the PTO housing.
•m.2009-022.oll_a
TYPICAL
1. Screws
2. Holding plate
Remove stator retaining screws.

Remove stator from PTO housing.
smr2011·014 103
Section 02 ENGINE
Gently set the gauge contact point on the next

tooth and read the dial indicator.
Repeat this procedure taking a reading at each
tooth.
Recheck reading on reference tooth to ensure
gauge has not changed position (gauge should
still read zero).
NOTE: If thf! rea di no exceeds the maximum al
lowable tolerance, straighten the tooth or replace
the trigger wheel.
MAXIMUM ALLOWABLE TOLERANCE
0.15 mm (.006 in)

s mr2009-022-009_1>
TYPICAL
1. Stator cable grommet
Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on the

stator screw threads and stator cable holding plate
screw threads.
Torque stator and cable holding plate screws to
specification.
STATOR AND CABLE HOLDING PLATE

SCREWS TORQUE
Install PTO housing as per procedures in this sub

section.
ROTOR AND TRIGGER WHEEL sm 12009-022 01 6_0
7. Trigger wheel
Rotor and Trigger Wheel Inspection 2. Dial indicator
Inspect rotor and trigger wheel condition. Pay

Properly reinstall PTO housing.
particular attention to the inside of the rotor for
cracks, rub marks or discoloration. If damaged,
Rotor and Trigger Wheel Removal
replace faulty part.
Lock crankshaft, refer to CYLINDER BLOCK sub
Check the trigger wheel for bent teeth using the
section for procedure.
following procedure.
Remove PTO housing, see procedure in this sub
Install a dial indicator on crankcase casting.
section.
Position the gauge on a tooth and set it to zero
Remove and discard the magneto rotor retaining
(0).Be sure to lock the indicator dial to prevent
screws.
movement of the dial during the remainder of the
procedure. Pull rotor and trigger wheel off crankshaft end.
Draw a line on the tooth to indicate it as the first

tooth measured (reference tooth).
Gently lift the gauge contact point off the tooth
and rotate the rotor to the next tooth.
NOTE: When lifting contact point off the tooth for
rotor rotation, be careful not to move gauge posi
tion or test readings taken on next tooth will not
be accurate with reference to the reference tooth.
104 smr201Hl14
Section 02 ENGINE
R1503mOlf54A
TYPICAL
1. Magneto rotor retaining screws
2. Rotor
TYPICAL 3. Trigger wheel
1. Rotor retaining screws 4. Ring gear
2. Rotor
3. Trigger wheel
Ring Gear Inspection
Rotor and Trigger Wheel Installation Inspect ring gear for damages. Pay particular at
tention to teeth condition. If badly worn, cracked,
or broken teeth are found, replace ring gear.
However, pay attention to the followi ng .
Align the trigger wheel to the crankshaft using the Ring Gear Installation
location pin on the crankshaft end.
Install NEW OEM rotor screws and torque them However, pay attention to the following.
to specification using a crisscross pattern.
Align the ring gear and trigger wheel to the crank
IW•Ji@!i Always install NEW OEM screws shaft using the location pin on the crankshaft end.
with pre-applied threadlocker. These are
stretch screws that are one time use only.
Not replacing rotor screws may lead to engine
damage and failure .
ROTOR SCREWS TORQUE

15 N•m (133 lbf•in) + an additional 50° rotation
with a torque angle gauge
RING GEAR
Ring Gear Removal
Lock crankshaft. R efer to CYLINDER BLOCKsub R1503motr548
section for procedure . TYPICAL

1. Location pin
Remove the PTO housing, see procedure in this 2. Location pin holes
subsection.
Install NEW OEM rotor screws and torque them
Remove and discard the magneto rotor retaining
screws. to specification in a crisscross pattern.
Pull rotor trigger wheel, and ring gear off crank

, l+ttoi[i!Jj Always install NEW OEM screws
shaft end. with pre-applied threadlocker. These are
stretch screws that are one time use only.
Not replacing rotor screws may lead to engine
damage and failure.
smr2011-014 105
Section 02 ENGINE
ROTOR SCREWS TORQUE Ensure proper operation of the starter drive sprag
clutch.
15 N•m (133 lbf•in) + an additional 50° rotation
with a torque angle gauge If any part of the assembly shows signs of ab
normal wear, cracks, broken teeth or malfunction
{sprag clutch), replace the faulty part.
STARTER DRIVE
Starter Drive Installation
Starter Drive Removal
Remove the PTO h ousing nnd ring gear as de
scribed in this subsection.
NOTE: When installing a new starter drive, oil the
Remove starter drive.
shaft, gear teeth and splines with engine oil.
Apply ISOFLEX GREASE TOPAS NB 52 (P/N 293 550
021 l on the starter drive bearings located in the
cylinder block and in the PTO housing.
I. Srarter drive
lil[.Ji@j Be careful not to lose the spring

discs and thrust washer located on the starter
drive shaft.
CYLINDER BLOCK
smr2009-02 2-009_a
PTO HOUSING
1. Spring discs
2. Thrust washer
3. Starter drive li![.Ji(llJj
Be sure not to forget the spring
discs and thrust washer on the starter drive
Starter Drive Inspection shaft when reassembling.
Inspect all starter drive parts for excessive wear,
cracks and other defects. Pay attention to the
condition of the drive gear teeth.
106 sm'2011-014
Section 02 ENGINE
Subsection 10 (LUBRICATION SYSTEM)
LUBRICATION SYSTEM
SERVICE TOOLS
ADAPTER HOSE . . . . . . . . . . . . . . . . . .................. . . . . . . . . . . . . . . . ...... . . . . . . . . . . . . . . . . . . . 529 035 652 ......................................... 115
ECM ADAPTER TOOL.................................................................. . 529 036 166 ................................. 117' 134
FLUKE 115 MULTIMETER ........................................................... . 529 035 868 ................................. 117, 134
OIL SEAL GUILJI::. .......................................................................... . 529 035 822 ........ ................................. 1 23
PRESSURE GAUGE.................... .................................................. . 529 035 709 ......................................... 115
SUCTION PUMP .......................................................................... . 529 035 880 ......................................... 113
SUPERCHARGER OIL SPRAY NOZZLE TOOL ............................ . 529 036 134 ......................................... 128
WATER PUMP SEAL PUSHER..................................................... . 529 035 823 ................................. 123-124
SERVICE TOOLS - OTHER SUPPLIER

FLUKE RIGID BACK PROBES....................................................... tp88 ......................................... 134
SERVICE PRODUCTS
LOCTITE243(BLUE) ....... .. ... . ... . . . . .... .... .. .. ... .............. . ... . ......
. . . . . . .. . 293 800 060 ................ 118-119,121, 123,
127-128, 132, 135
LOCTITE 5910 .............................................. ........................ .... ..... 293 800 081 ......................................... 119
PULLEY FLANGE CLEANER............ .. . . .... ... .. .. . .. 413 711 809 ................................. 114, 125
.. .... ... .......... . . .. .. . .
SUPER LUBE GREASE.................................................................. 293 550 030 ......................................... 115

XPS 4-STROKE BLEND OIL (SUMMER GRADE).......... . .. ... ..... 293 600 121 ......................................... 112 . . . . .
smr2011-015 107
Sectio� 02 ENGINE
9N·fu�
(80 lbfoin) �.
Loctite
243
IE!l = C
1m1201 0.023-lOO_c
t ::�
omporn e n m ust be replaced whe n removed.
��
��
- � �
108 srnr2011-015
Section 02 ENGINE
9N·m
(BO lbfoin)
�\ &Engineoil
::;;)
9N•m
(80 lbfoin)-----.
\
9N•m
(80 lbf-ln)-
3N•m
(27 lbfoin)
Left hand Locti:e 243
threads • �
'°'&
mIDJ Engine
Supercharger
:------------coctiiei2-,13-·:
:' & :'
oil : q /
c-
..::
-·;;;
: � ::
..:t.-
:
: ,_ ...,)""'- :
�
: 19N•m 11N•m :
:(168 lbf.in) (97 lbfoin);
·--------------------------�
Engineoil
�
'<i
<y
Engineoil& 9N•n;i
&
Loctite 5910 /(80 lbf•m)
&
Loctite 243
13N•m
1115 lbf•ft)�&L
octite 243
B •Component must be replaced when removed.
srnr201 HllM02.,a
smt2011-015 109
Section 02 ENGINE
ENGINE LUBRICATION CIRCUIT
Legend
---•Pressurized oil
- - - - - •Scavenged oil
• Bl ow by gas
·-·········
-
smf2009-02J.I OO_en
1. Oil dipstick
2. Rocker arm (intake)
3. Rocker arm (exhausV
4. Hydraulic valve lifter
5. Camshafr
6. Pistonpin
7. Into PTO housing
8. From oil filter
9. Piston cooling
10. Connecting rod
11. Balance shaft
12. Crankshaft
13.0il tank
110 smr2011-016
Section 02 ENGINE
ENGINE LUBRICATION CIRCUIT (CONT'D)
�I
Legend
--- Pressurized oil

--------•Scavenged oil
················� Blow-by gas
smr2 009
.o23·i01_eo
1. To air intake silencer 18. Oil spray nozzle

2. Rocker arm (incake) 19. Drive shaft
3. Rocker arm (exhaust) 20. Crankshaft
4. Rocker arm axle 21.PTO seal
5. Camshaft 22. Oil pressure switch
6. Pressure relief valve 23. Balance shaft
7. Oil separator 24. PTO housing
8. Cylinder head 25. Pressure pump
9. Blow-by valve 26. Pressure relief valve
70. Supercharger (if so equipped) 27. Oil strainer (pressure pump)
7 1. Oil filter 28. Scavenge pump
12. Hydraulic chain tensioner 29.0il tank
13. Supercharger bearing (if so equipped) 30. Oil strainer (scavenge pump)
14. Fr ction clutch 31. Oil drainage (PTO housing)
i
7 5. Piston pin 32. Oil cooler
16. Connecting rod 33. Scavenge of oil and blow-by gas
17. Piston cooling 34. Oil filler cap
smr2011-015 111
Section 02 ENGINE
GENERAL Oil Level Verification
During assembly/installation, use torque values Wl1Jil1Jj Check level frequently and refill if
and service products as in the exploded views. necessary. Do not overfill - it would make
Clean threads before applying a threadlocker. Re the engine smoke and reduce its power. Op
fer to SELF-LOCKING FASTENERS and LOCTITE erating the engine with an improper level
APPLICATION at the beginning of this manual for may severely damage engine. Wipe off any
spillage.
complete procedure.
A WARNING
1lft1JitiJj Hoses, cables or locking ties re

MAINTENANCE
ENGINE OIL TYPICAL iS MODELS SHOWN

-
1. Oil dipstick
Recommended Oil
Check the oil level as follows:
Use XPS 4-STROKE BLEND OIL (SUMMER GRADE)
(P/N 293 600 121 ). NOTE: It is of the utmost importance to follow
this procedure in order to obtain an accurate read
Naturally-Aspirated Engines ing of the engine oil level.
If the recommended XPS™ engine oil is not avail 1 Watercraft must be level. Check oil level either
.
able. use a 5W 40 or 1 OW 40 engine oil meet with watercraft in water or out of water.
ing the requirements for API service classification
2. If the watercraft is out of water, link a garden
SM, SL or SJ. Always check the API service label
hose to the hose adapter. Refer to EXHAUST
certification on the oil container, it must contain at
SYSTEM FLUSHING in the EXHAUST SYSTEM
least one of the above standards.
subsection.
Supercharger Engines
l+!ItJi@j When watercraft is out of water:
If XPS™ engine oil is not available, use a 1 OW40 - Never run engine without supplying water to
mineral engine oil compatible with wet clutches. the exhaust system.
NOTE: The XPS engine oil has been thoroughly - Never run engine longer than 2 minutes.
tested to be free of any additives that could impair Drive line seal has no cooling when water
the functionality of the supercharger clutch. craft is out of water.
W•Ji[IJj NEVER use synthetic oil. This would 3. Warm-up engine then let idle for 30 seconds
impair the proper operation of the super before stopping.
charger clutch. Do not add any additives to
4. Stop engine.
the recommended oil. Mineral oils not recom
mended by BRP may also contain additives 5. Open seat.
(friction modifiers) that may cause inappropri 6. On iS models, remove the ventilation box from
ate slippage of the supercharger and eventu the deck extension to gain partial access to en
ally lead to premature wear. For this reason, gine compartment.
XPS Synthetic Blend oil (Summer Grade) or a
NOTE: To remove the rear ventilation box, simply
BRP approved equivalent are the only recom
release the 3 clips retaining it and lift it off the deck
mended oils. Use of any oil not recommended
extension.
by BRP may void BRP's limited warranty.
112 smr2011·015
Section 02 ENGINE
l mr2007· 0153 100.a
7. Full
2. Add
3. Operatmg range
Otherwise, add oil until its level is between marks

as required.
To add oil, unscrew oil cap. Place a funnel into the
smo2009-002 -002 .
•
oil filler neck opening and add the recommended
1. Rear ventilation box
2. Deck extension oil to the proper level. Do not overfill.
3. Retaining clips
Oil Change
7. Wait at least 30 seconds for the oil to settle
in the engine, then pull dipstick out and wipe NOTE: Oil and oil filter must be replaced at the
clean. same time. Oil change and oil filter replacement
should be done with a warm engine.
A WARNING Bring engine to its normal operating temperature.
Engine oil may be hot. Certain components
in the engine compartment may be very hot.
IWumJ#I When watercraft is out of water:
Direct contact may result in skin burn. - Never run engine without supplying water to
the exhaust system.
- Never run engine longer than 2 minutes.
Drive line seal has no cooling when water
craft is out of water.
Run engine for 10 seconds a t 4000 RPM and shut

it off at this RPM. This will move oil from PTO
housing to oil tank to allow maximum oil draining.
Remove oil filler cap and dipstick.
A WARNING
Engine oil may be hot. Certain components
in the engine compartment may be very hot.
Direct contact may result in skin burn.
Siphon oil through the dipstick tube.
TYPICAL IS MODELS SHOWN

- REQUIRED TOOL
1. 01/ dipstick
8. Reinstall dipstick, push in comple tely. SUCTION PUMP

9. Remove dipstick and read oil level. It should be (P/N 529 035 880)
between the FULL and ADD marks.
Wl1Jil1Jj Never crank or start engine when

suction pump hose is in the dipstick tube.
Never start engine when there is no oil in en
gine.
smr2011·015 113
Section 02 ENGINE
NOTE: To properly posttton the suction pump

hose is located at the proper height to siphon
oil, it is suggested to put some electrical tape on
hose at 475 mm (18-11 /16 in) from its end. Then,
insert the hose until you reach the tape.
1 Oil filter screw

2. Oil filter cover
3. Oil filter
NOTE: No tools are required to remove the oil fil

ter cover, as it will pull off when the oil filter screw
is unscrewed.
Place rags in filler area to prevent spillage. If
spillage occurs, clean immediately with the PUL
LEY FLANGE CLEANER (PIN 413 711 809) to prevent
stains.
Oil Filter Inspection

R1503mott150A 1 Check oil filter cover 0-rings and oil filter screw
0-ring, change if necessary.
TYPICAL
1. Suction pump Check and clean the oil filter inlet and outlet area
2. Suction pump hose in the dipstick tube
for dirt and other contaminations.
Pull suction pump hose out of dipstick tube
Fully depress the throttle lever and HOLD it while
cranking engine for 10 seconds. Siphon oil again.
Repeat the crank-siphon cycle 2 - 3 times.
Refill engine with the recommended oil, see REC
OMMENDED OIL in this subsection.
Reinstall oil filler cap and dipstick.
Replace OIL FILTER, see procedure in this sub
section.
OIL FILTER
Oil Filter Removal
Remove: omr2009-023·004_
o
- Oil filter screw 1. Inlet bore from the oi1 pump to the oil filter
2. Outlet bore to the engine oil providing system
- Oil filter cover
- Oil filter. Oil Filter Installation
Pay attention to the following details.
Install a NEW oil filter.
Install 0-ring on oil filter cover.
114 smr2011-015
Section 02 ENGINE
Apply engine oil on filter ring, filter cover 0-rings OIL PRESSURE
and on oil filter screw 0-ring.
448 kPa 648 kPa
-
NOTE: In salt water area it is recommended to

.
Idle (cold} (65 PSI - 94 PSI}
coat mating surface of cover with SUPER LUBE for a very short time
GREASE (P/N 293 550 030).
Idle (at 80°C (176°F}) Min. 228 kPa (33 PSI)
Torque oil filter screw to specification.
400 kPa - 496 kPa
4000 - 7500
OIL FILTER SCREW TORQUE (58 PSI - 72 PSI)
Test at the Oil Pressure Switch
Location
INSPECTION
Remove oil pressure switch and install gauge.
ENGINE OIL PRESSURE

Oil Pressure Test Requirement
Bring engine to its normal operating temperature.
A WARNING
Certain components in the engine compart
ment may be very hot. Direct contact may re
sult in skin burn.
Qluitjl When watercraft is out of water:

- Never run engine without supplying water to
the exhaust system.
- Never run engine longer than 2 minutes.
Drive line seal has no cooling when water INSTALLATION AT PRESSURE SWITCH LOCATION
craft is out of water. 1. Remove oil pressure swirch snd install gauge here
To prevent the EMS to go in limp home mode (at

Required Tools for Oil Pressure Test
2500 RPM) or to generate a fault code, do the fol
REQUIRED TOOLS lowing:
1. Ground OPS to engine.
b
PRESSURE GAUGE
(P/N 529 035 709) 2. Plug OPS to harness.
3. Start engi ne.
'::>
ADAPTER HOSE 4. While engine is running, unplug OPS from har-
(P/N 529 035 652) ness.
Read oil pressure at different RPM as per table
NOTE: A 1/8 NPT pi pe extension may ease the above.
installation.
Reinstall oil pressure switch.
Oil Pressure Specifications
Test at the Cylinder Head Location
Use the following table to compare the oil pres
sure at different RPM. The oil pressure may be measured from cylinder
head if desired.
Remove plug lo cated on cylinder head and install
gauge.
$""2011-015 115
Section 02 ENGINE
7. Heavy wear on plain bearings.

- Check radial clearance of plain bearings. Replace
if out of specification.
HIGH OIL CONSUMPTION

1. Oil in breathing system.
- Check if breather V-ring is brittle, hard or dam
aged. Replace V-ring.
2. Valve stem seals worn or damaged.

- Replace valve stem seals.
3. Piston rings worn out (blue colored exhaust

smoke).
- Replace piston rings.
INSTALLATION AT CYLINDER HEAD
1. Remove plug and install gauge here OIL CONTAMINATION (WHITE
APPEARANCE)
Start engine and read pressure at different RPM
as per ta ble above . 1. Water ingestion through drive shaft and floating
Reinstall plug. ring
- Check if water is leaking between drive shaft and
floating ring. Repair or replace defective parts.
TROUBLESHOOTING Refer to PTO HOUSING AND MAGNETO subsec
tion.
probable source of troubles. It is a guideline and - Change engine oil and fitl er.
it should not be assumed to list all possible prob 2. Oil seal and rotary seal on water pump shaft
lems. leaking.
Always check for fault codes. If a fault code is de - Replace oil seal and water pump shaft assembly.
tected, service the fault code first. Refer to EN - Change engine oil and oil filter.
GINE MANAGEMENTsection.
3. Cylinder head gasket leaking.
LOW OR NO ENGINE OIL PRESSURE - Replace cylinder head gasket and tighten cylinder
head with recommended torque.
1. Oil level too low.
- Change engine oil and oil filter.
- Refill engine oil.
- Check for high oil consumption. See below.
4. Cylinder head screws not properly tightened.
- Retighten screws with recommended torque.
- Check for oil leaks (oil leaking out of leak indica-
tor hole, gaskets, oil seal or 0-rings). Repair or - Change engine oil.
replace.
5. Oil cooler 0-rings are leaking.
2. Oil pressure switch defective.
- Replace 0-rings.
- Check and replace if necessary.
- Change engine oil and oil filter.
3. Oil filter clogged.
6. Cylinder block or cylinder head casting is leak
- Replace engine oil and oil filter at the same time. ing.
4. Oil pressure regulator valve sticks open, or - Check for internal cracks in casting. Replace dam
aged components.
spring load is too small.
- Clean oil regulator piston and its bore. Replace if - Change engine oil and oil filter.
necessary.
- Measure spring free length. Replace if too small.
5. Oil pump(s) worn or damaged.

- Check oil pump rotors and its bore for wear limits.
Replace if out of specification.
6. Engine oil strainers are clogged.

- Remove and clean engine oil strainers.
116 smr2011·01!;
Section 02 ENGINE
PROCEDURES ENGINE RUNNING
TEST PROBES RESISTANCE (!l)

OIL PRESSURE SWITCH (OPS)
Infinitely high (OL)
OPS
Oil Pressure Switch Operation E ngine when pressure reaches
connector
ground 180 kPa (26.11 PSI) and
The switch threshold value to send a signal of low (pin 1)
220 kPa (32 PSI)
oil pressure may vary from a minimum of 180 kPa
(26 PSI) to a maximum of 220 kPa (32 PSI).
• mr 2009-023-1 02_
•
If resistance values are incorrect, replace OPS.

If the values are correct, check the continuity of
1. OPS the wiring harness.
Oil Pressure Switch Inspection Oil Pressure Switch Circuit Continuity

Test
First. carefully check the condition of the connec
tor terminals. Clean to remove dirt and corrosion Disconnect the ECM connector A from the ECM. " "
that could affect proper operation of the OPS. Check continuity of OPS circuit as per following
IMPORTANT: Do not apply dielectric grease on table.
terminal.
REQUIRED TOOL
Before checking the function of the OPS, an oil
•
pressure test has to be performed to be sure the ECM ADAPTER TOOL
oil pressure is not in fault. Refer to INSPECTION (P/N 529 036 166)
in this subsection.
When the engine oil pressure tests good but the FLUKE 115 MULTIMETER
OIL message in the information center is present (P/N 529 035 868)
and the beeper sounds:
- Ensure OPS connector is plugged to the switch.
OPS ECM
- Check the resistance of the OPS while engine RESISTANCE
CONNECTOR ADAPTER
is off and while engine is running.
Close to 0 f2
Pin 1 Pin E3
Oil Pressure Switch Resistance Test (continuity)
Disconnect the connector from the OPS.
Use a multimete.r to check the resistance as
shown.
ENGINE NOT RUNNING

TEST PROBES RESISTANCE (D)
OPS
E ngine Close to O (normally
connector
ground closed switch)
(pin 1)
5mr201l-015 117
Section 02 ENGINE
PTO OIL STRAINER

PTO Oil Strainer Removal
Remove engine oil. See procedure in OIL
CHANGE in this subsection .
Remove the PTO housing. Refer to PTO HOUS
ING AND MAGNETO subsection.
Remove the oil strainer.
1
•mr2009-023· 1 02_b
If continuity test failed, repair or replace the con

nector and wiring between ECM connector and
OPS.
If cont inuity test succeeded, check the ECM. Re
fer to ELECTRONIC FUEL INJECTION (EFI) sub
section.
Oil Pressure Switch Removal

Remove the throttle body. Refer to ELECTRONIC
FUEL INJECTION (EFI) subsection.
Unplug the OPS connector. R 1 !i03mo1r117A
Unscrew and remove the oil pressure switch. 1. PTO oil strainer
PTO Oil Strainer Cleaning and

Inspection
Clean oil strainer with a part cleaner then use com
pressed air to dry it.
Check and clean the oil outlet area for dirt and
other contaminations.
1. OPS
Oil Pressure Switch Installation

threads of oil pressure switch.
Torque oil pressure switch to specification.
T ORQU E
111503motr118A 1
Oil pressure switch I 9 N•m (80 lbf•in) 1. Oil inlet to the oil pump
118 smr2011·015
Section 02 ENGINE
PTO Oil Strainer Installation

Clean cylinder block to remove all remaining sili
cone residues in oil strainer area.
Apply a thin layer of LOCT ITE 5910 (PIN 293 800 081) 1
on oil strainer side.
Install it in the PTO housing.
Install the PTO housing using the procedure de
scribed in the PTO HOUSING AND MAGNETO
subsection.
Refill engine at the proper level with the recom
mended oil. Refer to ENGINE OIL for the proce
dure.
o;mr2006-01 4-() 20_
a
SUCTION PUMP OIL STRAINER 1. Suction pump cover g<1sker

2. Oil filler tube gasket
NOTE: The oil strainer does not need to be

If rubber rings are brittle, cracked or hard, replace
cleaned at every oil change. Clean it during other
them.
inspections, especially when the engine is disas
sembled. Clean both contact surfaces of oil suction pump
cover.
Suction Pump Oil Strainer Removal Check and clean the oil inlet and outlet area for dirt
Remove oil filler tube and suction pump cover, re and other contaminations.
fer to OIL SUCTION PUMP in this subsection.
Remove oil strainer from the suction pump cover.
"lUI�· ,
' , .
1. Oil inlet
2. Oil outlet
Suction Pump Oil Strainer Installation

2 For installation, reverse the removal procedure.
cm
2r 006-() 14-022 _• However, pay attention to the following.
1. Oil strainer
2. Suction pump cover Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on
threads of the suction pump cover screws and
Suction Pump Oil Strainer Cleaning tighten them to specification.
and Inspection
Clean oil strainer with a part cleaner then use com
pressed air to dry it.
Inspect rubber ring gaskets.
smr2011-015 119
Section 02 ENGINE
SUCTION PUMP COVER SCREWS TORQUE

9 N•m (80 lbfein)
Position screws according to their length as

shown.
smr2011.01 fi.003..0
TYPICAL
1. Oil pressure regulator
NOTE: The oil pressure regulator system opens

when the oil pressure exceeds 400 k Pa {58 PSI}.
Oil Pressure Regulator Removal

Remove engine oil. See procedure in OIL
CHANGE in this subsection.
1. Screws M6 x 25 Remove:
2. Screws stainless steel M6 x 45 - Oil pressure regulator plug
Torque suction pump cover screws as per se - Compression springs

quence illustrated below. - Valve piston
- Valve piston guide.
TYPICAL
1. Valve piston guide
TIGHTENING SEQUENCE 2. Valve piston
3. Inner compression spring
4. Outer compression spring
ENGINE OIL PRESSURE 5. Oil pressure regulator plug
6. 0-ring
REGULATOR
The oil pressure regulator is located on the bottom
of the PTO housing. Oil pressure regulator plug on oil pump hous
ing is spring loaded.
Oil Pressure Regulator Inspection

Inspect valve piston and valve piston guide for
scoring or other damages.
Check outer compression spring for free length.
120 smr2011.015
Section02 ENGINE
OUTER COMPRESSION SPRING FREE LENGTH 2
NEW NOMINAL 60 mm (2.362 in)
SERVICE LIMIT 50.3 mm (1.98 in)
Replace inner and outer compression spring as an

assembly.
Replace parts if important wear or damage are
present.
Clean bore and threads in the PTO housing from
metal shavings and other contaminations.
Oil Pressure Regulator Installation

However, pay attention to the following details.
Be careful that the 0-ring on plug screw is in
1. Screws
place. 2. Oil pump cover
5. Pull and remove the outer oil pump rotor.
threads of the oil pressure regulator plug.
Torque plug screw to specification.
1
OIL PRESSURE REGULATOR PLUG TORQUE
OIL PRESSURE PUMP

The oil pressure pump is located in the PTO hous
ing and is driven by the balance shaft.
Oil Pressure Pump Removal

1. Remove engine oil. See procedure in OIL
CHANGEin this subsection.
2. Remove the PTO housing. Refer to PTO
HOUSING AND MAGNETO subsection.
3. Remove water pump housing and the impeller.
1. Outer oil pump rotor
Refer to COOLING SYSTEM subsection.
4. Remove screws securing the oil pump cover. 6. Extract the coolant/oil pump shaft from outside
PTO housing cover with a pusher.
smr201Hl15 121
Section 02 ENGINE
F18E15A
7. Pusher
2. Coolanr/oil pump shaft
7. Remove rotary seal and oil seal. Refer to RO- R1503motr130A 2 1

TARY SEAL further in this subsection. 1. Outer rotor
2. Inner rotor
Oil Pressure Pump Inspection

OUTER AND INNER ROTOR CLEARANCE
Inspect coolant/oil pump shaft, housing and cover
SERVICE LIMIT
for marks or other damages.
Check inner rotor for corrosion pin-holes or other A
damages. If so, replace coolant/oil pump shaft. B 0.25 mm (.0098 in)
Ensure to also check oil pump housing and cover
c
and replace if damaged.
If clearance between inner and outer rotors ex

ceeds the tolerance, replace coolant/oil pump
shaft. Ensure to also check oil pump housing and
cover and replace if damaged.
If clearance between outer rotor and its bore in
oil pump exceeds the tolerance, replace the com
plete oil pump and the PTO housing.
Using a vernier depth gauge, measure side wear
as shown.
A 1 503mot r129A 1
1. Pittings on the teeth
Using a feeler gauge, measure the clearance be

tween inner and outer rotors.
R1503motr131A 2
1 PTO housing surface
2. Vernier depth gauge
122 smr2011-015
Section 02 ENGINE
R1503motr142A 2 1
1. Oil seal guide
2. Coolant/oil pump shaft
Rl503mou132A 2 1
1
u
1. Oil pump o ter rotor surface
2. Vernier depth gage
Difference between pump housing and outer ro

tor should not exceed the following specification.
If so, replace the complete oil pump assembly.
DIFFERENCE BETWEEN PUMP HOUSING

AND OUTER ROTOR
0.1 mm (.004 in)
NOTE: When the axial clearance of the coolant/oil

pump shaft increases, the oil pressure decreases.
Check the inside of oil pump housing and its cover
for scoring or other damages and replace if dam
2
aged. R1503moV143A
1. Coolant/oil pump shaft with oil seal guide

Oil Pressure Pump Installation 2. Rotary seal pusher to support PTO housing
For installation, reverse the removal procedure. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on
Pay attention to the following details. threads of oil pump cover screws.
Install a NEW rotary seal and a NEW oil seal. Refer Tighten oil pump cover screws and torque to spec
to ROTARY SEAL in this subsection. ification.
Install the coolant/oil pump shaft. OIL PUMP COVER SCREWS TORQUE
!L'Z'tJltiJI Never use a hammer for the 9 N•m (80 lbf•in)

coolant/oil pump shaft installation. Only use a
press to avoid damaging the ceramic compo After engine is completely reassembled, start en
nent of the rotary seal. gine and make sure oil pressure is within specifi
cations.
REQUIRED TOOL
OIL SEAL GUIDE ROTARY SEAL

(P/N 529 035 822)
Rotary Seal Removal
WATER PUMP SEAL PUSHER Remove the coolant/oil pump shaft. Refer to OIL
(P/N 529 035 823) PRESSURE PUMPin this subsection.
Carefully remove rotary seal with a screwdriver.
smr2011 ·015 123

Section 02 ENGINE
IM1Jil1Jj Be careful not to damage the surface

of the rotary seal bore in PTO housing.
Remove also the oil seal behind the rotary seal.

1. Oil seal
Install the NEW rotary seal.

1
REQUIRED TOOL
WATER PUMP SEAL PUSHER

(P/N 529 035 823)
lffet)@Jj Never use a hammer for the rotary

seal installation. Only use a press to avoid
damaging the ceramic component.
F18El8A
1. 01/ seal
Discard rotary seal and oil seal.
Rotary Seal Installation

The installation is the opposite of the removal pro
cedure. Pay attention to the following details.
NOTE: Never use oil in the press fit area of the oil
seal and rotary seal.
Push the NEW oil seal in place by using thumb.
Fl8E19A
1. Rotary seal
2. Rotary seal installer
Install the coolant/oil pump shaft. Refer to OIL

PRESSUREPUMPin this subsection.
OIL SUCTION PUMP

The oil suction pump is located on the front side of
the engine inside of the oil suction pump housing
at the bottom of the oil filler tube.
124 snv2011-015
Section 02 ENGINE
Oil Suction Pump Removal

1S Models
1. Remove jet pump and drive shaft. Refer to
2. Remove the moving deck. Refer to BODY
(GTX, RXT AND WAKE PRO) subsection.
3. Remove the air intake silencer. Refer to AIR IN
TAKE SYSTEM (iS AND aS MODELS) subsec
tion.
4. Detach the muffler from the exhaust manifold
and move muffler backwards. Refer to EX
HAUST SYSTEM subsection.
srr. t2009-02 J -0 1 1_ll
5. Remove engine support mount screws. 1. Suction pump cover screws
6. Move engine backwards, just enough to reach
4. Place rags under cover to prevent spillage. If
oil suction pump cover screws.
spillage occurs, clean with the PULLEY FLANGE
All Models CLEANER (PIN 413 711 809).
1. Remove retaining screws from oil filler tube. 5. Remove the oil suction pump housing.
6. Remove oil pump screws and cover.
1. Oil filler tube screws s mr200 9-015 -00 6_ o
TYPICAL
2. Remove oil filler tube. 1. Oil pump cover
2. Oil pump screws
3. Remove retaining screws.
7. Remove oil pump shaft.
8. Remove outer rotor.
smr2011-015 125
Section 02 ENGINE
R1503mc<O"l38A 2 1
1. Outer rotor
TYPICAL 2. Inner rotor
1. 01/ pump shafr
2. Outer rotor
OUTER AND INNER ROTOR CLEARANCE
Oil Suction Pump Inspection SERVICE LIMIT
Inspect oil pump shaft. housing and cover for A
marks or other damages.
B 0.25 mm (.0098 in)
Check inner rotor for corrosion, pin-holes or other
damages. If so, replace oil pump shaft. Ensure c
to also check oil pump housing and cover and re
place if damaged. If clearance between inner and outer rotors ex
ceeds the tolerance, replace oil pump shaft. En
sure to also check oil pump housing and cover and
replace if damaged.
If clearance between outer rotor and its bore in
oil pump exceeds the tolerance, replace the com
plete oil pump and the PTO housing.
Using a vernier depth gage, measure side wear as
shown.
1. Pittings on the teeth
Using a feeler gauge, measure the clearance be

tween inner and outer rotors.
R1503mo&r139A 1 2
1. Oil pump housing surface
126 smi2011-015
Section 02 ENGINE
R1503motr 1 40A 2 s m r 2009-023·008_a
1. Screws MB x 25
1. Oil pump outer rotor surface
2. Screws M6 x 45
Difference between pump housing and outer ro lighten suction pump cover screws as per follow
tor should not exceed the following specification. ing sequence.
If so, replace the complete oil pump assembly.
DIFFERENCE BETWEEN PUMP HOUSING

AND OUTER ROTOR
0.1 mm (.004 in)
NOTE: When the axial clearance of the oil pump

shaft assembly increases, the oil pressure de
creases.
Check the inside of oil pump housing and its cover
for scoring or other damages and replace if dam
aged.
Oil Suction Pump Installation

For installation, reverse the removal procedure. >ma009-023-00 9 _ a
Pay attention to the following details. TIGHTENING SEQUENCE

Refer to the appropriate procedures and install all
threads of the suction pump cover screws and
other removed parts.
tighten them to specification.
SUCTION PUMP COVER SCREWS TORQUE SUPERCHARGER OIL SPRAY

9 N•m (80 lbf•in) NOZZLE
Position screws according to their length as Supercharger Oil Spray Nozzle
shown. Removal
Remove the PTO housing. Refer to PTO HOUS
ING AND MAGNETO subsection.
Remove the Torx screw securing the oil spray noz
zle support.
Unscrew the Banjo bolt.
smr20·11-01s 127
Section 02 ENGINE
�1;..oQ 7_•
sm•200!-01 5-00 IL•
1. Banjo bolt
A. 7 mm (.039in)
2. Supercharger oil sprav nozzle
3. Oil spray nozzle supporr
4. Torx screw NOTE: Make sure that the oil spray nozzle is fac
ing to the center of the tool. Not following this
Supercharger Oil Spray Nozzle procedure will lead to an insufficient oiling of the
Inspection supercharger and a supercharger failure can oc
Check oil spray nozzle for: curs. Adjust the oil spray nozzle if necessary by
slightly bending it, take c are not to over bend the
Dirt
oil spray nozzle.
-
- Bend
- Other damages.
Replace if necessary.
Supercharger Oil Spray Nozzle

Installation
For installation reverse the removal procedure.
threads of Torx screw.
Install the oil spray nozzle support. 1. Center of supercharger oil spray nozzle tool
TORQUE
PISTON OIL SPRAY NOZZLES
Oil spray nozzle support
11 N•m (97 lbf•in)
(To rx screw) The piston oil spray nozzles are located on the up
per half of cylinder block.
Install oil spray nozzle with Banjo bolt.
TORQUE
Oil spray nozzle Banjo

19N•m (1681bf•in)
bolt
Adjust the position of the oil spray nozzle.
REQUIRED TOOL
SUPERCHARGER OIL
SPRAY NOZZLE TOOL
(P/N 529 036 134)
The distance between the adjustment tool and oil

spray nozzle must be within 1 mm (.039 in).
1. Piston oil sprav nozzles
128 smr2011·015
Section 02 ENGINE
NOTE: When the scope of repair work obligates Piston Oil Spray Nozzle Installation
you to split the cylinder block. take this opportu
nity to clean the oil spray nozzles. Uloili/j At assembly make sure the contact
surface of the oil spray nozzle is well fitted onto
Piston Oil Spray Nozzle Removal the cylinder block. If this is not ensured, the oil
spray direction will change, causing potential
Remove cylinder block lower half. Refer to CYLIN
engine damage.
DER BLOCK subsection.
Remove oil spray nozzle and Banjo fitting from
cylinder block upper half.
mm12CX&' 11..Q5Q_1
1. Oil spray nozzle

2. Contact surface
m mt'2009-111"°'8_•
1. Banjo fitting OIL SEPARATOR COVER

2. Oil spray nozzle
Oil Separator Cover Removal

Piston Oil Spray Nozzle Cleaning and
1. Remove the blow-by valve. See procedure in
Inspection
this subsection.
Clean oil spray nozzle and Banjo fitting from dirt
2. Remove camshaft position sensor.
and debris. Use a part cleaner then compressed
,
air and dry the parts.

Check if ball inside Banjo fitting moves freely.
smr2009.Q23 .01 & a
1. Camshaft position sensor

2. Screw
1. Ball
2. Spring 3. Remove cylinder head cover. refer to CYLIN
3. Banjo fitting
4. Oil spray nozzle
DER HEAD subsection.
4. Remove thrust washer from oil separator cover.
NOTE: If the oil spray nozzle is damaged or bent
during work in the cylinder block. it must be re
placed immediately.
smr201 I ·015 129

Section 02 ENGINE
Subsection 10 {LUBRICATION SYSTEM)
NOTE: Make sure not to loose thrust washer

when removing it from oil separator cover, oth
erwise thrust washer would fall into the PTO
housing.
sm(.1006-0 1 4-06 7 _a
1. Camshaft
2. Oil separator cover
NOTE: Be careful not to break the holding clips

from oil separator cover when its removed from
the timing gear.
s mr2009-023-0 1 G_a
1. Thrust washer Oil Separator Cover Inspection

2. Oil separator cover
Inspect oil separator cover for marks or other dam
5. Remove spark plug tube. ages. Ensure to check also the holding clips of oil
6. Remove rocker arm shaft together with rocker separator cover and for thrust washer. If any dam
arms, refer to CYLINDER HEAD subsection. age is visible replace oil separator cover.
7. Remove chain guide and camshaft guide.
s mr20-06-0\ d -006... •
s mr2 0 06-01 -037_a
Rocker arm
4
1.
2. Camshaft guide 1. Holding clips
3. Chain guide
Oil Separator Cover Installation

8. Move camshaft backwards as far as possible.
9. Remove oil separator cover from timing gear by
releasing the holding clips.
Properly install oil separator cover and thrust
washer. They need to be in a perfect even posi
tion with timing gear.
NOTE: Make sure not to lose thrust washer when
installed on oil separator cover.
For installation of rocker arm shaft with rocker
arms, follow the procedure as it is described in
CYLINDER HEAD subsection.
130 smr2011-01S
Section 02 ENGINE
BLOW-BY VALVE
Blow-By Valve Description
The function of the blow-by valve is the circulation
of the oil vapors.
Blow-By Valve Operation

Normal Operation
During its normal operation, the blow-by valve al
lows crankcase vapors to return in the intake sys
tem where they are harmlessly burned.
BY-PASS FUNCTION
Blow-By Valve Removal

iS and aS Models
Remove:
- Deck extension, refer to BODY (GTX, RXT AND
WAKE PRO) subsection
- Air intake silencer, refer to AIR INTAKE SYS-
TEM (WITH iS AND aS) subsection.
•mt200
-0
9 23 0 19-.R All Models
NORMAL OPERATION
Remove ventilation hose from blow-by valve.
By-Pass Function Remove the CPS connector from its support on
If, for any reason, the valve piston gets stuck blow-by valve.
at normal operation and the crankcase pressure
exceeds 40 kPa (6 PSI), the pressure unseats a
check ball and crankcase vapors can bypass the
valve piston.
smr2 009-023.() 1 3_1
1. Blow-by valve
2. CPS connector
Disconnect the TOPS switch connector of the

blow-by valve.
Unscrew and remove the blow-by valve.
smr2011·015 131
Section 02 ENGINE
smr2009-023-0 14_•
smr200 9-023-023_•
1. TOPS switch connector
2. Retaining screws
Turn valve upside down and blow air again. Air
Remove and discard 0-ring and V-ring. must not flow out.
NOTE: The blow-by valve can not be disassem
bled.
sm2009-023-024_a
If test fails, replace blow-by valve.
Blow-By Valve Installation

1. Blow-by valve
2. V-ring Install the blow-by valve with NEW 0-ring and
3. 0-ring V-ring.
Apply LOCT ITE 243 (BLUE) (P/N 293 800 060) on
Blow-By Valve Inspection
threads of blow-by valve screws.
If blow-by valve is damaged, replace it.
Tighten blow-by valve screws to specification.
Clean all contact surfaces of blow-by valve.
BLOW-BY VALVE SCREWS TORQUE
Place a clean rag on valve inlet.
Blow air through inlet port. Air must flow freely to
the outlet port.
Reinstall remaining removed parts.
132 smr2011-015
Section 02 ENGINE
TOPS SWITCH
Tip Over Protection Switch (TOPS
Switch) Function
The function of the TOPS switch is the engine pro
tection in the event the watercraft tip over.
During normal operation the TOPS switch state is
OFF, no signal to the ECM.
If the watercraft tips over, gravity causes a valve
piston to close and no engine oil will leak out of
the blow-by valve.
In this event. a pin (with magnet) opens a gap
to the TOPS switch (Hall effect sensor) and the
TOPS changes its state to ON and sends a signal
to the ECM.
•mr2001>03-2 020.)I
The ECM will shut down the engine by cutting the TIP OVER FUNCTION
ignition and the fuel injection.
TOPS Switch Input Voltage Test
Remove:
- Deck extension, refer to BODY (GTX, RXTAND
WAKE PRO) subsection.
- Air intake silencer, refer to appropriate AIR IN-
TAKE SYSTEM subsection.
blow-by valve.
Briefly press the START/STOP button to wake-up
the ECM.
Probe terminals as shown to check the voltage
output from the ECM.
•mi'2009-023-019.•
TOPS SWITCH CONNECTOR VOLTAGE
BLOW-BY VALVE CUT-AWAY Approximately
1. Valve housing Pins 2 and 3
2. Valve sleeve 5 Vdc
3. Valve piston
4. Check ball
5. Valve pin (with magneU
6. TOPS switch of the blow-by valve
If voltage test is good, check the TOPS switch out

put voltage.
If voltage test is not good, check the continuity of
the blow-by valve TOPS switch circuit.
NOTE: After voltage test, clear the fault codes in
the ECM using the B.U.D.S. software.
smr2011-015 133
Section 02 ENGINE
TOPS Switch Output Voltage Test TOPS SWITCH E CM

RESISTANCE
Remove the blow-by valve. CONNE CTOR AD A PTER
Back-probe TOPS connector and check voltage Pin 1 Pin F4

using the FLUKE 115 MULTIMETER (PIN 529 035 Close to 0 n
Pin 2 Pin G1
868). (continuity)
Pin 3 Pin C4
NOTE: To easily probe wire terminals through the
back of the connector, use the FLUKE RIGID BACK
PROBES (PIN TP88) or an equivalent.
smt20Q9-02:J.JOJ _b
1. Pin 1
2. Pin 2
3. Pin 3
smr2009·02J-OSO_a If continuity test is good. check ECM. Refer to

BLOW-BY VALVE IN NORMAL POSITION ELECTRONIC FUEL INJECTION (EFI) subsection.
7. Blow-by valve
2. REDp robe into pin 2 If continuity test is not good. repair or replace de
3. BLACK probe into pin 1 fective wires or connectors.
BLOW - BY
TOPS SWITCH TOPS Switch Replacement
VALVE V OLTAGE
CONNECTOR
POSITION Remove blow-by valve and turn it upside down.
Pin 1 and pin 2 Normal position 0.4 ± 0.1 Vdc Insert a small screwdriver between TOPS switch
and its retaining tab. Twist and hold the TOPS
Pin 1 and pin 2 Upside down 4.4 ± 0.2 Vdc
switch then release the other retaining tab.
Normal position Approximately
Pin 2 and pin 3
or upside down 5 Vdc
Replace TOPS switch if not within specification.
TOPS Switch Circuit Continuity Test

blow-by valve.
Disconnect the connector "A" from the ECM.
Check continuity of the blow-by valve TOPS
switch circuit as per following table.
When installing the TOPS switch, make sure
REQUIRED TOOL
printed information is visible.
ECM ADAPTER TOOL
(P/N 529 036 166)
i
FLUKE 115 MULTIMETER
(P/N 529 035 868)
134 smr2011·015
Section 02 ENGINE
c mr2009-023 062_a
1. TOPS valve inscriptions
OIL COOLER smt2007-0 1 S-00 7_.
1. Oil cooler crews

2. Oil cooler
The oil cooler is located below the air intake man
ifold. Remove oil cooler from engine. Ensure not to lose
0-rings located between oil cooler and engine.
R1503motr 1 48A
1. O·rings
1. Oil cooler
Oil Cooler Inspection
Oil Cooler Removal If 0-rings are brittle, cracked or hard, replace
them.
Remove engine from vehicle. Refer to ENGINE
REMOVAL AND INSTALLATION subsection. Clean both contact surfaces of oil cooler.
Disconnect cooling hoses from oil cooler. Check and clean the oil inlet and outlet area for dirt
and other contaminations.
Remove screws securing oil cooler.
Oil Cooler Installation

Apply engine oil on 0-rings.
threads of oil cooler screws.
lighten oil cooler screws to specification.
OIL COOLER SCREWS TORQUE

smr2011·015 135
136
Section 02 ENGINE
Subsection 11 (COOLING SYSTEM)
COOLING SYSTEM
SERVICE TOOLS
OETIKER PLIERS........................................................................... 295 000 070 ......................................... 146
TEST CAP...................................................................................... 529 035 991 ......................................... 145
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ......................................... 146
SERVICE PRODUCTS
BRP PREMIXED COOLANT .......................................................... 219 700 362 ......................................... 143
LOCTITE 243 (BLUE) ..................................................................... 293 800 060 ......................................... 149
LOCTITE 567 (PIPE SEALANT) ..................................................... 293 800 013 ......................................... 144
smr2011-018 137
Section 02 ENGINE
COOLING SYSTEM (CLOSED LOOP)

(GTI SERIES, GTS SERIES AND WAKE 155)
Bleed hose
from cylinder
Coolant temperature head to
sensor (CTS)
activates when
temperature exceeds
100°c (212°F)
Coolant housing
including thermostat
opens at 87°C (188°F) Coolant
and water pump returns
impeller from oil
cooler
Coolant flows
to ride plate
Coolant returns
from ride plate
I
Ride plate
(operates as heat
exchanger)
srv.!011-016-00 1 __
138 smr2011-016
Section 02 ENGINE
COOLING SYSTEM (CLOSED LOOP)

(GTX SERIES, RXT SERIES AND WAKE PRO 215)
Expansion
coolant tank
Coolant temperature
sensor (CTS) Bleed hose
activates when from cylinder
temperature exceeds head to
100°c (212°F)
Coolant housing
including thermostat
opens at 87°C (188°F)
and water pump
impeller
Coolant
returns
from oil
cooler
Oil
cooler
Coolant returns
Ride plate from ride plate
(operates as heat
exchanger)
omr2009·0 24· 1 00_ e n
smr2011·016 139
Section 02 ENGINE
COOLING SYSTEM COMPONENTS

(GTI SERIES, GTS SERIES AND WAKE 155)
4 N•m
(35 lbf·in)
�-4N•m
(35 lbfoin)
140 S'l'lr2011-016
Section 02 ENGINE
COOLING SYSTEM COMPONENTS

(GTX SERIES, RXT SERIES AND WAKE PRO 215)
lmJ
IT"""-�=---- 5 N •m
(44 lbfoin)
1.7 N•m
(15 lbfoin)
�-? /
/
/
�,.
�,,
/'
4 N•m
(35 lbfoin)
Imm= Component must be replaced when removed.

-smr201 0-024·002_b
smr2011·016 141
Section 02 ENGINE
COOLING SYSTEM COMPONENTS (ENGINE)
17N·m-
(150 lbfoin)
9 N·m --trii�-----.-.
(80 lbf•in)
3 N•m
(27 lbfoin)
(left-hand threads)
Im= Component must be replaced when removed.
142 smr2011-016
Section 02 ENGINE
GENERAL
complete procedure.
A WARNING
tabs, elastic stop nuts, self-locking faste ners, s m 2009-024-002 _&
cotter pins, etc.) must be replaced. 1. Bleed hose nipple

2. Coolant temperature sensor (CTS)
W1Ji[ilj!j Hoses, cables or locki ng ties re

ffl,Ji[ilj!j
Never modify cooling system ar
rangement, otherwise serious engine damage
could occur.
Technical Specifications
SYSTEM DESCRIPTION
TYPE Closed loop cooling system.
A closed loop cooling system is utilized on the
COOLANT FLOW Flow from water pump.
1503 4-TEC engines, which offers an efficient
engine cooling while keeping dirt and salt water TEMPERATURE
Thermostat.
out of the cooling system. This system keeps CONTROL
the temperature constant and prevents internal
Self-bleed type through
engine corrosion. SYSTEM
coolant tank (hose at
BLEEDING
A separate coolant tank ensures that enough en uppermost point of circuit).
gine coolant is in the circuit during any operating
Turns on at 100°C (212°F) on
condition. MONITORING naturally aspirated engines.
The coolant flow comes from the water pump im BEEPER Turns on at 110°C (230°F) on
peller into the cylinder block. It goes around the supercharged engines.
cylinders and straight up to the cylinder head. A
smaller quantity of engine coolant enters the cylin
der block on the exhaust side for a better cool
MAINTENANCE
ing. In the cylinder head the water channels flow
around the exhaust and then the intake valves and ENGINE COOLANT
leave the engine through a large hose. From there
A WARNING
the coolant goes back to the water pump hous
ing and depending on the engine temperature, it To avoid potential burns, do not remove the
flows through the thermostat directly back to the coolant tank cap or loosen the ride plate drain
water pump impeller, or it takes its way through plug if the engine is hot.
the heat exchanger.
Engine coolant is also directed towards the oil Recommended Coolant
cooler (coolant type). Use BRP PREMIXED COOLANT (P/N 219 700 362) or
Coolant temperature sensor and bleed hose nip a blend of 50% antifreeze with 50% demineral
ple are located on the cylinder head. ized water.
NOTE: Using a blend of 40% antifreeze with 60%
demineralized water will improve the cooling effi
ciency when watercraft is used in particularly hot
weather and/or hot water condition.
smr2011-016 143
Section 02 ENGINE
Ql•JltiJj A blend of 40% antifreeze with 60% Cleaning the System

demineralized water will improve the cooling
efficiency. Using water tap i nstead of dem QltJilltfiCleaning the cooling system as per
the following procedure is required when en
i neralized water, would contribute to make
deposits in cooling system and to reduce an gine overheats (assuming everything else is
tifreeze efficiency. This could lead to engine operating normally) or each time coolant is
replaced.
overheating.
To prevent antifreeze deterioration, always use Drain the cooling system.

the same brand. Never mix different brands un Add a cleaning product such as the Zerex® Super
less cooling system is completely flushed and Cleaner by Valvoline (or an equivalent) in coolant
refilled. tank then fill cooling system with demineralized
water.
IMtJi@il To prevent rust formation or freez
Reinstall cap on coolant tank.
ing condition in cold areas, always replenish
the system with 50% antifreeze and 50% dem Install watercraft in a test basin or ride on a water
ineralized water. Pure antifreeze will freeze at a plane. Start engine and run for approximately 15
higher temperature than the optimal water/an minutes.
tifreeze mix. Always use ethylene glycol an IMPORTANT: Ensure thermostat opens so that
tifreeze containing corrosion inhibitors specifi the cleaning product flows in ride plate properly.
cally recommended for aluminum engines.
Stop engine and let the cleaning product work for
Draining the System 12 to 16 hours.
Thereafter, engine can be run one last time to soak
off deposits.
Never drain or refill cooling system when en Drain and thoroughly rinse the cooling system
gine is hot. with clean fresh water .
Refill cooling system as described below.

Open seat.
On iS models, remove the rear ventilation box. Refilling the System
Remove the coolant tank cap. Watercraft should be level, engine cold and drain
plug removed for refilling.
Install a drain pan underneath the ride plate.
Place a container under drain plug to collect an
Unscrew the drain plug on ride plate .
tifreeze.
NOTE: Raising the front of the watercraft will con
Apply LOCTITE 567 (PIPE SEALANT) (P/N 293 800
tribute to drain the cool ing system.
013) on drain plug threads.
Ask someone to pour recommended antifreeze in
coolant tank .
When antifreeze flows out from the ride plate

drain hole, reinstall drain plug. Torque drain plug
to specification.
DRAIN PLUG TIGHTENING TORQUE
8.5 N•m (75 lbf•in)
�1 Continue to pour and fill coolant tank between

lllTV2 009 -024-10 2_o
marks.
1. Cooling drain plug
Dispose coolant as per local regulations .
Do not reinstall drain plug at this time.
144 smr2011-016
Section 02 ENGINE
Repeat this run-stop cycle 2-3 times until thermo

stat opens and stop engine.
ENGINE COOLANT ONLY
MAX.
s m!'201 1-016-004_4 smr2009-024 -003_ a
TYPfCAL - GT/ SERIES, GTS SERIES AND WAKE 155 1. This hose becomes hot when thermostat opens
1. Le vel between marks when engine is cold
Last, refill coolant tank and install pressure cap.
When engine has completely cooled down,
recheck coolant level coolant tank and top up if
necessary.
INSPECTION
COOLING SYSTEM LEAK TEST

A WARNING
To avoid potential burns, do not remove the
coolant tank cap or loosen the ride plate drain
omo2009-002 ·137 -• plug if the engine is hot.
TYPICAL - GTX SERfES, RXT SERIES AND WAKE PRO 215
1. Level between marks when engine is cold
Open seat.
Do not install pressure cap at this time. On iS m odels remove the deck extension. Refer
,
Link a garden hose to the hose adapter at the back to BODY subsection.
of the watercraft. Refer to EXHAUST SYSTEM Install the TEST CAP (P/N 529 035 991) on the
FLUSHING in the EXHAUST SYSTEM subsection. coolant tank.
1i![11Qilj Never run engine without supplying

water to the exhaust system.
Start engine and let run for a maximum of 2 min

utes. Stop engine and wait 15 minutes to cool
down. Refill tank as necessary.
@1JltiJj Never run engine longer than 2 min

utes. Drive line seal has no cooling when wa
tercraft is out of water.
5 2 003599 1
NOTE: Properly cool exhaust system by installing
a garden hose. Refer to EXHAUST SYSTEM sub NOTE: It is not necessary to install a hose pincher
section. on overflow hose.
smr2011·016 145
Section 02 ENGINE
Connect the VACUUM/PRESSURE PUMP (P/N 529 ENGINE OVERHEATING

021 800) to test cap and pressurize system
1. Low coolant level.
through coolant tank to 90 kPa (13 PSI).
- Refill and check for leaks (coolant leaking out
of engine leak indicator hole, hoses or clamps
missing/defective, cylinder head gaskets leaks,
ride plate leaking, etc.). Repair or replace.
2. Air in cooling system

- Refill and bleed cooling system.
3. Thermostat defective (does not open when en

gine gets hot)
- Replace thermostat housing.
4. Water pump failure

- Inspect and replace defective components.
omr2009-02< ·Ul3..o
5. Water temperature sensor defective
1. Vacuum/pressure pump - Check or replace. Refer to ELECTRONIC FUEL

2. Tesc cap INJECTION (EFI).
Check all hoses, ride plate, engine and oil cooler 6. Ride plate or hoses damaged
for coolant leaks. Spray a soap and water solution - Check or replace damaged components.
and look for air bubbles.
7. Exhaust system clogged
Check the leak indicator hole if there is oil or - Flush exhaust system.
coolant. If so, replace appropriate water pump
shaft seal. 8. Internal passage blocked in cooling system
- Inspect and clean.
PROCEDURES
PRESSURE CAP
Pressure Cap Inspection
Using a pressure cap tester, check pressure cap
efficiency. If the efficiency is feeble, install a new
90 kPa (13 PSI) cap (do not exceed this pressure).
CLAMPS
Clamp Replacement
To cut or secure Oetiker clamps of cooling system
hoses, use the OETIKER PLIERS (P/N 295 000 070).
1. Leak indicator hole
TROUBLESHOOTING
lems.
tected, service the fault code first. Refer to DIAG
146 smt2011-016
Section 02 ENGINE
3. Detach the air intake hose from the throttle

body.
NATURALLY-ASPIRATED ENGINE
1. Detach intake hose at throttle body
1. Cutting clamp
2. Securing clamp
NOTE: Always check general condition of hoses

and clamp tightness.
WATER PUMP HOUSING
smr2010-024-201_a
SUPERCHARGED ENGINE
1. Detach intake hose at throttle body
2. Supercharger hose
4. On supercharged engines, remove also the

hose from the supercharger.
5. Drain cooling system and engine oil.
6. Disconnect the coolant tank hose from water
pump housing and move coolant tank aside to
make room.
smr2009-024 ·004_b
Water Pump Housing Access

GT/ Sere
i s, GTS Series and WAKE 155
Remove the seat.
GTX Series, RXT Series and WAKE PRO 215

1. On iS models, remove moving deck and deck
extension. Refer to BODY subsection.
2. Remove the air intake silencer. Refer to the ap
- AIR INTAKE SYSTEM (EXCEPT iS AND as !mflOOS-024-l O SJJ
1. Coolant tank hose

MODELS)
- AIR INTAKE SYSTEM (iS AND as MODELS).
smr201Hl16 147
Section 02 ENGINE
7. Disconnect exhaust hose from the resonator.

Place hose over muffler.
TYPICAL
1. Exhaust hose 2. Cylinder head hose
2. Cut these locking ties 3. Oil cooler inlet hose
3. Retaining clamp 4. Oil cooler outlet hose
Water Pump Housing Removal Remove water pump housing screws.
Disconnect ride plate hoses from water pump

housing.
o mr2009-024· 1 07_a
TYPICAL
1. Ride plate outlet hose TYPICAL
2. Ride plate inlet hose
Pull the water pump housing to remove it.
Disconnect the cylinder head outlet hose and oil
cooler hoses. Water Pump Housing Inspection
Check if gasket is brittle, hard or damaged and re
place as necessary.
148 smr2Q11-016
Section 02 ENGINE

threads of water pump housing screws.
Install screws as per the following illustration.
1. Water pump housing gasket
Check if thermostat is in good condition. Refer to

THERMOSTATin this subsection.
7. Screws M6 x 25
2. Screws M6 x 105
Water Pump Housing Leak Test
Plug the connections of the oil cooler return hose, l4'l1)i$j To prevent leaking, take care that the
coolant tank hose, ride plate return hose and cylin gaskets are exactly in groove when you rein
der head return hose with a rag. stall the water pump housing.
Tighten screws to specification using the follow

ing sequence.
1. Oil cooler return connection WATER PUMP HOUSING SCREWS TORQUE

2. Coolant tank hose connection
3. Ride plate return hose connection
4. Cylinder head return hose connection
Fill the water pump h ousing with water.

WATER PUMP IMPELLER
If a bigger quantity of coolant leaks out at the ride
plate outlet connection, replace the water pump Water Pump Impeller Removal
housing.
Remove the WATER PUMP HOUSING, see pro
If there is no leak, check the operation of the ther cedure in this subsection.
mostat.
Unscrew the impeller clockwise.
Water Pump Housing Installation

smr201Hl16 149
Section 02 ENGINE
If there is no operation, replace the water pump

housing.
Thermostat Installation
For installation, reverse the removal procedure,
paying attention to the following details.
Refer to WATER PUMP HOUSING in this subsec
tion.
ROTARY SEAL
Rotary Seal Inspection
Check leak indicator hole for oil or coolant leak.
7. Impeller
fi!j1)it;j Coolant/oil pump shaft and impeller

have left-hand threads. Remove by turning
clockwise and install by turning counterclock
wise.
Water Pump Impeller Inspection

Check impeller for cracks or other damage. Re
place impeller if damaged.
Water Pump Impeller Installation

cedure. Pay attention to the following details.
1
ffl1Ji@j Be careful not to damage impeller smt2009-02.t.
-004 _.
wings during installation. 1. Leak indicator hole
Torque impeller to specification. Coolant leaking out of the hole indicates a defec
WATER PUMP IMPELLER TORQUE tive rotary seal. Leaking oil indicates a faulty oil
seal.
Rotary seal and oil seal must be replaced together.
THERMOSTAT Rotary Seal Replacement

Refer to LUBRICATION SYSTEM subsection.
The thermostat is a single action type.
Thermostat Removal
Remove the WATER PUMP HOUSING, see pro
NOTE: The thermostat is located inside the water
pump housing.
Thermostat Test
To check the operation of the thermostat, put it in
water and heat water.
Look inside the cylinder head return hose con
nection to see the movement of the thermostat.
Thermostat should open when water tempera
ture reaches 87°C (189°F).
150 smr2011-016
Section 02 ENGINE
Subsection 12 (CYLINDER HEAD)
CYLINDER HEAD
SERVICE TOOLS
CAMSHAFT LOCKING TOOL ........................................................ 529 035 839 ......................................... 161

DRIVE SHAFT AD APTER............................................................... 529 035 985 ......................................... 154
ENGINE LE/\K DOWN TEST KIT . .. . . . . . . .. ... . . . ... .. . .
.. .. . .. ..... . . . . .. . ... . . . .. 529 035 661 .. .....
..... ....
.······ ... . . ... .... 154
. .. .
VALVE GUIDE PUSHER (6 MM} .................................................... 529 036 087 ......................................... 170
VALVE GUIDE REMOVER (6 MM) ................................................ 529 036 086 ......................................... 170
VALVE SPRING COMPRESSOR CUP . ... . . ........ .... .. .... ... .... .. . . . . . . . . . . . 529 036 073 ......................................... 165
VALVE SPRING COMPRESSOR .................................................... 529 035 724 ......................................... 165

SNAP-ON VALVE STEM SEAL PLIERS ......................................... YA8230 ......................................... 166
SERVICE PRODUCTS
ISOFLEX GREASE TOPAS NB 52 . .. .... ... ............. ................. 293 550 021 ......................................... 162
.. . . . . . ..
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ................................. 161, 164

MOLYKOTE G-N 420 297 433 ......................................... 170
...................... . . . . . . . . . . . . . . .......................... . . . . . . . . . . . . . .
smr2011-017 151
Sectio� 02 ENGINE
Subsection 1 2 (CYLINDER HEA0)
9 N•m
.-- (80 lbfein)
& 01.,
Engine
f- mm 20N•m
(15 lbMt)
+ 90°
Engine oil
& Loctite
243
Yl
lsoflex
grease
Topas
/I
NB52
&
9N·m
(801bN
Forr8tYlLacement
see IND ER
BLOCK
&
I
Engine 01·1
I
'
152 smr2Q11-017
Section 02 ENGINE
GENERAL
NOTE: When diagnosing an engine problem. al Be careful to burns when working on a hot
ways perform an engine leak test. This will help engine.
pin-point a problem. Refer to ENGINE LEAK TEST
in this subsection for procedures. Preparation
Always place the vehicle on level surface. 1. Remove any required parts to give access to
Always disconnect the neQative wire from the bat engine.
tery before working on the engine. 2. Remove the tether cord.
Even if the removal of many parts is not neces 3. Remove jet pump (refer to JET PUMP subsec
sary to reach another part, it is recommended to tion).
remove these parts in order to check them.
4. Remove coolant pressure cap.
When disassembling parts that are duplicated in
the engine, (e.g.: valves, bushings), it is strongly A WARNING
recommended to note their position (cylinder 1, 2
To avoid potential burns, only remove the
or 3) and to keep them as a "group". If you find
coolant pressure cap b y wearing the appro
a defective component, it would be much easier
priate safety equipment.
to find the cause of the failure within the group of
parts (e.g.: you found a worn valve guide. A bent
5. Remove oil dipstick.
spring could be the cause and it would be easy to
know which one among the springs is the cause
to replace it if you grouped them at disassembly).
Besides, since used parts have matched together
during the engine operation, they will keep their
matched fit when you reassemble them together
within their "group".
complete procedure.
A WARNING
1. Oil dipstick
Torque wrench tightening specificat ions
must be strictly adhered to. 6. Unplug and remove ignition coils.
7. Remove spark plugs.
cotter pins, etc.) must be replaced. NOTE: Ignition coil may be used as an extractor.
Hoses, cable or locking ties removed during the

removal must be reinstalled as per factory stan
dards.
INSPECTION
ENGINE LEAK TEST

The procedure has to be done when engine oper
ating temperature of approximately 70°C (158°F)
is reached.
smt2011-017 153
Section 02 ENGINE
Leak Test Procedure

NOTE: Cylinder numbers are molded on cylinder
head cover.
1. Rotate engine crankshaft counterclockwise un
til the cylinder 1 is at Top Dead Center (TDC)
compression stroke.
1.1 As the engine crankshaft is turned over,
observe the movement of intake rocker
arm of the cylinder to be checked.
1 .2 After piston completes its cycle and the
intake valve closes, observe the piston.
1 3 When it reaches its uppermost position
.
this is TDC compression stroke.

1. Ignition coil
2. Spark plug
1
8. Remove cylinder head cover cowl.
9. Unscrew and remove cylinder head cover.
R1603motr155A
1. Intake rocker arms
2. Secure the drive shaft adapter with a wrench

1. Cylinder head cover screw (BJ
lever against hull to prevent further crankshaft
10. Install the DRIVE SHAFT ADAPTER (P/N 529 035 rotation.
985) on drive shaft end. 3. Install gauge adapter from the ENGINE LEAK
DOWN TEST KIT (P/N 529 035 661) into spark
plug hole.
4. Connect to adequate air supply.
NOTE: Each tester will have specific instruction
on the gauge operation and required pressure.
Refer to manufacturer's instructions.
5. Set needle of measuring gauge to zero.
6. Supply combustion chamber with air.
529!135985
11. To rotate engine crankshaft. use an appropri

ate wrench lever with drive shaft adapter.
154 smr2011-017
Section 02 ENGINE
OBSERVATION CAUSE
Air escaping on intake
Leaking intake valve(s)
port
Air escaping on
Leaking exhaust valve(s)
exhaust port
Air escaping into Excessively worn and/or

crankcase broken piston rings
Air bubbles out o f Leaking cylinder head

2 coolant tank gasket
Air/water
Damaged gasket and/or
escaping from
loosened screws
cylinder-block/head
Damaged gasket and/or

Coolant escaping from
loosened screws (refer t o
water pump housing
COOLING SYSTEM/
TYPICAL Damaged rotary seal on

Coolant escaping from
1. Leak down tester gauge water pump shaft (refer to
2. Gauge adapter leak indi cator h ole
COOLING SYSTEM/
3. Air supply hose
Oily contamination on Damaged oil seal on water

7. Note the amount of leaking or percentage (de leak indicator hole pump shaft
pending on tester).
LEAKAGE Reassembly
ENGINE CONDITION
PERCENTAGE
For reassembly, reverse the preparation proce
Up to 15% Excellent condition dure. Use torque values and service products
16% to 25% Good condition from the exploded views (refer to proper ENGINE
subsections).
Fair condition; engine will run
26% to 40% and performance might be
Properly install ignition coils. Refer to IGNITION
down in some cases SYSTEM subsection.
Poor co ndition diagnose and

41 o/o and higher TROUBLESHOOTING
,
repair engine
8. Proceed the same way with remaining cylin probable source of problems. It is a guideline and
ders. it should not be assumed to list all possible prob
lems.
Diagnostic
Pressurize area to be tested, spray soap/water so
tected, service the fault code first. Refer to EN
lution at the indicated location and look and/or lis
GINE MANAGEMENTsection.
ten for air bubbles.
UNUSUAL ENGINE NOISE OR
VIBRATIONS
1. Incorrect camshaft timing adjustment
- Replace damaged components and readjust
camshaft timing.
2. Camshaft timing gear screws got loose

- Retighten screws with the recommended torque.
3. Rocker arm(s) hydraulic element is broken or

worn out (improper valve adjustment).
- Replace faulty rocker arm(s).
sm<201 l-017 155

Section 02 ENGINE
4. Rocker arm screw not properly tightened 4. Broken rocker arm(s)

- Retighten screws with recommended torquing - Replace defective parts.
procedure.
5. Faulty chain tensioner PROCEDURES

- Replace chain tensioner.
CYLINDER HEAD COVER
6. Chain guide is worn out
- Replace chain guide. Cylinder Head Cover Access
7. Stretched timing chain or worn out sprocket Open or remove seat.
- Replace timing chain and sprocket. On iS and aS models, remove the rear ventilation
cover.
8. Camshaft is worn out
- Check if camshaft radial clearance is out of spec Cylinder Head Cover Removal
ification.
1. Unplug and remove ignition coils.
OIL LEAKAGE FROM CYLINDER HEAD
1. Cylinder head cover gasket is leaking
- Replace cylinder head cover gasket and retighten
screws with recommended torque.
- Check cylinder head cover for cracks or other
damage. Replace if necessary.
2. Cylinder head cover screws are leaking

- Replace cylinder head cover screws.
3. Spark plug tube gasket is leaking

- Remove cylinder head cover and replace spark
plug tube gasket.
- Clean spark plug area from oil spillage.
4. Blow by valve is leaking smt2 000-026-006 _a
- Replace blow by valve 0-ring. 1. Ignition coils
5. Camshaft sensor 0-ring is leaking 2. Remove screws securing the cylinder head
- Replace camshaft sensor 0-ring. cover.
6. Cylinder head gasket is leaking

- Remove cylinder head and check for damage.
- Replace cylinder head gasket and retighten
screws with recommended torquing procedure.
ENGINE LACKS ACCELERATION OR

POWER
1. Incorrect camshaft timing adjustment
- Replace damaged components and readjust
camshaft timing.
2. Intake or exhaust valves are leaking 1. Cylinder head cover screws
Perform ENGINE LEAK TEST.

3. Remove the cylinder head cover and its gasket.
-
- Check if valve seats properly in valve seat.

- Repair or replace damaged components.
3. Broken valve spring(s)

- Replace defective parts.
156 smr2011·017
Section 02 ENGINE
SPARK PLUG TUBES

Spark Plug Tube Removal
Remove the CYLINDER HEAD COVER, see pro
Pull spark plug tubes to remove them.
smr20Q&.010..0 28_
e
1. Cylinder head cover

2. Gasket
Cylinder Head Cover Inspection

Check if the gasket on the cylinder head cover
and the rubber bushing on the cylinder head cover
screws are brittle, cracked or hard. If so, replace
the gasket or the cylinder head cover screw ac
cordingly. R 1503motr83A
1. Spark plug tube

Cylinder Head Cover Installation
For installation, reverse the removal procedure. Spark Plug Tube Inspection
Check seals on spark plug tube. If seals are brittle,
Properly seat the gasket in the cover groove. cracked or hard, replace spark plug tube.
Install the cylinder head cover screws according
to following sequence. 1 3
•I ...
�' -•
TYPICAL
1. Spark plug tube
2. Seal to the cylinder head cover
3. Seal to the cylinder head
Spark Plug Tube Installation

For installation. reverse the removal procedure.
Pay attention to the following detail.
TYPICAL
Apply engine oil on seals.
Torque screws to 9 N• m (80 lbf•in). ROCKER ARMS

Install all other removed parts. Refer to proper
subsection for procedure.
Rocker Arm RemovaI
1. Remove the CYLINDER HEAD COVER, see
procedure in this subsection.
2. Remove spark plug tubes.
3. Remove and discard rocker arm shaft screws.
smr2011-017 157
Section 02 ENGINE
Measure rocker arm inside diameter. If diameter

is out of specification, change the rocker arm as
sembly.
ROCKER ARM INSIDE DIAMETER
20.007 mm - 20.020 mm
NEW
(.7877 in .7882 in)
-
Press the hydraulic lifter with your thumb. If the

hydraulic lifter can be fully pressed in, replace
rocker arm. Lifter must turn freely in rocker arm
bore. Otherwise, replace.
1. Rocker arm shaft screw Rocker Arm Shaft
4. Remove rocker arm shaft with rocker arms. Check for scored friction surfaces, if so, replace
parts.
Measure rocker arm shaft diameter.
R1503mol� A
A Measure rocker arm shaft diameter here
1. Rocker arm shaft ROCKER ARM SHAFT DIAMETER

2. Rocker arms (exhaust side)
3. Rocker arm (inrake side) 19.980 mm - 19.993 mm
NEW
(. 7866 in - .7871 in)
Rocker Arm Inspection SERVICE LIMIT 19.970 mm (.7862 in)
Inspect each rocker arm for cracks and scored fric
tion surfaces. If so, replace rocker arm assembly. Any area worn excessively will require parts re
Check the rocker arm rollers for free movement, placement.
wear and excessive radial play. Replace rocker Verify and clean oil orifices to ensure a good rocker
arm assembly as necessary. arm shaft lubrication.
1. Rocker arm (mtake side}

2. Rocker arm (exhaust side)
3. Rollers
A. Rocker arm inside diameter
158 smr2011·017
Section 02 ENGINE
1. Oil orifices from the camshaft to the rocker arm shah, then to 1. Rocker arm shah
2. Rocker arm shaft notches
the rocker arms and finally to the valve adjustment
5. Install NEW rock er arm shaft screws.

Rocker Arm Installation
For installation, reverse the removal procedure. l.+[.JmJj This assembly uses stretch screws.
Pay attention to the following details. As the screws have been stretched from the
previous installation, it is very important to
NOTE: The rocker arm shaft can only be installed
use new screws at assembly. Failure to re
in one specific position Therefore the camshaft
place screws and to strictly follow the torque
.
has to be positioned with its locking pin when the

procedure may cause screws to loosen and
piston of cylinder 3 is on ignition TDC.
lead to engine damage.
1. Lock camshaft. Refer to CAMSHAFT in this
subsection .
6. Torque screws at first to 1 O N•m (89 lbf•in) ac
cording to following sequence.
2. Make sure the position lines on oil separator
cover are lined up as shown in the following il
lustration.
7. Retorque screws to 20 N•m (15 lbf•ft).

1. Position lines 8. Finish tightening screws turning an additional
90° rotation with a torque angle gauge.
3. Apply engine oil on rocker arm shaft.
4. Position the rocker arm shaft with the notches
on top.
smr2011-017 159
Section 02 ENGINE
1. Chain guide
2. Timing gear screws
3. Camshah timing gear
1. Rocker arm shaft screw

NOTE: Secure timing chain with a retaining wire.
2. Torque angle gauge
Camshaft Timing Gear Inspection
CAMSHAFT TIMING GEAR Check camshaft timing gear for wear or deteriora
tion.
NOTE: Although it is not necessary to position
crankshaft to TDC for disassembly, it is a good If gear is worn or damaged, replace it as a set
practice to do it, as a troubleshooting step, to (camshaft timing gear and timing chain).
know before disassembly if valve timing was For crankshaft timing gear replacement, refer to
appropriate. CYLINDER BLOCK subsection.
Camshaft Timing Gear Removal Camshaft Timing Gear Installation

Lock crankshaft, refer to CYLINDER BLOCK sub For installation, reverse the removal procedure.
section. Pay attention to the following details.
Remove CYLINDER HEAD COVER, see proce
dure above in this subsection.
lillui@j Improper camshaft timing will dam
age engine components. Make sure camshaft
Lock camshaft. Refer to CAMSHAFTin this sub and crankshaft are still locked. If not, lock them
section. before beginning this procedure.
Remove the oil separator cover. Refer to LUBRI
Install the camshaft timing gear with the writing
CATION SYSTEM subsection.
visible, i.e. to be able to see the position lines
Remove the chain tensioner. Refer to CYLINDER when looking from outside of engine.
BLOCK subsection.
Remove the chain guide.
Remove the camshaft timing gear screws.
Remove the camshaft timing gear.
160 smr2C>11·017
Section 02 ENGINE
1 1 1
1. Position lines
IW•Dtllj Ensure to remove locking tools

when finished.
R 1503motr97A
1. Good (with 1503 aligned)
2. Never
CAMSHAFT
Install timing chain. Refer to CYLINDER BLOCK
subsection. Camshaft Locking Procedure
Ensure chain guides are properly installed. 1. Remove CYLINDER HEAD COVER, see proce
Loosely install gear chain screws.
2. Lock crankshaft, refer to procedure in CYLIN
Install chain tensioner.
DER BLOCK subsection.
NOTE: There can be 2 different positions to install
3. Lock camshaft using the CAMSHAFT LOCKING
the timing gear on the camshaft. Basically both
TOOL (P/N 529 035 839).
positions are working well, since the camshaft
and crankshaft are locked in their proper position.
Due to some tolerances, there could be one po - ------ .. - .. � - - - -
--s.
..
sition which fits better than the other one. To
check this, perform the following test.
Check if timing gear screws are still loose. If
4. Make sure the position lines on oil separator
screws are squeezed by the timing gear, remove
cover are lined up as shown in the following il
the chain tensioner again and rotate timing gear
lustration.
by one tooth clockwise. Then install the chain
tensioner again.
One at a time, remove timing gear screws and
apply LOCTITE 243 (BLUE) (P/N 293 800 060) on
threads.
Tighten timing gear screws to 9 N•m (80 lbf•in).
li!l"tJOIJj
Crankshaft and camshaft must be
locked on TDC position to place camshaft
timing gear and timing ch ain in the proper
position. To double check, take a look at the
timing gear lines. They must be parallel to the
cylinder head surface.
smr2009-025-00 7_ e
1. Camshaft locking tool

2. Position lines
smr2011·017 161
Section 02 ENGINE
Camshaft Removal CAMSHAFT BEARING JOURNAL

Remove the CAMSHAFT TIMING GEAR. see pro 39.892 mm 39.905 mm
-
cedure in this subsection. NEW

(1.5706 in - 1.5711 in)
Remove the ROCKER ARM. see procedure in this SERVICE LIMIT 39.880 mm (1.5701 in)
subsection.
CAMSHAFT BEARING JOURNAL
Remove the camshaft lock to remove the
(ENGINE FRONT)
camshaft.
?4.!=139 mm 24.960 mm
NEW
-
(.9819 in - .9827 in)
CAMSHAFT BEARING INNER DIAMETER
40.000 mm - 40.020 mm
NEW
(1.5748 in - 1.5756 in)
CAMSHAFT BEARING INNER DIAMETER

(ENGINE FRONT)
25.000 mm - 25.013 mm
NEW
(.9843 in .9848 i n)
-
1. Camshaft lock
2. Camshaft Replace parts that are not within specifications.
Camshaft Inspection Camshaft Installation

Check each lobe and bearing journal of camshaft For installation, reverse the removal procedure.
for scoring, scuffing, cracks or other signs of wear. Pay attention to the following details.
Measure camshaft bearing journal and lobe height Grease the camshaft bearing journals well by us
using a micrometer. ing the ISOFLEX GREASE TO PAS NB 52 (P/N 293 550
021) or a similar product.
Measure clearance between both ends of
camshaft and cylinder head. Install camshaft then place the camshaft lock in its
slot.
CAB AC
t f -} ft I
i-
A1 503motr1 02A
A. Camshaft lobe {exhaust valves)

B. Camshaft lobe {intake valves)
C. Camshaft bearing journal
D. Camshaft bearing journal - engine front
CAMSHAFT LOBE HEIGHT - EXHAUST VALVE
31.430 mm to 31.630 mm
NEW
(1.2374 in to 1.2453 in)
SERVICE LIMIT 31.380 mm (1.2354 in) 1. Camshaft lock
CAMSHAFT LOBE HEIGHT - INTAKE VALVE

For other parts, refer to the proper installation pro
31.540 mm 31.740 mm
- cedures in this subsection.
NEW
(1.2417 in - 1.2496 in)
162 smr2011-017
Section 02 ENGINE
CYLINDER HEAD Remove the CAMSHAFT TIMING GEAR, see pro

Cylinder Head Removal
Remove the M6 cylinder head screws.
Lock crankshaft, refer to CYLINDER BLOCK sub
section.
Drain coolant, refer to COOLING SYSTEM sub
section.
Remove blow-by valve from cylinder head. Refer
to LUBRICATION SYSTEM subsection.
Unplug the camshaft position sensors (CAPS).
Unplug the coolant temperature sensor (CTS).
Disconnect bleeding hose.
Disconnect the cylinder head outlet hose.
1. M6 cylinder head screws
Remove and discard the M11 cylinder head

screws securing cylinder head to cylinder block.
1. Coolant temperature sensor (CTS)

2. Bleeding nipple
3. Cylinder head outlet hose
Remove the intake manifold. Refer to INTAKE

MANIFOLD subsection.
Remove the exhaust manifold. Refer to EX
HAUST SYSTEM subsection. 1. M11 cylinder head screws
Unscrew the oil filler tube support from cylinder
head. Pull up cylinder head.
Remove gasket.
Cylinder Head Cleaning

Remove carbon deposits from combustion cham
ber, exhaust port and piston top.
Clean cylinder head, especially cylinder head
screw surface from oil spillage.
Blow out the oil orifices and check if they are not
clogged.
sm r 2 009-025-009 _
a
1. Retaining screws
2. Oil fill er tube support
smr2011-017 163
Section 02 ENGINE
WtlillJj Each installation of the cylinder

head requires a new cylinder head gasket. Us
ing a gasket twice will cause engine damage,
. the engine had not run.
even 1f

threads of M6 screws.
Install M6 screws and manually tighten them.
Install NEW M11 screws and tighten them man
ually.
smr2009-025-0I O _•
i4'!1)i@j This assembly uses stretch screws.
1. Oil orifices As the M 11 screws have been stretched from
the previous installation, it is very important to
Cylinder Head Inspection replace the old screws by new ones at assem
bly. Failure to replace screws and to strictly fol
Check for cracks between valve seats or other
low the torque procedure may cause screws t o
damages, if so, replace cylinder head.
loosen and lead to engine damage.
Check cylinder head mating surface for flatness'
using a straight edge. Using the following sequence, tighten screws as
described below.
smr2006-01 6-06 3...o
1 Cylinder head
2. Flat bar
3. Feeler gauge
Check cylinder head warpage.
CYLINDER HEAD WARPAGE

Maximum I 0.15 mm (.006 in)
1. First torque M11 screws to 40 N•m (30 lbf•ft).

If warpage exceeds specification, resurface the
cylinder head as follows. 2. Then tighten M11 screws turning a 120° rota
tion with a torque angle gauge and finish tight
Use a 400 - 600 grit wet sandpaper on a surface
ening with an additional 90° rotation.
plate and gently grind off the mating surface.
3. Torque M6 screws to 9 N•m (80 lbf•in).
NOTE: To ensure an even surface, rotate cylinder
head several times during resurfacing.
Replace cylinder head, if resurfacing fails.
Cylinder Head Installation

Ensure dowel pins are in place.
Install NEW cylinder head gasket.
164 smr2011-017
Section 02 ENGINE
R150 3 mott100A
1. M11 cylinder screws

2. Angle torque wrench
R1503motr103A
Remove all locking tools.
1. Valve spring compressor clamp
Install all removed parts. 2. Valve spring compressor cup
VALVE SPRINGS
Valve Spring Removal
Remove rocker arm shaft. Refer to ROCKER ARM
Remove CYLINDER HEAD, see procedure in this
subsection.
Compress valve springs, using the VALVE SPRING
COMPRESSOR (P/N 529 035 724) and the VALVE
SPRING COMPRESSOR CUP (P/N 529 036 073).
LOCATE VALVE SPRING COMPRESSOR CLAMP IN CENTER OF

THE VALVE
Remove valve cotters.
5 2 9035724 Withdraw valve spring compressor, valve spring

VALVE SPRING COMPRESSOR retainer and valve springs.
529036073
VALVE SPRING COMPRESSOR CUP
smr2011-017 165
Section 02 ENGINE
NOTE: Valve cotters must be properly engaged in

valve stem grooves.
.. T'\ 1 2 008-01 7-009_

3
1. Valve cotters
2. Valve spring rerainer
3. Inner valve spring
4. Outer valve spring
Valve Spring Inspection

Check valve springs for rust, corrosion or other
1. Position of the valve spring
visible damages. If so, replace faulty valve
springs.
VALVES
Check valve springs for free length and straight
ness. Valve Removal
Replace valve springs if not within specifications. Remove valve spring.
Push valve stem then pull valves out of valve
guides.
Al510ma.tr122A
A. Valve sprmg length
OUTER VALVE SPRING FREE LENGTH

R1503motr106A
NEW NOMINAL 45.45 mm (1.789 in)

1. Intake valve 38 mm
SERVICE LIMIT 43.00 mm (1.693 in) 2. Exhaust valve 31 mm
INNER VALVE SPRING FREE LENGTH Remove valve stem seal with a valve stem seal
pliers such as the SNAP-ON VALVE STEM SEAL PLI
NEW NOMINAL 41.02mm (1.615in)
ERS (P/N YA8230).
SERVICE LIMIT 38.8mm (1.528 in)
Valve Spring Installation

Colorsd area of the valve spring must be placed
on top.
166 smr2011-017
Section 02 ENGINE
R6Hlmo1r126A
A. Valve stem diameter

R610motr125A
VALVE STEM DIAMETER
Valve Inspection NEW
Valve Stem Seal 5.946 mm - 5.960 mm

EXHAUST
(.2341 in - .2346 in)
Inspection of valve stem seals is not needed
because NEW seals should always be installed 5.961 mm - 5.975 m m
INTAKE
whenever cylinder head is removed. (.2347 in - .2352 in)
Valve " SERVICE LIMIT
Inspect valve surface, check for abnormal stem EXHAUST

5.93 mm (.233 in)
wear and bending. If so, replace by a new one. INTAKE
Valve Stem and Valve Guide Clearance
Replace valve guide if it is out of specification or
Measure valve stem and valve guide in three has other damages such as wear or friction sur
places, using a micrometer and a small bore face. Refer to valve guide replacement below.
gauge.
VALVE GUIDE INNER DIAMETER
NOTE: Clean valve guide to remove carbon de
posits before measuring. NEW
Change valve if valve stem is out of specification EXHAUST 5.994 mm - 6.018 mm

or has other damages such as wear or friction sur (.236 in - .2369 in)
INTAKE
face. .
..
SERVICE LIMIT
EXHAUST
6.060 mm (.2386 in)
INTAKE
smr2011-017 167
Section 02 ENGINE
(CYLINDER HEAD)
Subsection 12
Valve Face and Seat
2 3
V01C1 HA
A. Valve face contact width

B. Valve seat contact width
A1603motr107A 1
Valve Seat Grinding
1. Valve seat
2. Exhaust valve contaminated area
NOTE: The valve seats may be reground with
3. Valve face (contact surface to valve seat)
a valve seat grinder which centers on the valve
Check valve face and seat for burning or pittings guide.
and replace valve or cylinder head if there are 1. Grind the valve seat at 45°. Remove no more
signs of damage. material than absolutely necessary to clean the
Ensure to seat valves properly. Apply some lap seat up.
ping compound on valve face and work valve on 2. Using a 35° stone, narrow the valve seat until
its seat with a lapping tool. the appropriate outer diameter is obtained.
Measure valve face contact width.
NOTE: The location of contact area should be in EXHAUST 80°
center of valve seat.
Measure valve seat width, using a caliper.
VALVE SEAT CONTACT WIDTH
NEW \
1.25mm-1.55mm \
'
EXHAUST
(.049 in - .061 in)
\
1.10mm- 1.30mm
INTAKE
(.043 in - .051 in)
\
'
80°
SERVICE LIMIT ___ _J
R1503 m otr 259A
EXHAUST 1.8 mm (.071 in)
A. Valve seat outer diameter EXHAUST
INTAKE 1.6 mm (.063 in)
If valve seat contact width is too wide or has dark

spots, replace the cylinder head.
168 smr2011-017
Section 02 ENGINE
INTAKE
350 4 0
A 5
R1 603motr260A
{1�
ss·
-
A. Valve seat outer diameter INTAKE
I
---.. ___,
I
R1503motr254 A
VALVE SEAT OUTER DIAMETER
1. Valve stem seal
INTAKE 37.35 mm (1.4705 in)
EXHAUST 30.3mm (1.1929in} Apply engine oil on valve stem and install valve.
W'11[11JjBe careful when valve stem is

3. Using a 55° stone for the intake and an 80°
passed through sealing lips of valve stem
stone for the exhaust valve, reduce the valve
seal.
seat contact width to the appropriate value
mentioned above.
4. Finally, coat the valve seating surface with a
fine paste of valve grinding compound using a
manual valve grinding mandrel. Lightly grind
the valves until a smooth, even, uniform sealing
surface of the appropriate inside and outside
diameter is obtained on both the valve and
the seat. Use only a hand held valve grinding
mandrel with a suction cup, rotating the valve
back and forth through about 45°, and then
advancing the valve 45° before repeating this
operation.
Valve Installation
R 1 603motr254B
Install NEW valve stem seal.

1. Sealing lips of valve stem seal
To ease installation of cotters, apply oil or grease

on them so that they remain in place while relea
sing the spring.
After springs are installed, ensure valve springs
and valve spring retainer are properly locked by
tapping on valve stem end with a soft hammer so
that valve opens and closes a few times.
l+![•Ji[llJj An improperly locked valve spring

will cause engine damage.
smr2011·017 169
Section 02 ENGINE
VALVE GUIDE
Valve Guide Replacement
lill.Jffllj
Do not heat cylinder head for this
procedure.
l1l(1JmJj The sharp edge near the top of the

valve guide must be machined away. Other
wise it will foul the valve guide hole in the
cylinder head and destroy the cylinder head,
as the valve guide is removed.
Use a special reamer as far as the top of the notch.
R1 !S03 mot r255A
TYPICAL
1 Punch
Check valve guide bore for abreased material.

The inlet and exhaust valve guides have the same
length and are interc hangeable .
NOTE: If valve guide has caused scoring during
1 extraction. replace the cylinder head.
Grease the bore in cyl inder head and the leading
2
end of valve guide with MOLYKOTE G-N (P/N 420
297 433).
TYPICAL
1. Special reamer
2. Notch
Chase valve guide out of the cylinder head to

wards combustion chamber by using VALVE GUIDE
2
REMOVER (6 MM) (P/N 529 036 086).
R1603motr256A
TYPICAL
1. Valve guide leading end
2. Cylinder head bore
3. Jig
With the VALVE GUIDE PUSHER (6 MM) (P/N 529 036

087), press the valve guide into the COLD cylinder
head as shown.
170 smr1011-017
Section 02 ENGINE
111ll0Jmotr217A
TYPICAL
A. Protrusion
VALVE GUIDE PROTRUSION
MINIMUM 12.4 mm (.4882 in)
MAXIMUM 12.8 mm (.5039 in)
NOTE: After installing new guides, they must be

reamed with a standard 6 mm reamer tool. These
are available from various tool suppliers.
Clean cylinder head carefully. Check that the valve
seat is concentric with the new guide axis (check
contact surface with engineer's blue).
smr2011-017 171
172
Section 02 ENGINE
Subsection 13 (CYLINDER BLOCK)
CYLINDER BLOCK
SERVICE TOOLS
CRANKSHAFT LOCKING TOOL ................................................... 529 . 035 821 ................. 184, 188, 190, 195
HANDLE 420
.......... . . . . . . . . . . . . . . .................. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . 877 650 ......................................... 193
PISTON C:IRC:LIP INSTALLER........................................................ 529 035 765 ......................................... 181
STARTER DRIVE SEAL PUSHER................................................... 420 876 502 ......................................... 193

SNAP-ON PISTON RING COMPRESSOR PLIERS . ..... ... . .. . . . . . . ..... RC980 ......................................... 181
SERVICE PRODUCTS
LOCTITE 243 (BLUE) ...... .. ........ .. .......... . ......... . ....... ..
. ........ . ........... 293 800 060 ......................................... 194
LOCTITE 5910 .......................... ...................... ........................... .. .. 293 800 081 ......................................... 193
LOCTITE CHISEL {GASKET REMOVER)....................................... 413 708 500 ......................................... 193
smr2011-018 173
Section 02 ENGINE
Subsection 13 (CYLINDER BLOCK}
Loctite 243 Engine

� oil
�'ft � �i
?�
23 N•m
(17 lbf.ft)
�
17 N·
(150 lbf-in) 1 •
See
ELECTRONIC
FUEL INJECTION
SYSTEM (EFIJ
23 N•m
(17 lbf.ft)
- 15 23 N•m
(17 lbMt)
1440 N•m 55 N•m
(30 lbf.ft) + (41 lbf.ft)
13
mm
174 smr'2011·018
Section 02 ENGINE
.
11
Engine <)
oil
Engine
45 N•m
oil 4 nr:n:n foft) 90°
� ( 33 lb
+
&
18
�
-
lla-
.. -19
&Engine oil
18
17
20
smr2011-01s 175
Section 02 ENGINE
GENERAL 4. Connecting rod axial play out of specification

- Measure connecting rod axial play on crankshaft.
When disassembling parts that are duplicated in
- Replace connecting rod or crankshaft if out of
the engine, (e.g.: pistons, connecting rods etc.),
specification.
it is strongly recommended to note their position
(cylinder 1 2 or 3) a nd to keep them as a "group".
, 5. Connecting rod screws got loose
If you find a defective component, it would be - Replace damaged components and retighten
much easier to find the cause of the failure within screws with the recommended torque.
the group of parts. Besides. since usArl parts
have matched together during the engine oper BLUE SMOKE IN THE EXHAUST
ation, they will keep their matched fit when you 1. Oil scrapper rings worn out
reassemble them together within their "group".
and service products as in the exploded views. ENGINE SUDDENLY TURNS OFF (POOR
Clean threads before applying a threadlocker. Re IDLING)
fer to SELF-LOCKING FASTENERS and LOCTITE 1. Piston rings worn out
complete procedure.
2. Piston/cylinder wall clearance out of specifica
A WARNING tion
To rque wrenc h tig ht en ing specificat io ns - Check piston/cylinder wall clearance.

must be strictly adhered to. - Replace if out of specificato
i n.
3. Melted or broken piston
- Check if oil spray nozzle is not clogged. Refer to
LUBRICATION SYSTEM subsection.
- Replace piston and cylinder block if necessary.
Hoses, cables or locking ties removed during a
procedure must be reinstalled as per factory stan
dards. PROCEDURES
TROUBLESHOOTING TIMING CHAIN

The following is provided to help in diagnosing the Timing Chain Inspection
probable source of troubles. It is a guideline and Check timing chain on camshaft gear for exces
it should not be assumed to list all possible prob sive radial play.
lems.
Check chain condition for wear and rollers condi
tion.
UNUSUAL ENGINE NOISE OR
VIBRATIONS
1. Heavy wear on plain bearings
- Check radial play of plain bearings.
- Replace plain bearn
i gs if out of specification.
2. Crankshaft and balancer shaft are not properly

aligned RS10motr201A
- Disassemble cylinder block and check if marks

1. Timing chain
are properly aligned.
3. Crankshaft or balancer shaft axial play out of If chain is excessively worn or damaged, replace
specification it as a set (camshaft timing gear and timing chain).
- Measure crankshaft and balancer shaft axial play.
Timing Chain Removal
- If axial play is out of specification, replace thrust
washers. Remove:
- Engine oil (refer LUBRICATION SYSTEM sub
section)
176 smr2011-018
Section 02 ENGINE
- Engine from vehicle (refer to ENGINE RE Chain Tensioner Inspection

MOVAL AND INSTALLATIONsubsection) Check chain tensioner for excessive wear or
- Cylinder head (refer to CYLINDER HEADsub cracks. Also check free movement of the chain
section) tensioner piston.
- PTO housing (refer to PTO HOUSING AND
MAGNETOsubsection) Chain Tensioner Installation
- Crankshaft (refer to CRANKSHAFTin this sub- The installation is essentially the reverse of the re
section) moval procedure but, pay attention to the follow
- Timing chain. ing details.
Use a NEW gasket ring when installing the chain
Timing Chain Installation tensioner plug screw.
The installation is essentially the reverse of the re Torque chain tensioner plug screw to 17 N•m
moval procedure. However, pay attention to the (150 lbf•in).
following details.
Ensure to perform proper valve timing. PISTONS AND CONNECTING
IN.Ji@ii Improper valve timing will damage RODS
engine components.
Piston and Connecting Rod Removal
Lock crankshaft and camshaft at TDC (refer to 1 . Disassemble CYLINDER BLOCKas per proce-
CYLINDER HEAD subsection for the camshaft dure in this subsection.
locking procedure).
NOTE: It is recommended to measure connecting
Install chain, then install chain tensioner. rod big end axial play prior to remove connecting
rod. Refer to INSPECTIONbelow.
CHAIN TENSIONER 2. Remove connecting rod.cap screws no. 4.
Chain Tensioner Removal
NOTE: Removal of the intake manifold allows
easier access to the chain tensioner, but is not
necessary. Refer to INTAKE MANIFOLDsubsec
tion.
Remove:
- Chain tensioner plug screw no. 1
- Gasket ring no. 2 (discard it)
- Chain tensioner no. 3.
3 2
1. Connecring rod screws
NOTE: Before removing the connecting rod caps,

mark them to remember the right position when
reassembling.
3. Pull piston no. 5 with connecting rod no. 6 out
of the cylinders.
4. Remove one piston circlip no. 7 and discard it.
R 1 503motr39A
1. Plug screw
2. Gasket ring
3. Chain rensioner
smt2011-01s 177
Section 02 ENGINE
1 2
R810motr134A 1
1. Piston circlip
NOTE: The removal of both piston circlips is not

necessary to remove piston pin.
1. Crankshaft
5. Push piston pin no. 8 out of piston. 2. Feeler gauge
. 3 CONNECTING ROD BIG END AXIAL PLAY
\ NEW
0.100 mm
(.004 in
-
-
0.352 mm
.014 in)
\) SERVICE LIMIT 0.500 mm (.02 in)
Connecting Rod Small End Radial Play

Measure connecting rod small end.
R1503mo
t r'27A
1. Piston
2. Piston pin
3. Circlip
6. Detach piston from connecting rod.
Connecting Rod Inspection

Connecting Rod Big End Axial Play
Using a feeler gauge, measure distance between
butting face of connecting rod and crankshaft
counterweight. If the distance exceeds specified
tolerance, replace the worn part.
R610mou73A
7. Bore gauge
2. Connecting rod
CONNECTING ROD SMALL END DIAMETER
23.01 mm 23.02 mm
NEW
-
(.9059 in - .9063 in)

178 sml'2011·018
Section 02 ENGINE
If the connecting rod small end diameter is out Use NEW bearings, when connecting rod big end
of specification, replace small end bearing sleeve diameter is out of specification.
no.9.
Piston Pin Inspection
NOTE: For small end bearing sleeve replacement
contact a machine shop. After installing a NEW Using synthetic abrasive woven, clean piston pin
small end bearing sleeve on the connecting rod, from deposits.
the inner diameter and the oil holes need to be Inspect piston pin for scoring, cracking or other
machined to specification. damages.
Measure piston pins (refer to PISTON PIN IN Measure piston pin. See the following illustration
SPECTION in this subsection). Compare to inside for the proper measurement position.
diameter of connecting rod to obtain connecting
rod small end radial play.
CONNECTING ROD SMALL END RADIAL PLAY
SERVICE LIMIT I 0.080 mm (.003 in)
Connecting Rod Big End Radial Play

Measure inside diameter of connecting rod big
end. Compare to crankshaft pin.
To measure the connecting rod big end diameter,
R610motr137A A
use the OLD screws no 4. .
A. Piston pin diameter in the area of the bushing

Install the OLD bearings no. 10 as they were
mounted initially. PISTON PIN DIAMETER
Do the torque procedure as described below. 22.996 mm 23.000 mm
NEW
-
(.905 in - .906 in)
Measure connecting rod small end diameter (re

fer to CONNECTING RODS INSPECTION above)
to check connecting rod small end radial play.
Piston Inspection
Inspect piston for scoring, cracking or other dam
ages. Replace piston and piston rings if neces
sary.
Using a micrometer, measure piston at 18 mm
(.709 in) perpendicularly (90°) to piston pin axis.
R610motr76A
A. Connecting rod big end bearing
CONNECTING ROD BIG END DIAMETER
SERVICE LIMIT I 45.080mm (1.775in)
CONNECTING ROD BIG END

RADIAL PLAY
smr201Hl18 179
Section 02 ENGINE
With the micrometer set to the dimension, adjust

a cylinder bore gauge to the micrometer dimen
sion and set the indicator to 0 (zero).
A610 mott136A
1. Measuring perpendicularly (90°) to piston pin axis

A 1Bmm (.709in)
The measured dimension should be as described 7. Use the micrometer co set the cylinder bore gauge
2. Dial bore gauge
in the subsequent table. If not, replace piston.
PISTON MEASUREMENT
130 AND 155 ENGINES
99.951 mm 99.969 mm
NEW NOMINAL
-
(3.935 in - 3.936 in)
215 AND 260 ENGINES

99.931 mm 99.949 mm
NEW NOMINAL
-
(3.934in - 3.935in)
Piston/Cylinder Wall Clearance

Adjust and lock a micrometer to the piston dimen
sion. TYPICAL
1. Indicator set to 0 tzero)
1
NOTE: Make sure the cylinder bore gauge indica
tor is set exactly at the same position as with the
micrometer, otherwise the reading will be false.
Position the dial bore gauge 62 mm (2 .44 in) above
cylinder base, measuring perpendicularly (90°) to
piston pin axis.
Read the measurement on the cylinder bore
gauge. The result is the exact piston/cylinder wall
clearance.
FOOB08A
7. Micrometer set to the piston dimension
NOTE: Make sure used piston is not worn.
180 smr2011-01 a
Section 02 ENGINE
PISTON/CYLINDER CLEARANCE
130 AND 155 ENGINES
0.024 mm - 0.056 mm
NEW NOMINAL
(.001 in .002 in)
-
215 AND 260 ENGINES
0.044 mm - 0.076 mm
NEW NOMINAL
(.0017 in .003 in)
-
CORRECT POSITION OF THE PISTON CIRCLIP

If clearance
exceeds specified tolerance, re-hone
cylinder sleeve and replace piston by an oversize
one.
Piston and Connecting Rod Installation
1. Using a piston ring compressor such as the
NOTE: It is not necessary to have all pistons
SNAP-ON PISTON RING COMPRESSOR PLIERS
replaced with an oversize if they are not all out of
(P/N RC980), slide piston into cylinder.
specification. Mixed standard size and oversize
piston are allowed.
Piston and Connecting Rod Assembly

Apply en gine oil on the piston pin.
Insert piston pin into piston and connecting rod.
Use the PISTON CIRCLIP INSTALLER (P/N 529 035
765) to asse mble the piston circlip.
R150 3 rnotr29A
IM1)1$j Secure piston pin with new piston

li![oi(iJj Install piston with punched arrow to
circlips. ward exhaust side.
NOTE: Take care that the hook of the piston circlip
i s pos iti oned properly. 1
I
R1S03mntr28A
R1503m o u 30A
1. Sleeve with piston circlip inside

2. Assembly jig from piston clip installer 1. Arrows toward exhaust side
smr2011-018 181
Section 02 ENGINE
2. Correctly install bearings and carefully clean

split surface on both sides (cracked area).
3 1 2
R 1 503molt3 IA
1. Angle torque wrench
PISTON RINGS
Piston Ring Removal
1 Haff bearing of connecting rod big end Remove piston as described above.
2. Split surface of the connecting rod
3. Protrusion of bearing in fine with connecting rod groove
Remove rings no. 11.
3. Torque NEW connecting rod screws as per fol
Piston Ring Inspection
lowing proce dur e:
3.1 Install screws and torque to 45 N•m Ring/Piston Groove Clearance
(33 lbf•ft). Using a feeler gauge measure each rin g/piston
NOTE: Do not apply any threadlocker prod groove clearance. If the clearance is too large, the
uct on th read s of connecting rod screw s. piston and the piston r ing s should be replaced.
3 .2 Finish t ightening the screws with an ad RING/PISTON GROOVE CLEARANCE

ditional 90° turn using an angle torque
NEW
wrench.
0.025 mm - 0.070 mm
RECTANGULAR
W,JfllJj Failure to strictly follow this proce (.001 in .0028 in)
-
dure may cause screw to loosen and lead to

0.015 mm - 0.060 mm
engine damage. Knowing that the screws have TAPER-FACE
(.0006 in - .0024 in)
been stretched from the previous installation,
it is very important to use new screws at as 0.020 mm - 0.055 mm
OIL SCRAPER RING
sembly. (.0008 in - .0022 in)
SERVICE LIMIT
ALL 0.15 mm (.006 in)
182 smr2011-018
Section 02 ENGINE
PISTON RING INSTALLATION

ORDER RING POSITION
Stamped dot
FIRST STEP Oil scraper ring
fac ing UP
SECOND Stamped 'E' and

Taper-face ring
STEP 'TOP" facing UP
Rectangular Stamped 'E" and

THIRD STEP
ring 'TOP" facing UP
R 1 503 motr32A
1. Piston
1 __________
·-- ----------=
:_�-
2. Filler gauge 2
Ring End Gap
-------------�
�
RING END GAP
RECTANGULAR
NEW
0.30 mm 0.50 mm
-
(.012 in - .02 in)

---======--=- �
0.35 mm 0.55 mm
3
TAPER-FACE
-
(.014 in - .022 in)

1. Rectangular ring
0.35 mm 0.50 mm 2. Taper-face rmg
OIL SCRAPER RING
-
3. Oil scraper ring

(.014 in .02 in)
-
SERVICE LIMIT IW.JifllJj Ensure that top and second rings are
not interchanged.
ALL 1.50 mm (.0591 in)
NOTE: Use a ring expander to prevent breakage
Measure pos1t1on for ring end gap in the area during installation. The oil ring must be installed
of 8 mm to 16 mm (.315 in to .63 in) from top of by hand.
cylinder.
Check that rings rotate smoothly after installation.
NOTE: In order to correctly position the ring in the
Space the piston ring end gaps 120° apart and do
cylinder, use piston as a pusher.
not align the gaps with the piston pin bore or the
Using a feeler gauge, check ring end gap. Replace thrust side axis.
ring if gap exceeds above described specified tol
erance.
Piston Ring Installation

Install rings in the following order and layout:
smr2011-018 183
Section 02 ENGINE
Bring piston of cylinder 3 to ignition TDC, using a

dial gauge or another similarly suitable tool.
l4![1)i$j Do not scratch or damage piston and

cylinder surface.
A31C2DA
1. DO NOT align ring gap with piston trust side axis

2. DO NOT align ring gap with piston pm bore axis
A 120" ::.mr2'C09-02 6-003_a
1. Dial gauge
CRANKSHAFT NOTE: When the piston of cylinder 3 is at ignition

Crankshaft Locking Procedure TDC, the position lines on oil separator cover must
be lined up as shown in the following illustration.
IW•Ji$j The crankshaft must be locked at
TDC for removal and installation of crankshaft,
balancer shaft and camshaft.
NOTE: When the crankshaft is locked, the piston

of cylinder 3 is at ignition TDC.
Remove:
- Intake manifold (refer to INTAKE MANIFOLD
subsection)
- Spark plugs
- Cylinder head cover (refer to CYLINDER HEAD
subsection
- Crankshaft access plug screw.
1. Pos1t1on lines
Use a small screwdriver to check if the groove in

the crankshaft is aligned with the hole.
In this position, lock the crankshaft using the
CRANKSHAFT LOCKING TOOL (P/N 529 035 821).
Crankshaft Removal
1. Crankshaft access plug screw 1. Drain engine oil (refer to LUBRICATION SYS
2. Gasket ring
TEM subsection).
Turn engine counterclockwise.
184 smr2()11·018
Section 02 ENGINE
2. Remove engine from vehicle (refer to ENGINE

REMOVAL AND INSTALLATO I N subsection).
3. Remove cylinder head (refer to CYLINDER
HEAD subsection).
4. Remove PTO housing (refer to PTO HOUSING
AND MAGNETO subsection).
5. Remove starter gear (refer to PTO HOUSING
6. Remove starter drive.
7. Remove oil suction pump (refer to LUBRICA
TOI N SYSTEM subsection).
8. Remove engine mounting brackets.
9. Remove oil reservoir plug screws no. 12 with 1. Connecting rod screws
0-ring no. 13.
NOTE: Before removing the connecting rod caps,
mark them to remember the right position when
reassembling. It is recommended to measure
connecting rod big end axial play prior to re
move connecting rod. Refer to PISTONS AND
CONNECTING RODS in this subsection for the
procedure.
R1503motr05A
ENGINE UPSIDE DOWN

1. Oil reservoir plug screw with 0-ring
10. Remove cylinder block screws no. 14 and

no.15.
R1503m otr07 A 1
1. Mark on connecting rod
13. Remove thrust washers no. 16.
BOTTOM VIEW OF ENGINE

1. Screws
11. Remove cylinder block lower half.

12. Remove connecting rod screws.
smr2011-0IB 185
Section 02 ENGINE
Crankshaft Radial Play

Measure all crankshaft journals. Compare to in
side diameter of crankshaft bearings (elsewhere
in this subsection).
R 1503mott09A
1. Thrust washer
14. Remove crankshaft no.17.
R15G3motr13A
1. Micrometer
2. Crankshaft area for bearing
CRANKSHAFT JOURNAL DIAMETER

49.991 mm 50.01 mm
NEW
-
(1.9681 in 1 .9689 in)

-
SERVICE LIMIT 49.95 mm (1 .9665 in)
CRANKSHAFT JOURNAL RADIAL CLEARANCE

Crankshaft Pin
Measure all crankshaft pin diameters. Compare to
1. Crankshaft inside diameter of connecting rod bearings (else
where in this subsection).
Crankshaft Inspection
Crankshaft Gear Inspection 1 2
Replace crankshaft if the gears are worn or other

wise damaged.
A.1503motr1'-'
1. Micrometer
2. Crankshaft pin area for bearing
1. Balancer gear
2. Cr
ankshaft timing gear
186 smr2011·018
Section 02 ENGINE
CRANKSHAFT PIN DIAMETER
45.032 mm 45.048 mm
NEW
-
(1.7729 in - 1 .7735 in)
CRANKSHAFT PIN RADIAL CLEARANCE
Crankshaft Axial Clearance

When assembling the cylinder-block, measure the
crankshaft axial clearance.
R150,3motr17A 2
1. Mark on balancer shaft

2. Mark on crankshaft
For correct installation of the connecting rods, re

fer to PISTONS AND CONNECTING RODS in this
subsection.
14'l'IJifB#I
It is absolutely necessary t o follow
this procedure. Otherwise severe engine dam
age can occur.
Insert thrust washers no. 16 as soon as crankshaft

is in place as per following illustration.
R1503motr41A 2 IM.Jifilj Never forget thrust washers on cen

ter of crankshaft to control axial adjustment.
1. Dial gauge
2. Crankshaft
CRANKSHAFT AXIAL CLEARANCE
0.08 mm 0.22 mm
NEW
-
(.003 in - .009 in)
Crankshaft Installation
Pay attention to following details.
NOTE: Before installing the crankshaft. make
sure that the timing chain is on the crankshaft
and the chain guide has been installed first. Those
R1503 motr09A
parts cannot be installed when the crankshaft is
in place. THRUST WASHER INSERT DIRECTION
1. Thrust washer
fifl•Jifilj Crankshaft and balancer shaft marks

have to be aligned.
fflomJj Thrust washers have to be flush with
the cylinder block sealing surface.
smr2011-018 187
Section 02 ENGINE
R 1&03motrt6A
Rt503motr18A
1. Thrust washer
2. Sealing surface 1. Crankshaft locking roof
Install cylinder block lower half. Refer to CYLIN

BALANCER SHAFT
DER BL OCK in this subsection.
Install the crankshaft cover before mounting the Balancer Shaft Removal
engine bracket. Apply engine oil on 0-ring and 1. Drain engine oil (refer to LUBRICATION SYS
press cover in. Crankshaft cover has to be flush TEM subsection).
with cylinder block surface.
2. Remove engine from vehicle (refer to ENGINE
REMOVAL AND INSTALLATION subsection).
3. Remove cylinder head (refer to CYLINDER
HEAD subsection).
4. Remove PTO housing (refer to PTO HOUSING
5. Remove starter gear (refer to PTO HOUSING
6. Remove starter drive.
7. Remove oil suction pump (refer to LUBRICA
TION SYSTEM subsection).
8. Remove engine mounting brackets.
9. Remove oil reservoir plug screws no. 12 with
0-ring no. 13.
R1&03mo1ft9A 2
1. 0-ring
2. Crankshaft cover
Install the CRANKSHAFT LOCKING TOOL (P/N 529

035 821) right away to position crankshaft at TDC
before installing the camshaft and the rocker arms
(refer to CYLINDER HEAD subsection).
Rtl503mo110S"
ENGINE UPSIDE DOWN

1. Oil reservoir plug screw with 0-ring
188 smr2011-018
Section 02 ENGINE
10. Remove cylinder block screws no. 14 and

no.15.
R1503motr23A
1. Micrometer
2. Balancer shaft area for bearing
1. Screws
BALANCER SHAFT SEAT DIAMETER
11. Remove cylinder block lower half.
31.984 mm - 32.000 mm
12. Remove thrust washers no. 18. NEW
(1.2592 in - 1.2598 in)

1
BALANCER SHAFT SEAT RADIAL CLEARANCE

Balancer Shaft Axial Clearance

When assembling the cylinder-block, measure the
balance shaft axial play.
R1503motr20A
1. Thrust washer
13. Remove balancer shaft.
Balancer Shaft Inspection

Check balancer shaft and replace if damaged.
If the gear on the balancer shaft is damaged, re
place balancer shaft.
R 1503motr42A 2
Check gear on the crankshaft at the same time
1. Dial gauge
and replace crankshaft if necessary (refer to 2. Balancer shaft
CRANKSHAFT above).
BALANCER SHAFT AXIAL CLEARANCE
Balancer Shaft Bearing Seat Play
0.02 mm - 0.25 mm
Measure all balancer shaft bearing seats. Com NEW
(.001 in - .01 in)
pare to inside diameter of balancer shaft bearings
(see CYLINDER BLOCK INSPECTION in this sub SERVICE LIMIT 0.35 mm (.014 in)
section).
smr2011-018 189
Section 02 ENGINE
Balancer Shaft Installation 2

Pay attention to following details.
1l![1)ltltj Balancer shaft and crankshaft marks

have to be aligned.
1
Al503mou22A
1. Thrust washer
2. Sealing surface
Install cylinder block lower half. Refer to CYLIN

DER BLOCKin this subsection.
Install the crankshaft cover before mounting the
R1503morrl7A 2 engine bracket. Apply engine oil on 0-ring and
1. Mark on balancer shaft
press cover in. Crankshaft cover has to be flush
2. Mark on crankshaft with cylinder block surface.
14!['1il1Jj
Never forget thrust washers no. 18
on PTO side to control axial adjustment o n
balancer.
Insert thrust washers as soon as balancer shaft is

in place as per following illustration.
R1503motr19A 2
1. 0-ring
2. Crankshaft cover

R1503moir20 8 before installing the camshaft and the rocker arms
THRUST WASHER INSERT DIRECTION
1. Thrust washer
W•Vtflj Thrust washers have to be flush with ------ ··-··-
the cylinder block sealing surface. - - -- ,-
190 smr2011-018
Section 02 ENGINE
R15-03motr18A
1. Crankshaft locking tool

R1503motr37A 2
1. Marks on balancer shaft bearings
2. Marks on crankshaft bearings
CYLINDER BLOCK
Cylinder Block Disassembly Cylinder Block Inspection
Remove: Cylinder
- Engine oil (refer to LUBRICATION SYSTEM Check cylinder for cracks, scoring and wear ridges
subsection) on the top and bottom of the cylinder. If so, re
- Engine from vehicle (refer to ENGINE RE place cylinder.
MOVAL AND INSTALLATION subsection)
Cylinder Taper
- Cylinder head (refer to CYLINDER HEAD sub
section) Measure cylinder bore and if it is out of specifica
tions, re-hone cylinder sleeve and replace piston
- PTO housing (refer to PTO HOUSING AND
with first oversize.
MAGNETO subsection)
- Starter gear and starter drive (refer to PTO NOTE: It is not necessary to have all cylinders
HOUSING AND MAGNETO subsection) re-honed if they are not all out of specification.
- Oil suction pump (refer to LUBRICATION SYS Mixed standard size and oversize cylinders are
allowed.
TEM subsection)
- Balancer shaft (refer to BALANCER SHAFT Measure cylinder bore at 3 recommended posi
elsewhere in this subsection) tions. See the following illustration.
- Crankshaft (refer to CRANKSHAFT elsewhere

in this subsection)
- Piston with connecting rod (refer to PISTONS
AND CONNECTING RODS elsewhere in this
subsection).
B e ari ng s
When bearings no. 19 and no. 20 need to be re
moved from the cylinder block, mark them to iden
tify the correct position at installation. See the fol
lowing illustration for an example:
smr2011·018 191
Section 02 ENGINE
Bearings
r
To measure the wear of the crankshaft bearings
no. 19 and balancer shaft bearings no. 20, both
cylinder block halves with OLD bearings have to
B be screwed together as per tightening procedure
described below.
Measure the inside diameter of the bearings with
abore gauge .
A t&03moir24A
1 First measuring diameter

2. Second measurmg d1amerer
3. Third measuring diameter
A. 60 mm (2.362mJ
8. 110mm (4331 in)
CYLINDER TAPER IN DIAMETER
NEW MAXIMUM 0.038 mm (.001 in)
Distance between measurements should not ex

R1503motr33A
ceed the service limit mentioned above.
ENGINE UPSIDE DOWN
Cylinder Out of Round 1. Bore gauge
Measure cylinder diameter in piston axis direction CRANKSHAFT BEARING INSIDE DIAMETER
from top of cylinder. Take an other measurement
90° from first one and compare. SERVICE LIMIT I 50.1 mm (1.9724 in)
NOTE: Take the same measuring points as de

scribed in CYLINDER TAPER above.
R1 5 03 m ou 25A R 1503motr34A
A. Perpendicular to crankshaft axis ENGINE UPSIDE DOWN

8. Parallel to crankshaft axis 1. Bore gauge
CYLINDER OUT OF ROUND BALANCER SHAFT BEARING INSIDE DIAMETER
NEW MAXIMUM 0.008 mm (.0003 in) SERVICE LIMIT I 32.11 mm (1.2642 in)
SERVICE LIMIT 0.015 mm (.0006 in) Replace bearings if they are out of specifications.
192 smr2011-018
Section 02 ENGINE
Cylinder Block Assembly

For assembly, reverse the disassembly proce
dure. Pay attention to the following details.
Torque Banjo screw to 19 N•m {168 lbf•in).
To install starter drive bearing no. 21 of starter
drive assembly, use the STARTER DRIVE SEAL
PUSHER (P/N 420 876 502) and the HANDLE (P/N 420
877 650).
4 20876502
R1503motr36A
1. Bearing protrusion in cylinder block notch
Apply engine oil on all bearings, in the bottom area

of the cylinder bore and also on the band of the
42087765-0 piston ring compressor tool.
For proper installation of pistons, refer to PIS
Use NEW bearings when diameters are out of
specification. TONS AND CONNECTING RODS in this subsec
tion.
If OLD bearings can be used again, make sure
they are at the same position as they were before. NOTE: Before installing the crankshaft, make
sure that the timing chain is on the crankshaft
Correctly install bearings. Top crankshaft bearing and the chain guide has been installed first. Those
halves have a bore which has to be placed in the
parts cannot be installed after as the crankshaft
upper cylinder block. is in place.
Clean oil passages and make sure they are not
clogged.
Clean all metal components in a solvent.
Cylinder block mating surfaces are best cleaned
using a combination of the LOCTITE CHISEL (GAS
KET REMOVER) (P/N 413 708 500) and a brass brush.
Brush a first pass in one direction then make the fi
nal brushing perpendicularly (90°) to the first pass
(cross hatch).
fill1Ji@j Do not wipe with rags. Use a new

clean hand towel only.
IMPORTANT: When beginning the application of

R1503motr35A
the crankcase sealant, the assembly and the first
torquing should be done within 10 minutes. It is
1. Cylinder block upper half
2. Oil bore in cylinder block suggested to have all you need on hand to save
3. Oil bore in bearing time.
Bearings have to be flush with the cylinder block NOTE: It is recommended to apply this specific
split surface and their protrusions have to fit in the sealant as described here to get an uniform appli
notched areas in the cylinder block seat. cation without lumps. If you do not use the roller
method, you may use your finger to unif ormly dis
tribute this sealant.
Ap pl y LOCTITE 5910 (P/N 293 800 081) on mating
surfaces.
smr2011·018 193
Section 02 ENGINE
M1Jiti#I Do not use other products to seal

'"
_,...
crankcase. Do not use an activator with the

Loctite 5910. Using other products or non sil
/'\-
icone-based sealant over a previously sealed @ � rm-
crankcase with Loctite 5910 will lead to poor
adhesion and possibly a leaking crankcase.
- -
NOTE: Refer to the product label for the sealant
curing time. Respect the manufacturer's recom -
mendations prior to start engine.
[j]
Use a plexiglass plate and apply some sealant
on it. Use a soft rubber roller of 50 mm 75 mm
-
(2 in - 3 in) available in arts products suppliers for

printmaking, roll the sealant to get a thin uniform
"""201 0-02&· 000..o
coat on the plate (spread as necessary). When
ready, apply the sealant on crankcase mating Torque cylinder block screws no. 15 to 23 N•m
surfaces. (17 lbf•ft) using the following sequence.
sm<20 1<>026-00 •..o
F 1 2R17A
NOTE: Before continuing the assembly process,
the axial clearance of balancer shaft and crank
Do not apply in excess as it will spread out inside
shaft has to be checked. Refer to CRANKSHAFT
crankcase.
and BALANCER SHAFTin this subsection for the
lighten cylinder block screws as per following pro procedure.
cedure:
Install the crankshaft cover before mounting the
Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on engine bracket. Apply engine oil on 0-ring and
screw threads. press cover in. Crankshaft cover has to be flush
Torque cylinder block screws no. 14 to 40 N•m with cylinder block surface.
(30 lbf•ft) using the following sequence and then
repeat the sequence to 55 N•m (41 lbf•ft).
194 smr201Hl18
Section 02 ENGINE
R1503motT19A 2
1. 0-ring
2. Crankshaft cover

before installing the camshaft and the rocker arms
I
-I
---····
·····
..
__ ,
·- J
'
A 1 503mot r 18A
1. Crankshaft locking tool
Install cylinder head, PTO housing and the other

parts in accordance with the proper assembly pro
cedures.
smr2011-018 195
196
Section 03 ELECTRONIC MANAGEMENT SYSTEMS
Subsection 01 (ENGINE MANAGEMENT SYSTEM)
ENGINE MANAGEMENT SYSTEM
FRONT
MAPS
KS
ETA MATS
CTS INJECTOR 1, 2, 3
TOPS ECM
CPS IGNITION COIL 1, 2, 3
CAPS
EGTS
A Engine Wiring Harness Connector KS Knock Sensor

B
CAPS
Vehicule Wiring Harness Connector
Camshaft Position Sensor
OPS
MAPS
Oil Pressure Sensor
Manifold Absolute Pressure Sensor IN�
CPS Crankshaft Position Sensor MATS Manifold Air Temperature Sensor
CTS Coolant Temperature Sensor ETA Electric Throttle Actuator OUT�
ECM Engine Control Module TLS Throttle Lever Sensor
EGTS Exhaust Gas Temperature Sensor TOPS Tip-Over Protection System
sm r 2009-02 7 -00 2..,en
smr2011-019 197
1503 4-TEC CONTROL SYSTEM
INPUTS OUTPUTS
Throttle accelerator sensor (TAS) Relay
Throttle position sensor (TPS) Fuel pump
Crankshaft position (CPS) Starter solenoid
Coolant temperature (CTS) Fuel injector (3)
Manifold absolute pressure (MAPS) Electric throttle

actuator (ETA)
Manifold air temperature (MATS)
Controller area
Exhaust gas temperature (EGTS) network (CAN)
Oil pressure (OPS)
Knock sensor (KS)
Battery voltage (BV)
Digitally Encoded
Security System (O.E.S.S.)
Start/Stop switch
Tip-over protection system (T.O.P.S.)
Off-throttle assisted steering (0.T.A.S.)
Controller area network (CAN)
198 smr201 l-019

Subsection 01 (ENGINE MANAGEMENT SYSTEM}
GENERAL
SYSTEM DESCRIPTION
A highly advanced engine management system
(EMS) is used to ensure a high power output with
cleaner combustion.
There are 7 main systems that interact with the
engine management system:
1. Electronic fuel injection
2. D.E.S.S. System
3. Ignition System
4. Starting System
• mr2009-02 7 .()()6_ a
5. 0.T.A.S. 1. ECM on intake manifold

(Off-Throttle Assisted Steering)
6. T.O.P.S. It features a permanent memory that will store
(Tip-Over Protection System) fault codes, customer information and other
engine information, even when the battery is
7. iControl System
removed from the vehicle.
Engine Control Module (ECM) The ECM controls the following engine manage
ment functions:
Engine RPM Limiter

The ECM limits maximum engine speed. It moni
tors engine RPM through the CPS and varies fuel
injection, ignition and throttle plate opening as
necessary.
Engine Speed Control

smr2009-027•005 The ECM controls the engine idle RPM. In addi
ECM tion, it can vary the engine speed by command
ing the electric throttle actuator (ETA) to open or
The ECM is the main component of the engine
close based on throttle position and various other
management system. It controls the electrical
inputs. The ETA also allows for other functions of
system and the engine management functions by
the iControl system .
processing the information obtained from various
switches, controls and sensors that it compares Drowned Mode
to predetermined parameters stored in the ECM. If the engine is flooded and does not start, this
It also interacts with the other electronic systems special mode can be activated to prevent fuel in
through the CAN bus (information center and jection and ignition while cranking in order to ven
iControl System) for various functions that affect tilate the engine to dry the cylinder walls.
engine management. NOTE: This mode can also be used if the engine
The ECM is mounted on the intake manifold. is water-flooded.
To activate DROWNED MODE, proceed as per fol
lowing steps.
1. Install the tether cord cap on the engine cut out
switch.
2. While the engine is stopped, fully pull and
HOLD the throttle lever.
3. Press the START/STOP button. DROWNED
MODE is now on.
Releasing the throttle lever will allow the ECM to
revert back to normal mode.
smr2011-019 199
If the engine does not start, it may be necessary to

remove the spark plugs and crank the engine with
rags over the spark plug holes. Refer to IGNITION
SYSTEM subsection.
Monitoring System
The ECM monitors electrical and electronic com
ponents of the engine system, the iControl sys
tem, the information center (gauge), some com
ponents of the electrical system as well as signals
from other electronic modules.
For more information, refer to DIAGNOSTIC AND
FAULT CODES.
Limp Home Mode

The ECM may automatically set the engine in
LIMP HOME MODE using default parameters
when certain major faults are detected. For more
information, refer to DIAGNOSTIC AND FAULT
CODES.
Diagnostic Mode
The ECM features a self-diagnostic mode that is
initiated on system power up for certain systems
and components (when pressing the START but
ton), and when the engine is running for others.
Refer to DIAGNOSTIC AND FAULT CODES sub
section for more information.
200 smr201 l-019

Subsection 02 OCONTROL SYSTEM)
iCONTROL SYSTEM
GENERAL iS (INTELLIGENT SUSPENSION)
The iControl (intelligent Control) system may con The intelligent suspension is an electronically
sist of the following systems depending on the controlled hydro/mechanical system consisting
PWC model: of a hydraulic pump, an actuator, suspension
- Intelligent Throttle Control (iTC) arms, springs and one shock absorber. They are
- Intelligent Brake and Reverse (iBR)
installed in the hull and connected to the moving
deck. The suspension system is used to isolate
- Intelligent Suspension (iS).
the riders from the rough water.
The information center (gauge) and handlebar
For a comprehensive and complete description of
switches are used to navigate through and select
this system, refer to SUSPENSION (iS) subsec
several functions. modes of operation and change
tion.
certain settings and system parameters using the
appropriate handlebar controls.
Each control is electronic and provides a com
mand signal to an electronic module whose
function is to assure proper operation of its sys
tem within set parameters.
For a comprehensive and complete description
of the information center, refer to INFORMATION
CENTER (GAUGE) subsection.
iTC (INTELLIGENT THROTTLE

CONTROL)
The iTC is an electronic throttle control system
(ETC) that includes a cable-less throttle control
(TAS) located on the RH side of handlebar and
an electric throttle actuator (ETA) located on the
throttle body.
The iTC allows functions such as touring/sport
mode, cruise control, slow speed mode, ski mode
and O.T.A.S.™ as well as a more precise control
of the engine power.
For a comprehensive and complete description
of this system, refer to INTELLIGENT THROTTLE
CONTROL (ITC) subsection.
iBR (INTELLIGENT BRAKE AND

REVERSE)
The iBR is a brake and reverse system used to
avoid obstacles, gradually slow down or stop
the watercraft, or drive backwards by lowering
the iBR gate that redirects the water flow at the
outlet of the jet pump nozzle.
For a comprehensive and·complete description of
this system, refer to !BR AND VTS subsection.
smr2011-020 201
202
Subsection 03 (CONTROLLER AREA NETWORK (CAN))
CONTROLLER AREA NETWORK (CAN)

SERVICE TOOLS
ECM ADAPTER TOOL............................................ . . . ..... . .
.. ... . ...... 529 036 166 ......................................... 205
FLUKE 115 MULTIMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................. 529 035 868 ......................................... 205
GENERAL
SYSTEM DESCRIPTION
The CAN (Controller Area Network) protocol is an ISO standard for serial data communication.
The CAN bus is the neNous system of the iControl system and the engine management system (EMS).
It links the electronic modules (ECUs) together so that they communicate to interact as required.
Two wires connect each component and they are in constant communication with each other at a rate
of about every 10 or 20 milliseconds depending on the component. CAN lines consist of a pair of twisted
wires (WHITE/BLACK and WHITE/RED}.
CAN BUS- HI (FUSE BOX)
C7 C11 C9 C10 cs C12

0 0 0 0 0 0
Q;_
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:c
EE
:c
EE
:c
EE
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EE
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131
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.,
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SOUNDER
DIAGNOSTIC
CONNECTOR
. .
�� I
�
ECM GAUGE iS iBR
B-C2 13 3 3 4 2
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C1 cs C3 C4 C2 C6
CAN BUS- LOW (FUSE BOX)
ECM Engine Control Module

iBR Intelligent Brake and Reverse module WH/BK = WHITE/BLACK
iS Intelligent Suspension module WH/RD = WHITE/RED
smr201 1.02 1·00l _aen
CAN BUS DIAGRAM
smr2011·021 203
Subsection 03 (CONTROLLER AREA NETWORK (CAN))
TROUBLESHOOTING
DIAGNOSTIC TIPS
Check the fault codes using B.U.D.S. as a first troubleshooting step. Refer to DIAGNOSTIC AND FAULT
CODES subsection.
Make sure the modules are powered before testing CAN.
CAN Communication Problems

The following chart gives some symptoms and behaviors relative to the CAN component in cause. The
list is not exhaustive, only the most significant items are given to help in troubleshooting.
CAN FAULTY
VEHICLE BEHAVIOR OR OBSERVATION
WIRES (no OBSERVATION IN B.U.D.S.
IN INFORMATION CENTER
communication)
Engine is set to limp home mode. B.U.D.S. will not be able to communicate
Short circ.uit in CAN iBR gate will not move. ·Locked' in neutral. with any electronic module.
wires iBR light is ON. 'No vehicle detected· message will
Check engine light is ON. be displayed in B.U.D.S.
3 modules instead of 4 will be active.

Check engine light is ON.
"Cluster• tab and its data will
Information center iBR light is ON.
not be available in B.U.D.S.
(cluster) Some functions not displayed
ECM, iBR and iS will report a cluster
such as: Engine hours, iS, VTS and RPM.
CAN problem.
Engine is set to limp home mode.
Check engine light is ON.
ECM tab and its data will
ECM (Engine iBR light is ON.
not be available in B.U.D.S.
Control Module) iBR gate 'locked" in neutral.
iBR and iS will report an ECM CAN
Some functions not displayed such as:
problem.
Engine hours and RPM.
Engine is set to limp home mode.

iBR gate will not move. "Locked" in neutral. 3 modules instead of 4 will be active.
iBR light is ON. iBR tab and its data will
iBR ( intelligent
Check engine light is ON. not be available in B.U.D.S.
Brake and Reverse)
Some functions not displayed ECM and iS will report an iBR CAN
such as: Lake water temperature, no VTS, problem.
no F. N and R indication.
iS handlebar controls have no effect.

iS (intelligent No DOCK mode. Suspension will remain
iS tab and its data will not be available in
Suspension) to its last position before the CAN problem.
B. U .D.S.
iS position is not displayed.
The menu Depth Sounder.

Depth sounder Indicator will not be visible. Nothing will be observable.
The Depth menu will not be available.
B.U.D.S. will not be able to communicate

Diagnostic with any electronic module.
Nothing will be observable.
connector "No vehicle detected' message will
be displayed in B.U.D.S.
NOTE: If the gauge cannot communicate with an optional module (iS module or depth sounder) during
the initial power up, the gauge will interpret this as if the vehicle is not equipped with it. No further test
of the system occurs and no indication or fault message will be visib l e. If communication is interrupted
after the gauge has already detected them, then the gauge will indicate that there is a communication
fault.
204 smr2011-021
Subsection 03 (CONTROLLER ARE A NETWORK (CAN))
CAN Continuity Tests

If a communication problem is present, perform
the appropriate continuity test relating to the com
ponent reported by, or not available in B.U.D.S.
Test wire continuity between the corresponding
terminal of the CAN bus bar in the fuse box and
the suspected component as follows.
For fuse box access, refer to POWER DISTRIBU
TION AND GROUNDS subsection.
Remove both CAN bus bars.
smr2011-02 7 -002 ...
FUSE BOX PIN IDENTIFICATION
If continuity is good, CAN wires are in good con

dition.
If continuity is not good, check wiring, connectors
and terminals condition.
NOTE: It may be necessary to check the continu
ity to more than one component.
Reconnect connectors and reinstall removed
parts.
smr201 1 ·027·C03-t1
1. CAN LO bus bar

2. CAN HI bus bar
Inspect bus bar condition.

Disconnect the connector from the component to
be tested. Refer to its appropriate subsection.
Use the FLUKE 115 MULTIMETER (P/N 529 035 868)
and select n.
Refer to the CAN BUS DIAGRAM above and
read wire resistance between the each bus bar
terminal and the applicable component terminal.
Check the continuity of the WHITE/RED wire and
the continuity of the WHITE/BLACK wire.
The following gives an example between the CAN
LO wire and the ECM.
NOTE: When working with the ECM, install the
ECM ADAPTER TOOL (P/N 529 036 166) on ECM "B"
connector. For connector identification, refer to
ELECTRONIC FUEL INJECTION (EFI) subsection.
CONTINUITY TEST EXAMPLE: ECM TO

FUSE BOX
ECM FUSE BOX

RESISTANCE
CONNECTOR TERMINAL
Close to 0 n
B-C2 G1
(continuity)
smr2011-021 205
206
Subsection 04 (COMMUNICATION TOOLS AND 8.U.D.S.)
COMMUNICATION TOOLS AND

B.U.D.S.
SERVICE TOOLS
MPl-2 DIAGNOSTIC CABLE .... . . . ..
. . . . .. . . . . . . . . . . . . . . ................ .. .
. .. ...... . 710 000 851 ......................................... 209
MPl-2 INTERFACE CARD . . . . .. . . . . . . . . . . . . . . ............................ . . . . . . . . . . . . . . 529 036 018 ......................................... 210

MALE-FEMALE EXTENSION SERIAL CABLE . . .. . . . . . . .. . . ................. DB9 . . . .. .... . .
.. ... .. .
. . . . . . . . . . . . . .. . . . . 210
. . .
GENERAL USB LIGHT
STATUS WHAT TO DO
Refer to PROCEDURES for instructions on the
communication tools. - Check USB connection between
If communication problems occur, refer to TROU MPl-2 and PC computer.
Light is
BLESHOOTING in this subsection. OFF - Check USB operation on PC
computer (hardware or Wi ndows
drivers)
TROUBLESHOOTING
.
- Connections are GOOD.

Light is
DIAGNOSTIC TIPS Communication can take place on
GREEN
USB side.
IMPORTANT: Make sure all connections are
made and vehicle is powered up before starting Prerequisite for CAN communication:
B.U.D.S. to allow proper communication between - MPl-2 connected to diagnostic connector on ve
the vehicle and B.U.D.S. software. hicle.
- ECM turned on (press the START button).
MPl-2 Connection Troubleshooting
- tether cord installed on the vehicle engine cut-
MPl-2 Status Lights off switch.
The MPl-2 includes 2 status lights that indicate the - B.U.D.S. started and logged on.
connection condition: USB and CAN. Both lights
CAN LIGHT
must be GREEN for the MPl-2 to function prop
erly. Otherwise, refer to the following charts. STATUS WHAT TO DO
Light is Check connection between MPl-2 and

USB OFF diagnostic connector on vehicle.
Light is
Check CAN wires/connectors on vehicle.
RED
Light is Connections are GOOD. Communication

GREEN can take place on CAN side.
Communication Problems when Using

B.U.D.S.
Prerequisite for USB communication:
Missing Module
- PC Computer turned on
Ensure the appropriate number of modules is
- MPl-2 connected to PC computer.
shown at the bottom RH side of B.U.D.S. screen.
smr2011-022 207
Subsection 04 {COMMUNICATION TOOLS AND B.U.D.S.)
NUMBER Message Box: "Some of the Information

MODEL OF MODULES Normally Displayed..."
MODULES If the following message box is displayed in
GTS 2 ECM and cluster 8.U.D.S.:
ECM, cluster. iBR

Models with iS 4
and iS
Some orl�t infoimateon norma•y dlrp11ytd ..ti IHI 1111H1n9 d\11 lo
t,\
� cornn><netl1on envrwih 1"1o ECM.
Models
3 ECM, cluster and iBR
without 1S
lQi<J
l
smr20C9-02�1 6
1. Click on the OK button in the box.

2. Ensure the tether cord is properly installed.
3. Briefly press the vehicle START button to acti
vate the ECM. Do not hold START button to
a v o id engine starting.
rmr201 1 ·02o--OO Z.. a
1. Number of modules 4. Click on the Read Data button in B.U.D.S.
If one or more ECU is not communicating with the Message Box: "Engine must be Stopped ... "
MPI, refer to DIAGNOSTIC AND FAULT CODES. If the following message box is displayed in
B.U.D.S.:
No Vehicle Detected
If an "X" is shown in the status bar and the pro
tocol tool is blinking between Kw2000 500K and
Kw2000, it means that no ECU is communicating
with the MPI.
llill Kw2000
, --�1..., SOOK
..::i
_ i
1. Click on the Cancel button in B.U.D.S.
2. Ensure the tether cord is properly installed.
3. Briefly press the vehicle START button to acti
r mr2 0 1 0-020-009 vate the ECM. Do not hold START button to
avoid engine starting.
1. Check connections between the PC computer
and the vehicle. 4. Continue with the procedure undertaken prior
to the appearance of the message box.
2. Ensure the electrical system is powered up.
NOTE: The tether cord must be installed. PROCEDURES
3. Ensure both USB and CAN lights on the MPl-2
are GREEN. Refer to MPl-2 CONNECTION MPl-2
TROUBLESHOOTING subsection.
The MPl-2 (Multi-Purpose lnterface-2) in conjunc
If B.U.D.S. does not automatically exit the follow
tion with the MPl-2 diagnostic cable is used with
ing message box, click the Try active detection
B.U.D.S. software to communicate with the ECM
mode button. This will manually establish the
(engine control module) and other modules.
communication with the ECUs.
MPl-2 Power
The MPl-2 interface card uses the power from the
PC computer USB port.
mv02 1 1).{)20-01 o_.
208 smr2011-022
Subsection 04 (COMMUNICATION TOOLS AND B.U.D.S.)
Connecting the PC to the Vehicle

iS Models
1. Open the boarding platform.
•""201 1 -022 -00 I _ a
TYPICAL - ACCESS FROM FRONT STORAGE COMPARTMENT

1. Diagnosric connector
1. Re·boardmg platform
2. Remove the RH storage bin.
TYPICAL - ACCESS FROM REAR RH PANEL

1. Diagnostic connector
7. Connect one end of the MPl-2 DIAGNOSTIC CA

1. RH storage bin BLE (P/N 71 o ooo 851) to vehicle connector.
Models Without iS
3. Remove the RH access panel on the boarding
platform.
GTl/GTS Series and Wake Models

4. Open front storage compartment.
5. Remove storage basket.
All Models
6. Disconnect the 6-pin diagnostic connector from
its holder (protective cap).
smt2011-022 209
TYPICAL
1. Diagnostic cable connected to vehicle
8. Connect the other end of diagnostic cable to the

MPl-2 INTERFACE CARD (P/N 529 036 018).
MPl-2 INTERFACE CARD CONNECTED TO USB PORT
A CAUTION If the computer you are using is

connected to a power outlet, there is a poten
tia I risk of electric shock when working i n con
tact with water. Be careful not to touch water
while working with the computer.
10. Use B.U.D.S. software as described further in
5 2903601 8
B.U.D.S. SOFTWARE
NOTE: An optional MALE-FEMALE EXTENSION SE
RIAL CABLE (P/N DB9l available at electronic retail B.U.D.S. SOFTWARE
outlets can be used between diagnostic cable and
MPl-2 interface. Do not exceed 7.6 m (25 ft). B.U.D.S. (Bombardier Utility and Diagnostic Soft
ware) is designed to allow programming key(s) to
the vehicle, allow electrical and electronic compo
nent monitoring, activation of certain components
for diagnostic purposes, and to carry out settings
changes.
For more information pertaining to the use of the
B.U.D.S. software, use its help which contains de
tailed information on its functions.
Always use the latest applicable B.U.D.S. version
available on BOSSWeb.
> 29035€97
OPTIONAL MALE-FEMALE EXTENSION SERIAL CABLE
9. Connect the MPl-2 INTERFACE CARD (P/N 529

036 018) to the USB port of a PC (personal
computer).
210 smr2011-022
How to Read the Electronic Control GTX/RXT Series and Wake Pro
Units Using B.U.D.S. Software
IMPORTANT
IMPORTANT: Ensure all connections have been
When the engine is not started, approximately
made before starting 8.U.D.S. to allow proper
3 minutes after pressing the START button, the ECM
operation. Refer to MP/-2 in this subsection.
will stop communicating with B.U.D.S. Therefore,
1. Press the START button to wake up the electri operations with B.U.D.S. will be interrupted.
cal system.
To reestablish communication, briefly press the
2. Install the tether t.:ord on the engine cut-off START button. Do not hold START button to
switch. avoid engine starting if engine starting is not
desired.
3. Start B.U.D.S. and logon.
NOTE: B.U.D.S. will automatically choose the ap
Electronic Modules ECU Update
propriate MPI 2 p rotoco l .
4. Ensure the appropriate number of modules is 14'[.JilflJj Failure to strictly follow a procedure
shown in the status bar. to update a module may permanently damage
the module.
NUMBER
MODEL OF MODULES Whenever B.U.D.S. is started, check for an up
MODULES date icon in the B.U.D.S. status bar.
GTS 2 ECM and cluster
ECM, cl uster iBR

Models with iS 4
,
and iS
Models
3 ECM, cluster and iBR
without iS
:�
1 \
- 1 �.
rmao 1 1.02o «> u •mr:>Ol 0-0 3 0-002_0
1. Number of modules TYPICAL
5. Read ECUs by clicking the Read Data button. If the icon is visible, it indicates that a file is avail
able in B.U.D.S. to update at least one of the elec
tronic modules:
NOTE: If an update file is available on BOSSWeb
but the B.U.D.S. software being used is not up
to date, the update icon will not appear. Refer to
the service bulletins to see if there is an update
available.
Use the Module submenu and check all modules
Write Data one at a time to see which module(s) can be up
dated.
vmr2000-0 1 2.1 OO _ocn
B.U.D.S. is now ready to use.
smr2011-022 211
NOTE: When selecting the update menu in

B.U.D.S a dialog box will appear and the update
.•
file description may give some clue to finding the

vehicle-related information in BOSSWeb.
Cluster
-
!BR
IS
-
smr2009·0 28-003
TYPICAL
1. If the Update option is greyed o u t, no update

file is available for this module.
2. If the Update option is black, an update file is
•»Iii'#> --
available for this module.
TYPICAL
roofs ttefp 1. File description
-----
� Information Writing Changes in an ECU
�- �-
If the word Modified appears at the end of the
vehicle file name at the top of the B.U.D.S. page,
then a change has been made that requires it to
!BR be saved to the related electronic module.
!S 1 1
sm(.200!Hl2�2
1. Greyed out: No update to perform

i;4o y.,. - l!OO'" l"* �
1'
_£J i I
Black: Update file available
Before app l ying an update, log in BOSSWeb and

l ook in Service for the Unit history to find out if
!! !! � 1
�
any information or publication related to the vehi
Veticle s.ittc•J I MOru:onno I Acnvooon I -l
FOIJlls
cle is available. If so. carefully follow the given in

TYPICAL
structions. 1. Indicate setting or data modified; Write Data to save
1. Click the Write Data button.
BOSS Web
1<��1·1 TS, 'I.I)�
fie :faew Mfl® Module !ools J:!elp
°''"-' Cl�tn , .•.

C:lothtt19 (J.l.M
ClrfUUl9/\ Cl�
C..-..,.-""',..�·
Cl.atn st..w1 @t.fiijlill
Clifik Here a.1.r.T. Plw• �•OM•n•nc• cfa.itn
dofSeason Read Data Write Data
to Access &dt•.,._d Uli\lt M..rrtt.n•.nc.
I ClHr Sale
.. ...,
IMY2009- l l &O' I
SERVICE, UNIT HISTORY NOTE: A message box will confirm a successful

operation.
212 smt2011-022
2. Remove tether cord from the engine cut-off

switch.
Disconnect M Pl connections and store the vehicle
diagnostic connector in its protective cap.
ssi2009--002004 G
TYPICAL
1. Diagnostic connector in its cap
lllt1Jilij Failure to secure the diagnostic con

nector in its protective cap may result in corro
sion or other damage to the terminals.
NOTE: There is a 120 n resistor in protective cap

to minimize the possibility of communication er
ror.
3. Reinstall al removed parts, refer to appropriate
subsections.
smt2011·022 213
214
Subsection 05 (DIAGNOSTIC AND FAULT CODES)
DIAGNOSTIC AND FAULT CODES

GENERAL INFORMATION CENTER MONITORING
Information center
MONITORING SYSTEM VTS and iS switch
This system monitors the electronic components MODE and SET switch
of the EMS (engine management system), iBR, in
formation center, iS and other components of the Cruise switd1
electrical system to detect if they are faulty or de CAN
fective. The monitoring system becomes active
GPS
when the START button is pressed.
NOTE: Some components need the engine to be Fuel level sensor
running for them to be monitored (fuel injectors Depth sounder
for example).
ECM
The following components or functions are moni
tored. iBR module
EMS MONITORING iS module
Battery voltage iS MONITORING

EMS sensors (TAS, TPS, CPS, CAPS, MAPS, iS module and motor
MATS, CTS, OPS, EGTS, TOPS. knock sensor).
Throttle actuator. ignition coils and fuel injectors Vehicle speed
Suspension position
ECM
CAN
Engine RPM
TOPS
CAN
Information center
D.E.S.S. system
iBR module
START switch and starter solenoid
F uel pump When a malfunction is currently detected, the re

lated electronic module:
O.T.A.S.
- Sets an active fault code.
Information center
- Adapts the proper protection strategy accord-
iBR module ing to the failure.
- Sends out warning signals to the information
iBR MONITORING center/beeper codes to inform the rider of a par
iBR module and motor ticular condition.
When a minor or transient fault occurs, the fault
BRLS
message and beeper will cease automatically if
Engine RPM the condition that caused the fault does not exist
Vehicle speed anymore.
If a minor fault is active, the engine will operate
iBR gate position
without a noticeable loss of performance.
CAN
Releasing the throttle and letting the engine re
Lake temperature se nso r turn to idle speed may allow normal operation to
resume. If this does not work, try the following:
Information center
- Remove tether cord from the engine cut-off
ECM switch.
- Wait 3 minutes to allow the ECM to shut down.
- Start engine.
- Check if the fault code is still active.
smr2011-023 215
The electronic system will react differently de The following conditions will stop the suspension.
pending on the fault type. If a severe failure
iS PROBLEM SYSTEM BEHAVIOR
occurs, the engine may not be allowed to be
started. In other cases, the engine may operate Suspension operation
in limp home mode (reduced speed) or not be Any active fault code will be disabled
related to the iS that
affected at all. It will remain at the
prevents its proper
These strategies are used to protect the engine operation position it was at when
system from damage and to maintain safe opera the fa ult code was set
tion of the vehicle.
Limp Home Mode

When a major component of the EMS or the iBR
is not operating properly, limp home mode will be
set. Engine speed will be limited and therefore
vehicle speed.
This mode allows the rider to return home which
would otherwise not be possible without this ad
vanced system.
When this mode is active, LIMP HOME MODE
will be displayed in the information center.
Major Fault and Vehicle Reaction

The following EMS conditions will trigg er a limp
home mode.
MAX ALLOWED
ENGINE PROBLEM
RPM
High engin e temperature

3000
(from 110°C (230°F))
High exhaust temperature

3000
(from 110°C (230°F))
Low oil pressure
(below 180 - 220 kPa 2500
(26 - 32 PSI))
The following conditions will trigger limp home

mode.
iBR PROBLEM SYSTEM BEHAVIOR
iBR gate will be moved

Any active fault code and locked in forward
related to the iBR that position (if possible)
prevents its proper Engine will be set in limp
operation home mode (reduced
speed)
216 smr201 ·1·023

Indicator Lights and Message Display Information

The fault indicators and messages displayed in the information center will inform you of a particular con
dition or if an anomaly occurs.
GT!/GTS Series and Wake

FAULT
MESSAGE DISPLAY DESCRIPTION
INDICATOR (ON}
@ HIGH TEMPERATURE Engine or exhaust system overheating
Check engine (minor fault req. maint.) or

CHECK ENGINE or LIMP
iBR system fault or
HOME MODE
LIMP HOME MODE (major eng. fault}
© LOW or HIGH BATIERY

VOLTAGE
Low/high battery voltage
LOW OIL PRESSURE Low engine oil pressure detected
8 iBR MODULE ERROR iBR system fault
RXT/GTX Series and Wake Pro

PILOT LAMPS
MESSAGE DISPLAY DESCRIPTION
(ON)
g
LOW or HIGH BATIERY
Low/high battery voltage
VOLTAGE
@ HIGH TEMPERATURE Engine or exhaust system overheating
©
CHECK ENGINE or LIMP Check engine (minor fault req. maint.) or
HOME MODE LIMP HOME MODE (major eng. fault)
@ LOW OIL PRESSURE Low oil pressure
8 - iBR system fault
8 - OTAS system fault
smr2011-023 217
FAULT MESSAGES
RIGHT KEYPAD ERROR Gauge control button malfunction
LOW OIL PRESSURE Engine low oil pressure detected
HIGH EXHAUST TEMPERATURE High exhaust temperature detected
HIGH TEMPERATURE High engine temperature detected
Engine management �y�tAm malfunction or

CHECK ENGINE
maintenance required
HIGH BATTERY VOLTAGE High battery voltage detected
LOW BATTERY VOLTAGE Low battery voltage detected
LIMP HOME MODE Major fault detected, engine power limited
FUEL SENSOR DEFECTIVE Fuel level sensor fault
WATER TEMP SENSOR DEFECTIVE Problem in iBR. not sending water temperature info
CALIBRATION CHECKSUM ERROR Information center programming corrupted
MAINTENANCE REQUIRED Watercraft maintenance required
SUPERCHARGER MAINTENANCE REQUIRED Maintenance on supercharger required
DEPTH SOUNDER MODULE COMMUNICATION Error message if depth sounder is disconnected while
PROBLEM riding
Error message if communication with the suspension

IS MODULE COMMUNICATION PROBLEM
module is lost while riding
Error message if communication with the iBR module

iBR MODULE ERROR
is lost while riding
Message when a function is not or cannot be properly

FUNCTION CANNOT BE ACTIVATED
activated
218 snv2011-023
Beeper Signals
When one of the below conditions occurs, the monitoring system emits the following beep signals.
BEEPER CODES DESCRIPTION
Bad D.E.S.S. sy stem connection.

Reinstall tether cord correctly over engine cut-off sw i tch .
Wrong D.E.S.S. key .

lJ�A A tAthAr r.ord with a D.E.S.S. key that has been programmed for the
watercraft.
1 long beep Defective D.E.S.S. key.

( while i nstalling D.E.S.S. Use another progra mm ed D.E.S.S. key.
key on engine cut-oft switch if ,
ECM is on) Dried salt water in D.E.S.S. key.
Clean D.E.S.S. key with fresh water to remove salt water.
Defective engine cut-off switch.

Check. Refer to DIGITALLY ENCODED SECURITY SYSTEM subsection.
Improper operation of ECM or defective wiring harness.

Check. Refer to ELECTRONIC FUEL INJECTION (EFI) subsection.
Watercraft is upside down.

Turn watercraft uprig ht.
TOPS switch is disconnected or defective. Refer to LUBRICATION
A 2 second beep every 15 minute
in terval subsect jon.
Engine management system fault.

Read the fault code.
Low fuel level.

Refill fuel tank. If problem persists, check sensor and circuit. Refer to FUEL
A 2 second beep every 5 minute TANK AND FUEL PUMP subsection.
interval Fuel tank level sensor or circuit malfunction.
Check sensor and circuit. Refer to FUEL TANK AND FUEL PUMP
subsection.
High engine temperature.

High exhaust temperature.

Continuously beeps Refer to ELECTRONIC FUEL INJECTION (EFI) subsection.
Low oil pressure.

Turn off engine as soon as possible. Check oil level and refill. Refer to
LUBRICATION subsection.
smr2011-023 219
FAULT CODES 3. Press the UP or DOWN arrow button repeat-

edly to display each subsequent code.
A fault code is an indication that a malfunction is
detected by the monitoring system of the vehicle. NOTE: When the last fault code has been dis
played and the button is pressed again, the sys
Fault Code Categories tem loops back to the first fault code displayed,
and all fault codes can again be displayed. If there
A fault code consists of an alphanumeric designa
was one active fault code when entering FAULT
tor followed by a hexadecimal number of 3 digits.
CODE mode, and it becomP.s occurred (no longer
Tt1e alµhanurneric designator defines the category
active), a NO ACTIVE FAULT CODE message will
of the fault code while the hexadecimal number
scroll in the display.
refers to a unique fault.
4. To exit the FAULT CODE display function, the
FAULT CODE CATEGORIES MODE or SET button must be pressed once.
EXAMPLE There is no time out on this function.
ALPHANUMERIC MODULE/
OF FAULT
DESIGNATOR SYSTEM
CODE
Body
(include
From BO to 83 82200
information center
and switch faults)
From CO to C3 i8R and iS C007B
Power train
and related
From PO to P3 P062F
system faults
(includes ECM)
Communication
From UO to U3 between modules U0073
and sensors smo2009-002 - 1 14 _w
FAULT CODE DISPLAY FUNCTION

RELATED MODULE AND FAULTS
FAULT CODE
MODULE
CATEGORY
ECM (en gine control Stores mainly "P" codes

module) and some "U" codes
iBR (intelligent brake Stores ma inly "C" codes

and reverse) and a few "U" codes
iS (intelligent Stores mainly "C" codes

suspension) and a few "U" codes
Stores mainly "C" codes

Cluster
and a few "U" codes
Reading Fault Codes Using the

Information Center
TYPICAL - ENGINE FAULT CODE EXAMPLE
NOTE: A fault code must have the "Active" state
to be displayed in the multifunction gauge. Reading Fault Codes Using 8.U.D.S.
1. Press the MODE button repeatedly until the Software
FAULT CODE function is visible in the multi NOTE: All fault code types can be read with
function display. B.U.D.S.
2. Press the SET button or the UP or DOWN arrow 1. Connect vehicle to the latest applicable
button to enter the function and display the first B.U.D.S. software. Refer to COMMUNICA
fault code. TION TOOLS AND B.U.D.S. subsection.
220 smr2011-023
2. Click on the Read Data button.

3. Click on the Faults tab.
- -
5 2
rmr2 0 11-071>-00 1_b
TYPICAL FAULT PAGE

�
1. Fault tab
2. Fault indicator light
3. Fault code state drop box
4. Fault nomenclature
5. More details button
6. Clear occurred faults button
' ""2011-070-0 11_•
7. Selected fault
TYPICAL 8. More information indicator
1. Fault tab
FAULT PAGE DESCRIPTION
4. Click on the drop-down l is t on the LH lower cor
ner. ITEM INFORMATION
5. Choose the fault state to display. Fault tab Click tab to display the fault page
Fault When flashing, it indicates there is
II
1 indicator light active fault(s)
Fault code
J state drop
Click drop box to select the type of
!Active Faults box
faults to display
All Faults
Display specific information and
F ault
Active and Occurred Faults statistics related to the fault (see
nomenclature
fault nomenclature table)
rm<2011-021-001_a
To display possible causes and
TYPICAL More details
1. Drop down list service actions related to the
button
selected fault
FAULT
INFORMATION Clear
STATE To clear all occurred faults in related
occurred
ECU(s)
Display all possible faults regardless faults button
All faults
of state
When a fault is selected. additional
Active Display only faults matching this state. information pertaining to that
faults Empty area if there is no active fault fault will be displayed when
Selected
clicking the "More details" button.
Display only faults fault
Active and To select a fault, click on the fault
that have either state.
occurred with the mouse or use the cursor up
Empty area if there is neither
faults or down to scroll to the desired fault
active nor occurred fault
smr2011-023 221
---
�-- I I I
��
-
FAULT NOMENCLATURE
, '°" I - f«;- I
�
COLUMN INFORMATION �A:l!I» � ��-iT•T-:f=-:=.�-r
�
Fault code number.
When 2 stars (**) precedes the
Code code, detailed conditions when the
1� _. !
fault occurred, can be displayed by
clicking the 'More details' button
Display the fault state (active, occurred,

State
inactive) p:;;:,
.. 3
I ., I -a- �11
Displays the module that ""'2011-021.()50_.
reports the fault code. TYPICAL

1. Click here
This is the module that detects
or has received a message
of an anomaly and reports it. I I I ·- I
Module
List of modules:
Multifunction gaugeECM
§)t3 .._...
I-I
(CM
�-; �. �
-y 1 HY
· ,,__
,,,......,....._.....,
(engine control module) ...

_ .
iBR (intelligent brake and reverse) I .-
�4RA4 ' ...
--�-"""
!• .....
..... � -.ea�·
_...,
_,. ., ,
_,._ ·_,, ,.... ,, ,...; ,..;--"--.,,
1"rt> o•
iS (intelligent suspension) ...... " ll
ff:Ml'J
) v
Number of times this fault
Count occurred within the driving cycle
Value: From 0 to 255
Not to be used
Cycle time
Value: From O to 255 minutes rm,2011-0
7 0-002_•
TYPICAL - MORE DETAILS PAGE

Not to be used 1. Possible causes related to the selected fault
Total time
Value: From 0 to 64 255 minutes 2. Service acto
i ns
3. Operating conditions when fault occurred
Description Provides a short description of the fault
MORE DETAILS PAGE DESCRIPTION
When reading a fault code in B.U.D.S., pay partic ITEM INFORMATION
ular attention to which module reports a fault. It
is indicated in the Module column. Possible List the possible causes that
causes triggered the fault
The Description column gives a short description
of the fault. SeNice List the possible actions to perform
actions to solve the fault
1 2 Conditions List the operating conditions of the
I !
when fault engine and/or vehicle when the fault
occurred was triggered
Summary , r- 1
-dI Oes-i-
-- ,... ___
Fault Code States

Code
The various electronic control units {EC Us) used in
the vehicle can generate a variety of fault codes
depending on the level of monitoring they are ca
pable of. Fault codes have 3 possible states:
- Active
- Occurred
mv201 l--0'21.()02J - Inactive.
SOME COLUMNS REMOVED FOR CLARITY PURPOSE Click the Fault tab then click on the drop-down list
1. Module that reports a faulr
2 Fault description on the LH lower corner.
Choose the fault code state you want to display.
Click on the More Details button, on the RH lower
corner. to display the "Possible Causes" and the
"Service Actions" to step further in the diagnosis.
222 smt2011-023
II
1 Click on the Faults tab.
NOTE: Only the Occurred state faults can be
cleared.
jActive Faults
Click the "Clear Occurred Faults" button.
All Faults
mY20 11-021-001_ .
Clear Qocured Faults
TYPICAL
1. Drop down list
r mr.1008-039-00 9
FAULT
INFORMATION CLEAR OCCURED FAULTS
STATE
Display all possible faults regardless of This will reset the appropriate counter(s) and will
All faults
state also record that the problem has been fixed in the
related module memory.
Active Display only faults matching this state.
faults Empty area if there is no active fault Observe the "Occurred" fault(s). They should all
disappear. Otherwise, follow this procedure.
Active
Display only faults that have either state. - Remove tether cord cap from engine cut-off
and
Empty area if there is neither active nor switch.
occurred
occurred fault
faults - Wait 3 minutes.
- Repeat procedure to clear faults again.
Active Fault Codes
An active fault code is an indication of a fault that FAULT CODE DIAGNOSTIC
is currently triggered.
Missing Module
The active fault may or may not compromise nor
mal operation of the related system(s). Service If a module is missing, several fault codes will ap
action in B.U.D.S. should be used to correct the pear.
problem that caused the fault code. To quickly find which module is missing, perform
Once the fault condition(s) of the active fault is no the following:
longer present, its state will change to "occurred". 1. Connect vehicle to the latest applicable
B.U.D.S. software. Refer to COMMUNICA
Occurred Fault Codes
TION TOOLS AND B. U.D.S. subsection.
An occurred fault code indicates a fault that was
2. Click on the Read Data button.
active, but n o longer is.
3. Click Module in the menu bar.
The occurred fault does not presently affect sys
tem or component operation but is retained as a 4. Look at the list of modules.
history of the faults that were detected. 5. If a module is not visible, then it is not commu
nicating through the CAN bus (controller area
Inactive Fault Codes
network).
An inactive fault code represents a fault code that
is neither active, nor occurred. It is simply part of a
list of all possible faults which may be monitored
by the various ECUs, which may become active
or occurred if the monitoring system detects an
applicable fault.
How to Clear Fault Codes Using

B.U.D.S.
Connect vehicle to the latest applicable B.U.D.S.
software. Refer to COMMUNICATION TOOLS
AND 8.U.D.S. subsection.
Click on the Read Data button.
smr2011·023 223
S ub s ecti on 05 (DIAGNOSTIC AND FAULT CODES}
Eile �ew Ml:l® tlelp
Quster .,
lBR
Read Data
cm12011-023-001_a
1. Hist ory tab

2. Additional history pages
•m'201().()30-001 3. Drop-down list in Last Minute page
TYPICAL - MODULE SUBMENU LIST (MODELS WITH iBR
AND iS) Last Minute Drop-Down List:
From the Last Minute page, click on the drop
6. Refer to the following table to find the appropri
down list on the LH lower corner.
ate subsection in this manual to diagnose the
missing module. Choose the values to display.
MISSING
SECTION TO REFER TO '2 ouu ::::\e.i::tt.: :::::::::::�:::::::::::1::
........
MODULE I t
I I
1 500 -.... -.. - : ................ - .. ! - .. - - .. .. .. ... � ..

ELECTRONIC FUEL INJECTION (EFI)
- ..
ECM
Cl u ster GAUGE
iBR 1BRAND VTS RPM & Engine Temperature
RPM & Intake Pressure
iS SUSPENSION (IS)
RPM & Throttle Accelerator Sensor
RPM & Present Torque -45
Diagnostic lips Using B.U.D.S.
History Page
L ast Minute Histo Table
---�- 1
HISTORY PAGE DESCRIPTION
a m r 20 1 1-¢23.002
.•
ITEM INFORMATION 1. Drop down list
Last Displays several parameters recorded

minute in the last minute of engine operation
Display the minimum and

Minimum/ maximum values encountered.
Maximum Click ·c1ear Min/Max• to reset the
values
Display the time proportion in what

R un ti me
mode the engine was running in
RPM Display the RPM range proportion in

profile which the engine was running in
To see the last minute of operating conditions,

click on the History tab in B.U.D.S.
224 smr2011-023
Guidelines to Solve Fault Codes
CONDITION ACTION
Use B.U.D.S. to:

Read fault codes.
Display "Active' faults to see components currently not operating normally.
Display "Occurred" faults to troubleshoot intermittent problems.
Monitor system(s), sensor(s), switches and actual conditions.
Troubleshooting vehicle
Activate component(s) for troubleshooting.
Set components etc.
Know the last minute of operating conditions by using the "History" page.
Know the operating conditions, if available, when a fault code occurred by
using the "More details' button in the fault page.
Check sensor connections or mixed up connections.
Before vehicle maintenance:

Read the electronic modules with 8.U.D.S.
Save and print the B.U.D.S. file (keep faults option only).
New fault(s) appear after a vehicle
maintenance or repair After vehicle maintenance:
Read the electronic modules with 8.U.D.S.
Compare the fault code(s) before and after the maintenance
using the printed copy and the current B.U.D.S. reading.
Investigate only the newly fault codes.
Clear all occurred faults in B.U.D.S.
Communication faults displayed as Normal behavior when flashing a module.

"Occurred" after module flashing Clear all occurred faults and check again.
Read the fault description in B.U.D.S.

Click on the "More Details" button.
Sensor 'Active" fault Look at the "Conditions" when available.
Read the "Possible Causes".
Apply the "Service Actions".
Several fault codes active at the

Likely to be caused by burnt fuse(s) or bad bus bar connection(s).
same time
Check related fuse(s) and relay.

Check related power and ground wires.
Low system voltage
Check for common power supply to several sensors/modules
on one module
(refer to POWER DISTRIBUTION AND GROUNDS).
Power problem on sensor(s)
NOTE: Some sensors are supplied by the battery while others are
supplied by a module.
Low system voltage

Check battery condition and connections.
on several modules
(several communication faults
Check voltage regulator/rectifier.
will also appear)
A battery charger has likely been used to substitute the vehicle battery.
High system voltage on several
Clear all occurred faults and check again.
modules
Check voltage regulator/rectifier.
Check the module that is reported as missing.

When all modules report that a
module is missing
Check related power and ground wires.
When several modules are in fault Search for a common problem such as a faulty sensor.
smr201 1-023 225

CONDITION ACTION
When several modules and sensors report that a module is missing.

The missing module may report CAN bus failure. CAN bus off.
Check related CAN wires (continuity, short to
CAN bus failure, CAN buss OFF
ground, short between CAN low and high).
Check module pins and wiring terminals.
Then, the other modules should stop reporting that module is missing.
May have been generated due to a system or component that was

momentarily operating outside normal parameters.
May be generated when disconnecting and reconnecting a component,

replacing a burnt fuse, or may be due to a momentary high or low voltage.
Before being "Occurred", a fault has always been "Active'

Occurred fault(s) for a certain time, indicating that an unexpected condition
or problem has been present during the driving cycle.
A frequent momentarily fault or an intermittent fault may never
be seen as "Active· in B.U.D.S. while there is still a pending problem.
This type of malfunctions can be discovered by looking at
the "Occurred" faults and then by evaluating the fault count.
As long as a fault is present. it is displayed as 'Active'.
Low value: Suggests handling problems

Fault count (connections, terminal contact/shape etc.).
(0 - 255) High value: Suggests a frequent and unsolved problem.
The problem should be investigated.
Fault conditions
Look for abnormal, excessive values.
(More details button)
When the basic troubleshooting has been done and the fault
code(s) persists. often the problem is related to the wiring
harness, connections or electromechanical components.
Hard to find problems Short to ground. to battery or between wires.
Wire splices, chafing, terminal problems
(pulled out, bent, out of shape, corroded etc.).
Bad contacts in switch or relay.
226 smt2011-023
GUIDELINES TO SOLVE SPECIFIC BATTERY VOLTAGE ENGINE SPEED

FAULT CODES Lower than 6.5 Vdc Lower than 1280 RPM
Lower than 11 .8 Vdc Greater than 1280 RPM
Several Fault Codes Are Active
Simultaneously
Fault Code P0563
If this occurs, check the following:
Battery voltage too high. It occurs when battery
- Check the 30 A fuses in fuse box.
voltage is above 16 Vdc when engine is running.
- Check the bus bar condition and connections in
Refer to (,nARGING SYSTEIV!
the fuse box{es).
- Check the diagnostic connector for the pres Fault Code U016A
ence of water or corrosion.
Loss of vehicle speed. This fault may occasion
- Check the CAN wires.
ally appear as occurred. Normal operation is not
affected. If the count is high, check the related
Fault Code C2121, C2221 components.
iBR or iS application parameters corrupted
(backup no. 1 or no. 2). This fault may occa Fault Code U0129
sionally appear as occurred. It happens when CAN communication error between iS and iBR
power to the module is shut off before the mod modules or iBR CAN message time-out or va
ule has time to complete its shutdown. Normal lidity. This fault may occasionally appear as oc
operation is not affected. If it occurs often, check
curred. Normal operation is not affected. If the
supply voltage to module. count is high, check the related components. En
sure connector is plugged.
Fault Code C2122, C2222
iBR or iS last session interrupted. This fault may Fault Code U0300
occasionally appear as occurred. It occurs when
Incorrect ECM or information center for the en
power to the module is shut off before the mod gine. Installed part is not appropriate for the vehi
ule has time to complete its shutdown. Normal cle. Using BUDS, check if the security coding of
operation is not affected. If it occurs often, check the cluster is matched with the ECM security cod
supply voltage to module. ing. Engine will crank but will not start. Refer
to PARTS CA?ALOGSfor proper part according to
Fault Code C2150, C2233, C2250
vehicle.
iBR or iS motor or system current software
breaker. Motor or module current too high. This Fault Code U16A1, U16A2, U16A3,
fault may occasionally appear as occurred. Nor U16A4,U16A5
mal operation is not affected. If it the count is
Cluster or iBR CAN time-out error-missing CAN
high, check the moving mechanism of the system
ID xxxh. This fault may occasionally appear as oc
if it is stiffer than normal to operate.
curred. Normal operation is not affected. If the
count is high, check the related components.
Fault Code C2232
Motor open. If suspension operates when using Fault Code U0401, U0457
the iS Up/Down switches, the suspension will op
ECM or cluster CAN message time-out or va
erate normally when riding even if this fault is ac
lidity. This fault may occasionally appear as oc
tive. In this case, the fault can be ignored. The
curred. Normal operation is not affected. If it the
fault will be set to "occurred" when the iS module
count is high, check the related components.
will be shut down. If the suspension does not op
erate when using the iS Up/Down switches, refer
to SUSPENSION (IS) subsection.
Fault Code P0562

Battery voltage too low. It occurs when both
battery voltage and engine RPM conditions are
met. See following chart. Refer to CHARGING
SYSTEM subsection.
smr2011-023 227
FAULT CODE TABLE

NOTE: Always refer to the fault code list available in the latest applicable version of B.U.D.S. software.
When using the service action suggested in the Fault section of B.U.D.S., t he system circuits are referred
as A-M4 for instance. It means ECM connector "A" and the circuit wire M4 as found in the WIRING
DIAGRAM
FAULT REPORTING
DESCRIPTION POSSIBLE CAUSE SERVICE ACTION
CODE MODULE
82210 CLUSTER Left keypad fault Problem with left The switch may be defective,
(Switch kept activated keypad. verify the functionnality of
more than 60 seconds) the switch or the wires.
Refer to the shop manual for
switch diagnosis/testing procedure.
82211 CLUSTER Suspension UP/DOWN Problem with left Look for pin 8 if shorted to ground
switches shorted to keypad. or pin C .
ground fault
82212 CLUST ER Suspension UP/DOWN Problem with left Look for pin 8 if disconnected to
switches disconnected keypad. pin 14 on the cluster. Look for pin
fault C if disconnected to pin 15 on the
cluster.
B2213 CLUSTER VTS UP/DOWN Problem with left Look for pin A if shorted to ground
switches shorted to keypad. or pin C.
ground fault
82214 CLUSTER VTS UP/DOWN Problem with left Look for pin A if disconnected to
switches disconnected keypad. pin 13 on the cluster. Look for pin
fault C if disconnected to pin 15 on the
cluster.
82220 CLUSTER Right keypad fault Problem with right The switch may be defective, verify
(Switch kept activated keypad. the functionnality of the switch
more than 60 seconds) or the wires. Refer to the shop
manual for switch diagnosis/testing
procedure.
82221 CLUSTER MODE/SET switches Problem with right Look for pin 8 if shorted to ground
shorted to ground fault keypad. or pin C.
82222 CLUSTER MODE/SET switches Problem with right Look for pin 8 if disconnected to
disconnected fault keypad. pin 17 on the cluster. Look for pin
C if disconnected to pin 18 on the
cluster.
82223 CLUSTER UP/DOWN switches Problem with right Look for pin A if shorted to ground
shorted to ground fault keypad. or pin C.
82224 CLUSTER UP/DOWN switches Problem with right Look for pin A if disconnected
disconnected fault keypad. to pin 16 on the cluster.
Look for pin C if disconnected
to pin 18 on the cluster.
C0042 i8R Brake Lever Sensor Damaged sensor, Check for 0.5 to 3 V on pin F and
(8RLS) signals A damaged circuit wires, 0.25 to 1.5 on pin C.
open/shorted to ground damaged connector
or damaged iBR pins.
Fault detected when
the engine is running or
stopped.
228 smr201 1-023

FAU LT REPORTING
CODE MODULE
C0043 iBR Brake Lever Sensor Damaged sensor, Check for 0.5 to 3 V on pin F and
(BRLS) signals B damaged circuit wires. 0.25 to 1.5 on pin C.
open/shorted to ground damaged connector
Fault detected when
stopped.
C0073 iBR Torque request failure ECM software failure. Perform ECM software update
CPS wires shorted. if available or replace ECM.
Verify CPS connection.
C2100 iBR Sensors caliBRation is Incompatible firmware Replace iBR unit.

corrupted or memory failure. Refer to the Service Manual
for more details.
C2100 iBR Actuator movement The reverse gate cannot Clean and check for damage in
move to the desired the reverse gate and nozzle area.
position. Refer to the Service Manual for
more details.
C2101 iBR Actuator movement The reverse gate cannot Clean and check for damage in
warning move to the desired the reverse gate and nozzle area.
position within expected Refer to the Service Manual for
time. more details.
C2110 iBR Reverse gate position iBR malfunction. Replace iBR unit.
sensor error Refer to the Service Manual
for more details.
C2110 iBR Angle position sensor iBR malfunction. Replace iBR unit.
warning Refer to the Service Manual
for more details.
C2110 iBR iBR overheat iBR cooling Check iBR cooling circuit.
system failure. Replace iBR unit.
iBR unit failure. Refer to the Service Manual
for more details.
C2110 iBR Monitoring CPU iBR malfunction. Perform an iBR software

message timeout or update if available.
validity Replace the iBR unit.
Refer to the Service Manual
for more details.
C2110 iBR Monitoring CPU limp iBR malfunction. Perform an iBR software
force update if available.
Replace the iBR unit.
for more details.
C2111 iBR ECM erratic RPM signal RPM signal received Check CPS sensor connection
from engine ECM not
plausible.
C2120 iBR Application calibration Incompatible firmware Perform an iBR software

is corrupted or memory failure. update if available.
Replace the iBR unit.
tor more details.
smr2011-023 229
FAULT REPORTING
CODE MODULE
C2121 iBR Application parameters Battery power lost or Perform an electrical system
corrupted (backup #1 memory failure. shut downlaod to clear
or #2) fault. Verify starting and
charging system circuits.
for more details.
C2122 iBR Last session Unexpected battery Perform an electrical system shut
interrupted power lost. down and clear fault. Verify starting
and charging system circuits.
Refer to the Service Manual for
more details.
C2130 iBR Motor current software Motor current too high. Clean and check for damage in
breaker the reverse gate and nozzle area.
more details.
C2130 iBR Internal motor drive Motor voltage feedback

failure not fitting with the
command.
C2131 iBR iBR DC motor shorted iBR motor failure. Check iBR circuit A and B.
to ground or 12 V iBR motor wires Refer to th e Service Manual for
dammaged. more details.
C2132 iBR Motor Open No current while

activated.
C2142 iBR Brake Lever Sensor Damaged sensor. Check for 0.5 to 3 V on pin F and
(BRLSl signals A damaged circuit wires, 0.25 to 1.5 on pin C.
shorted to battery damaged connector
Fault detected when
stopped.
C2143 iBR Brake Lever Sensor Damaged sensor. Check for 0.5 to 3 V on pin F and
(BRLS) signals B damaged circuit wires. 0.25 to 1.5 on pin C.
shorted to battery damaged connector
Fault detected when
stopped.
C2144 iBR Brake Lever Sensor Damaged sensor, Check for 4.5 to 5 volts on
(BRLSl power shorted damaged circuit wires, sensor connector pin A & D.
to battery damaged connector Refer to the Service Manual for
or damaged iBR pins. more details.
Fault detected when
stopped.
C2145 iBR Brake Lever Sensor Damaged sensor, Check for 4.5 to 5 volts on
(BRLS) power shorted damaged circuit wires. sensor connector pin A & D.
to ground damaged connector Refer to the Service Manual for
or damaged iBR pins. more details.
Fault detected when
stopped.
230 smr201 l.023

FAULT REPORTING
CODE MODULE
C2146 iBR Brake Lever Sensor Damaged sensor, Check for 0.5 to 3 V on pin F and
(BRLS) signals A/B damaged circuit wires, 0.25 to 1 .5 on pin C.
reading difference damaged connector
Fault detected when
the enQine is runninQ or
stopped.
C2150 iBR System current iBR input current too Clean and check for damage in
software breaker high. the reverse gate and nozzle area.
more details.
C2151 iBR System disabled and System is locked. Need Use B.U.D.S. iBR unlock function.
need activation activation. Refer to the Service Manual for
more details.
C2155 iBR Water temperature iBR cooling Check iBR cooling circuit.
sensor overheat system failure. Replace iBR unit.
iBR unit failure. Refer to the Service Manual
for more details.
C2161 iBR Low voltage detected Battery failure, rectifier Check fuses #6 (refer
failure, damaged to WIRING DIAGRAM).
circuit wires, battery Check ground continuity
terminal connection, to the engine block.
damaged AC generator Refer to the Service Manual
or damaged connectors. for more details.
C2200 iS Sensors calibration is Incompatible firmware Defective iS module, replace

corrupted or memory failure module and return to supplier.
(Internal memory failure,
return to supplier).
C2210 iS Bridge/CPU Hardware failure or Check for over utilization/heat.

temperature sensor external heat source.
overheat
C2220 iS Application calibration Incompatible firmware Program calibration with B.U.D.S.

is corrupted or memory failure
(8.U.D.S. should repair
that).
C2221 iS Application parameters Battery power lost or Check power wiring and fuse.
corrupted (backup #1 memory failure (Reset
or #2) after power-down-up,
clear fault. If happens
often, verify supply
voltage).
C2222 iS Last session Unexpected battery Check power wiring and fuse.
interrupted power lost.
C2230 iS Internal motor drive Motor voltage feedback Defective iS module, replace
failure not fitting with the module and return to supplier.
command.
C2231 iS Motor shorted to Current leak detected Check suspension actuator pump
ground/battery when the bridge is off. wiring.
C2232 iS Motor open No current while Check suspension actuator pump

activated. and/or wiring.
smr201l-023 231
FAULT REPORTING
CODE MODULE
C2233 iS Motor current software Motor current too high. Check suspension actuator pump.
breaker
C2240 iS Seat position sensor Sensor not connected. Check system circuit at iS module.
error Open, Shorted to (refer to WIRING DIAGRAM).
Gnd
C2250 iS System current Battery input current too Check suspension actuator pump.
software breaker high.
C2251 iS System disabled and System is locked for Activate iS using B.U.D.S. activation
need activation safety. Need activation. function.
C2252 iS TOPS active Warning only: TOPS Refer to the Service Manual for
detected by the system, more details.
the suspension is
disable while the TOPS
is "ON'.
C2260 iS System under voltage System under voltage Check battery and charging system.
warning.
P0008 ECM Engine phase detection

fault
P0030 ECM Heater Power Stage

fault for lambda sensor
upstreams of catalyst

upstreams of catalyst -
short circuit to GND

short circuit to V+

downstreams of
catalyst

downstreams of
catalyst - short circuit
to GND

downstreams of
to V+
232 smr2011-023
FAULT REPORTING
CODE MODULE
P0106 ECM Intake pressure sensor Sensing port Check system circuits
out of range dirty or blocked. A-84, A-G4. A-H2.
Sensor failure Make sure that the sensor housing is
or unexpected correctly inserted into the manifold.
reading at idle. Check sensor connector for:
Sensor fallen out of a) 5 volts on pin 1.
housing or leaking inlet. b) 0 volt on pin 2.
c) 0 volt on pin 3.
for more details.
P0107 ECM Manifold absolute Sensing port Check system circuits

pressure sensor dirty or blocked. A-84, A-G4, A-H2.
shorted to ground Sensor failure Make sure that the sensor housing is
or not connected. or unexpected correctly inserted into the manifold.
housing or leaking inlet. b) O volt on pin 2.
Connector c) 0 volt on pin 3.
disconnected. Refer to the Service Manual
for more details.
P0108 ECM Manifold absolute Sensing port Check system circuits

pressure sensor open dirty or blocked. A-84, A-G4, A-H2.
circuit or shorted to Sensor failure Make sure that the sensor housing is
battery or unexpected correctly inserted into the manifold.
housing or leaking inlet. b) O volt on pin 2.
c) 0 volt on pin 3.
for more details.
P0112 ECM Intake manifold Damaged sensor, Check the sensor for approximately
temperature sensor damaged circuit wires. 2280 to 2736 ohms at
shorted to ground damaged connector or 19 to 21 C (66 to 70°F).
°
damaged ECM pins. Check for approximately 2280

to 2736 ohms at 19 to 21°C
(66 to 70°F) between ECM
connector pins A-H3 and A-J3.
more details.
P0113 ECM Intake manifold Damaged sensor, Check the sensor for approximately
temperature sensor damaged circuit wires, 2280 to 2736 ohms at
open circuit or shorted damaged connector or 19 to 21°C (66 to 70°F).
to battery damaged ECM pins. Check for approximately 2280
connector pins A-H3 and A-J3.
more details.
smr2011-023 233
FAULT REPORTING
CODE MODULE
P0116 ECM Engine coolant Damaged sensor, Check for debris or

temperature signal damaged circuit wires, blockage in cooling system.
not plausible damaged connector or Check the sensor for approximately
damaged ECM pins. 2280 to 2736 ohms at
19 to 21°C (66 to 70°F).
Check for rinnroximately 2280
connector pins A-A1 and A-J2.
more details.
P0117 ECM Engine coolant Damaged sensor, Check for debris or

temperature sensor damaged circuit wires, blockage in cooling system.
fault - Short circuit to damaged connector or Check the sensor for approximately
GND damaged ECM pins. 2280 to 2736 ohms at
19 to 21°C (66 to 70°F).
Check for approximately 2280
connector pins A-A 1 and A-J2.
more details.
P0118 ECM Engine coolant Engine overheated Check for debris or

temperature sensor or damaged blockage in cooling system.
fault - Short circuit sensor. Connector Check the sensor for approximately
to V+ or connector disconnected. 2280 to 2736 ohms at
disconnected. 19 to 21°C (66 to 70°F).
connector pins A-A1 and A-J2.
more details.
P0122 ECM TAS (Throttle Damaged sensor, Check system circuits

Accelerator sensor) damaged circuit wires, B-E1, B-K1, B-K3.
1 fault (short circuit to damaged connector or Check for 0 volt on
GND) damaged ECM pins. sensor connector pin E.
Check for 5 volts on
sensor connector pin D.
Check for 0.5 to 3 volts
on sensor connector pin F.
more details.
P0123 ECM TAS (Throttle Damaged sensor. Check system circuits

Accelerator sensor) damaged circuit wires. B-E1. B-K1. B-K3.
battery) damaged ECM pins. sensor connector pin E.
sensor connector pin D.
Check for 0.5 to 3 volts
on sensor connector pin F.
more details.
234 smr2011-023
FAULT REPORTING
CODE MODULE
P0127 ECM lntercooler system High air intake Clean intercooler

fault temperature detected. water circuit system.
Fault detected Refer to the Service Manual
when the engine is for more details.
running and stopped.
Blocked intercooler
water circuit.
P0130 ECM Lambda Sensor fault

signal not plausible

short circuit to GND

short circuit to V+
P0133 ECM Oxygen sensor

reacts too slow ->
contaminated
P0134 ECM Oxygen sensor

reacts too slow ->
defective
P0135 ECM Lambda Sensor heating

fault upstreams of
catalyst

downstream of catalyst
- signal not plausible

- short circuit to GND

downstreams of
to V+
P0141 ECM Lambda Sensor heating

fault downstreams of
catalyst
P0171 ECM Multiplicative mixture

adaptation exeeds
upper limit-> mixture
too lean
P0172 ECM Multiplicative mixture

adaptation below lower
limit-> mixture too rich
smf201i-023 235
FAULT REPORTING
CODE MODULE
P0201 ECM Injection Power Damaged injector, Check for 11.4 to 12.6 ohms
Stage fault - open damaged circuit between engine connector pin 2
line/Cylinder 1 wires, damaged and ECM connector pin A-83.
connector or damaged Check for 12 volts on pin
ECM output pins. 2 of injector connector.
Check fuse #13 (refer
to WIRING DIAGRAM).
Check for damaged circuit wires.
more details.
line/Cylinder 2 wires, damaged and ECM connector pin A-K1.
to WIRING DIAGRAM).
Check for damaged circuit wires
more details.
line/Cylinder 3 wires, damaged and ECM connector pin A-J1.
to WIRING DIAGRAM).
. Check for damaged circuit wires.
more details.
P0217 ECM High engine coolant High engine coolant Check for debris or
temperature detected temperature detected. blockage in cooling system.
Check the sensor for approximately
2280 to 2736 ohms at
19 to 21°C (66 to 70°F).
connector pins A-A 1 and A-J2.
more details.
P0222 ECM TAS (Throttle Damaged sensor, Check system circuits

Accelerator sensor) damaged circuit wires. B-A3, 8-83, 8-J3.
GND) damaged ECM pins. sensor connector pin B.
sensor connector pin A.
Check for 0.25 to 1.6 volts
on sensor connector pin C.
more details.
236 smr2011-023
FAULT REPORTING
CODE MODULE
P0223 ECM TAS (Throttle Damaged sensor. Check system circuits

Accelerator sensor) damaged circuit wires, 8-A3, 8-83, B-J3.
battery) damaged ECM pins. sensor connector pin 8.
sensor connector pin A.
Check for 0.25 to 1.5 volts
on sensor connector pin C .
more details.
P0231 ECM Fuel pump open circuit Damaged pump, Check for approximately 1
or short to ground damaged circuit ohm between pins A and 8
wires, damaged of the fuel pump connector.
connector or damaged Check fuse # 1 8 {refer
ECM output pins. to WIRING DIAGRAM).
Check for damaged
connector. damaged ECM
output pins or ECM failure.
more details.
P0232 ECM Fuel pump short circuit Damaged pump, Check for approximately 1
to battery damaged circuit ohm between pins A and 8
wires. damaged of the fuel pump connector.
connector or damaged Check fuse #18 (refer
ECM output pins. to WIRING DIAGRAM).
Check for damaged
connector, damaged ECM
output pins or ECM failure.
more details.
P0261 ECM Injector 1 open circuit Damaged injector. Check for 1 1 .4 to 12.6 ohms
or shorted to ground damaged circuit between engine connector pin 1
wires, damaged and ECM connector pin A-83.
connector or damaged Check for 1 2 volts on pin
Check fuse # 1 3 (refer
to WIRING DIAGRAM).
more details.
P0262 ECM Injector 1 shorted to Damaged injector, Check for 11.4 to 12.6 ohms
battery damaged circuit between engine connector pin 1
wires, damaged and ECM connector pin A-83.
to WIRING DIAGRAM).
more details.
smr2011-023 237
FAULT REPORTING
CODE MODULE
P0264 ECM Injector 2 open circuit Damaged injector, Check for 11.4 to 12.6 ohms
wires, damaged and ECM connector pin A-K1.
to WIRING DIAGRAM).
more details.
P0265 ECM Injector 2 shorted to Damaged injector. Check for 11.4 to 12.6 ohms
wires, damaged and ECM connector pin A-K1.
to WIRING DIAGRAM).
more details.
P0267 ECM Injector 3 open circuit Damaged injector, Check for 11.4 to 12.6 ohms
wires, damaged and ECM connector pin A-J1.
to WIRING DIAGRAM).
more details.
P0268 ECM Injector 3 shorted to Damaged injector, Check for 11.4 to 12.6 ohms
wires, damaged and ECM connector pin A-J1.
to WIRING DIAGRAM).
more details.
P0300 ECM Multiple misfire

detected
P0301 ECM Misfire cylinder 2

(physical cylinder 1l

(physical cylinder 2)

(physical cylinder 3)
238 smr2011-023
FAULT REPORTING
CODE MODULE
P0325 ECM Knock sensor 1 fault Damaged sensor. Bring engine to 5000 RPM. If
damaged circuit fault code appears then check for
wires, damaged approximately 5 Mohms between
connector or damaged system circuits A-C3 and A-G2.
ECM output pins. Refer to the Service Manual for
Open circuit. more details.
P0330 ECM Knock sensor 2 fault
P0335 ECM Crankshaft signal error Damaged sensor, For the CPS, check for 700 to
damaged circuit wires, 900 ohms between terminals
damaged connector, A-H1 and A-K2 of ECM connector.
damaged ECM pins or Refer to the Service Manual for
damaged tooth wheel. more details.
Connector
disconnected.
P0340 ECM Camshaft 1 signal error Damaged sensor, For the CAPS, check for 12
damaged circuit wires, volts on sensor connector pin 3.
damaged connector. Check continuity for circuits
damaged ECM pins or A-D4, A-E2 and terminal
damaged tooth wheel. 4 on engine connector.
Connector Check fuse #12 (refer
disconnected. to WIRING DIAGRAM).
Engine must run to
erase the corrected fault.
for more details.
P0351 ECM Ignition coil 1 open Damaged coil, damaged Check for 0.85 to 1.15 ohms
circuit or shorted to circuit wires, damaged between engine connector pin 1
ground or to battery connector or damaged and ECM connector pin A-M4.
ECM output pins. Check for 12 volts on
pin 2 of coil connector.
to WIRING DIAGRAM).
for more details.
P0352 ECM Ignition coil 2 open Damaged coil, damaged Check for 0.85 to 1.15 ohms
to WIRING DIAGRAM).
for more details.
P0353 ECM Ignition coil 3 open Damaged coil. damaged Check for 0.85 to 1.15 ohms
to WIRING DIAGRAM).
for more details.
smr2011-023 239
Subsection 05 (DIAGNOSTIC AND FAULT CODES}
FAULT REPORTING
CODE MODULE
P0354 ECM Ignition Power Stage Damaged coil, damaged Check for 0.85 to 1.15 ohms
fault - short circuit to circuit wires, damaged between engine connector pin 1
GND/Cylinder 1 connector or damaged and ECM connector pin A-M4.
ECM output pins. Check for 1 2 volts on
Check fuse 1t13 (refer
to WIRING DIAGRAM).
Refer to the SeNice Manual
for more details.
P0355 ECM Ignition Power Stage Damaged coil, damaged Check for 0.85 to 1 .15 ohms
fault - short circuit to circuit wires. damaged between engine connector pin 1
ECM output pins. Check for 1 2 volts on
to WIRING DIAGRAM).
Refer to the SeNice Manual
for more details.
to WIRING DIAGRAM).
for more details.
V +/Cylinder 1 connector or damaged and ECM connector pin A-M4.
to WIRING DIAGRAM).
for more details.
V+/Cylinder 2 connector or damaged and ECM connector pin A-M2.
to WIRING DIAGRAM).
for more details.
V+/Cylinder 3 connector or damaged and ECM connector pin A-M1.
to WIRING DIAGRAM).
for more details.
240 smr2011·023
FAULT REPORTING
CODE MODULE
P0360 ECM Ignition Power stage Signal not plausible, Check for 0.85 to 1.15 ohms
max error & false verify battery voltage between engine connector pin 1
detection of low battery too low during ignition. and ECM connector pin A-M4.
voltage/Cylinder 1 Check for 12 volts on
to WIRING DIAGRAM).
for more details.
to WIRING DIAGRAM).
for more details.
to WIRING DIAGRAM).
for more details.
P0365 ECM Camshaft 2 signal error
P0420 ECM Catalyst conversion

insufficient
P0500 ECM Vehicle speed signal Cluster fault Check C.A.N. circuits wires.
fault detected by ECM Replace instrument Cluster.
C.A.N. circuit failure, Verify outside of the building if
Instrument cluster or the GPS LED becomes active
ECM failure after 1 minute and stays steady
more details.
P0501 ECM Vehicle speed not Cluster or iBR fault Check C.A.N. circuits wires.
plausible detected by ECM. Replace instrument Cluster.
C.A.N. circuit failure. Verify outside of the building if
Instrument cluster, iBR the GPS LED becomes active
or ECM failure. after 1 minute and stays steady
more details.
P0504 ECM Brake signal not iBR fault detected Check C.A.N. circuits wires.
plausible by ECM. Replace iBR.
C.A.N. circuit failure, Refer to the Service Manual
ECM software failure. for more details.
P0512 ECM Starter power stage Damaged solenoid, Verify fuse #16 (5AMP).
detects high current damaged circuit wires, Check for 12 volts on
damaged connector or pin 2 of the starter relay.
damaged ECM. Refer to the Service Manual
for more details.
smt2011-023 241
Subsection 05 {DIAGNOSTIC AND FAULT CODES)
FAULT REPORTING
CODE MODULE
P0513 ECM Invalid D.E.S.S. Key Key not programmed in Program a good key.
detected ECU.
P0520 ECM Oil pressure switch Engine leak, oil pump Check resistance at 0 RPM
functional problem failure, damaged sensor, and above 3500 RPM.
damaged circuit wires, Switch is normally closP.rl.
damaged connector or ECM connector pin A-E3
damaged ECM pins. When blow-by pressure
exceeds 40 kPa (6 PSI), the
resistance is infinitely high.
more details.
P0523 ECM Oil pressure sensor Engine leak, oil pump Check resistance at 0 RPM
fault failure, damaged sensor, and above 3500 RPM.
damaged circuit wires, When blow-by pressure
damaged connector or exceeds 40 kPa (6 PSI), the
damaged ECM pins. resistance is infinitely high.
Fault detected when Refer to the Service Manual for
the engine is running or more details.
stopped.
P0524 ECM Low oil pressure Low oil level, engine Check oil level.
condition leak, oil pump fault. Check impedance of sensor.
more details.
P0544 ECM Exhaust gas Damaged sensor, Check for approximately 2280
temperature sensor damaged circuit to 2736 ohms at temperature of
functional problem wires, damaged 19 to 21°C (66 to 70°F) between
connector or damaged system circuits A-H4 and A-J4.
more details.
shorted to ground wires, damaged 19 to 21°C (66 to 70°F) between
more details.
open circuit or shorted wires, damaged 19 to 21°C (66 to 70°F) between
to battery connector or damaged system circuits A-H4 and A-J4.
more details.
P0560 ECM Battery voltage not Battery failure, rectifier Check fuses #6 (refer
plausible failure, damaged to WIRING DIAGRAM).
242 smr2011-023
FAULT REPORTING
CODE MODULE
P0562 ECM Battery voltage too low Battery failure, rectifier Check fuses #6 (refer
failure, damaged to WIRING DIAGRAM).
P0563 ECM Battery voltage too Battery failure, rectifier Check for regulator-rectifier failure.
high failure or battery Refer to the Service Manual for
terminal connection. more details.
P0564 CLUSTER Cruise switch fault The cruise switch is Verify the cruise switch if it is
shorted or activated normally open and close when
more than 60 seconds. activated.
P0606 ECM ECM ADC fault Damaged ECM. Replace ECM
P060D ECM TAS (Throttle Damaged sensor, Check system circuits B-E 1.
Accelerator sensor) damaged circuit wires, B-K1, B-K3, B-A3, B-B3, B-J3
synchronization error damaged connector or Check for 0 volt on sensor
damaged ECM pins. connector pin B and E.
Check for 5 volts on sensor
connector pin A and D.
Check for 0.5 to 3 volts on sensor
connector pin Fand 0.25 to 1.5 on C
more details.
P060E ECM Throttle Actuator

- Controller Fault-
digital position control
exceeds limit
P0610 ECM Variant coding fault
P0629 CLUSTER Fuel sensor Damaged sensor, Check for 2.6 ohms (full tank)
disconnected fault damaged circuit wires, to 93.6 ohms (empty tank)
damaged connector or between pin C and pin D
damaged ECM output at the fuel pump connector.
pins. Check system circuit at
the gauge Pin 19 and 20.
(refer to WIRING DIAGRAM).
P062C ECM Cluster CAN error Cluster fault Check C.A.N. circuits wires.
- Loss of vehicule detected by ECM. Replace instrument Cluster.
speed information from C.A.N. circuit failure, Verify outside of the building if
cluster Instrument cluster or the GPS LED becomes active
ECM failure. after 1 minute and stays steady
more details.
P062F ECM ECM EEPROM fault - Damaged ECM. Replace ECM.

exchange ECM
P0686 ECM ECM Fast ADC fault

(knock detection line)
smr2011-023 243
FAULT REPORTING
CODE MODULE

open line

downstreams of
catalyst - open line
P1106 ECM Altitude correction

factor (fho) not
plausible - out of range
P1120 ECM Throttle positions Damaged throttle Check system circuit, perform
calculated from TPS actuator, damaged closed throttle with B.U.D.S.
1 and TPS 2 not circuit wires, damaged Replace throttle actuator, repalce
corresponding connector or damaged ECM.
ECM.

open line

- open line
P1171 ECM Additive mixture

adaptation exceeds
upper limit -> mixture
too lean
P1172 ECM Additive mixture

adaptation below lower
limit -> mixture too
rich
P1264 ECM Ignition Power stage Damaged coil, damaged

overload circuit wires, damaged
connector or damaged
ECM output pins.
Fault detected when
the engine is running.
P1502 ECM T.O.P.S. functional Boat or sensor upside Check continuity for
problem down. damaged circuits A-C4, A-G1, A-F4.
circuit wires, damaged Refer to the Service Manual
connector or damaged for more details.
ECM output pins.
P1503 ECM T.O.P.S. switch short Boat or sensor upside Check continuity for
circuit to 12 V down, damaged circuits A-C4, A-G 1, A-F4.
ECM output pins.
P1504 ECM T.O.P.S. switch short Boat or sensor upside Check continuity for
circuit ground down, damaged circuits A-C4. A-G1. A-F4.
ECM output pins.
244 smr2011-023
FAULT REPORTING
CODE MODULE
P1505 ECM T.O.P.S. switch fault Boat or sensor upside Check continuity for
non plausible state down, damaged circuits A-C4, A-G1, A-F4.
ECM output pins.
Open circuit.
P1506 ECM T.O.P.S. switch open Boat or sensor upside Check continuity for
circuit down, damaged circuits A-C4, A-G1, A-F4.
circuit wires. damaged Refer to the Service Manual
ECM output pins.
Open circuit.
P1509 ECM Lake Water

Temperature sensor
fault
P1550 ECM Otas sensor voltage Damaged sensor, Check continuity for circuits
not plausible damaged circuit wires, B-H3, B-H 1 and fuse #12.
damaged connector Refer to the Service Manual
or damaged ECM. for more details.
Open circuit.
P1590 E CM VTS position sensor

circuit out of range
P1591 ECM VTS position sensor

circuit voltage low
P1592 ECM VTS position sensor

circuit voltage high
P1593 ECM VTS malfunction
P1606 ECM ECM ADC fault - Damaged ECM. No service action available for fault
exchange ECM P1606.
P160E ECM Throttle Actuator - Damaged throttle Check system circuit. perform
Controller Fault - digital actuator. damaged closed throttle with B U. D S
. . .
position control below circuit wires. damaged Replace throttle actuator. repafce
limit connector or damaged ECM.
ECM.
P1610 ECM Throttle Actuator - Damaged throttle Check system circuit, perform
Power Stage fault actuator, damaged closed throttle with B.U.D.S.
circuit wires, damaged Replace throttle actuator, repalce
connector or damaged ECM.
ECM.
ECM.
P1612 ECM Throttle Actuator - Damaged throttle Check system circuit. perform
Power Stage fault actuator, damaged closed throttle with B.U.D .S.
circuit wires. damaged Replace throttle actuator, repalce
ECM.
smr2011·02J 245
FAULT REPORTING
CODE MODULE
ECM.
P1614 ECM Throttle A<.:luator - Damaged throttle Check system circuit, perform
Return-Spring check actuator, damaged closed throttle with B.U.D.S.
not passed/Spring does circuit wires, damaged Replace throttle actuator, repalce
not close connector or damaged ECM.
ECM.
P1615 ECM Throttle Actuator - Damaged throttle Check system circuit. perform
Position monitoring actuator, damaged closed throttle with B.U.D.S.
fault circuit wires, damaged Replace throttle actuator. repalce
ECM.
Default position check actuator. damaged closed throttle with B U.D S
. . .
or learning fault circuit wires, damaged Replace throttle actuator, repalce

ECM.
Adaptation of upper actuator, damaged closed throttle with B.U.D.S.
mechanical limit failed circuit wires, damaged Replace throttle actuator, repalce
ECM.
Adaptation of lower actuator, damaged closed throttle with B.U.D.S.
mechanical limit failed circuit wires, damaged Replace throttle actuator, repalce
connector or damaged E CM .
ECM.
P1621 ECM Throttle Actuator - Damaged t hrottle Check system circuit, perform
Abortion of adaptation actuator, damaged closed throttle with B.U.D.S.
circuit wires, damaged Replace throttle actuator. repalce
ECM.
Repeated abortion of actuator, damaged closed throttle with B.U.D.S.
adaptation circuit wires, damaged Replace throttle actuator, repalce
ECM.
P1654 ECM Voltage of D.E.S.S. key Damaged D.E.S.S. Remove D.E.S.S. key and
switch out of range key switch, damaged check system circuit 8-8 2.
circuit wires, damaged Refer to the Service Manual for
connector or damaged more details.
ECM output pins.
P1657 ECM Electrical fault Damaged D.E.S.S. Remove D.E.S.S. key and
of D.E.S.S. key key switch, damaged check system circuit B-82.
communication line circuit wires, damaged Refer to the Service Manual for
ECM output pins.
246 smr2011·023
FAULT REPORTING
CODE MODULE
P1658 ECM Faulty D.E.S.S. key Damaged D.E.S.S. Remove D.E.S.S. key and
communication key switch, damaged check system circuit B-82.
circuit wires, damaged Refer to the Service Manual for
ECM output pins.
P1661 ECM il::!H malfunction iBR fault detected by Remove D.E.S.S. key
ECM. Perform an electrical
system shut down.
Clear fault.
P1662 ECM iBR torque request is iBR fault detected by Perform iBR software update if
not plausible ECM. available or replace iBR.
P1679 ECM Main Relay Stinking Permanent 12 V is ECU pin B-M4 is permanently
present on ECM Pin supplied thru 15 amp fuse and i t
B-M4. should be accessory 12 Vdc.
P1690 ECM VTS control up circuit

open circuit or shorted
to ground
P1691 ECM VTS control up circuit

shorted to battery
P1692 ECM VTS control down

circuit open circuit or
shorted to ground
P1693 ECM VTS control down

circuit shorted to
battery
P1694 ECM VTS Power stage fault
P1695 ECM VTS Power stage fault
P1686 ECM ECU Fast ADC fault

P16B7 ECM ECU Fast ADC fault

{knock detection line)
P16B8 ECM ECU Fast ADC fault

P16CO ECM Fault of ECM ADC
P16C1 ECM Fault of ECM ADC
P16C2 ECM Fault of ECM

monitoring module
P16C3 ECM Monitoring fault due

to Accelerator Sensor
check
P16C4 ECM Monitoring fault due to

engine speed check
P16C5 ECM Safety fuel cut off activ

- Monitoring level 1
P16C6 ECM Safety fuel cut off activ

- Monitoring level 2
smr2011-023 247
FAULT REPORTING
CODE MODULE
P16C7 ECM Monitoring fault due Damaged throttle Check system circuit, perform
to thronle valve actuator, damaged closed throttle with B.U.D.S.
plausibility check circuit wires. damaged Replace throttle actuator, repalce
ECM.
P16C8 ECM Monitoring fault due to Damaged throttle Check system circuit, perform
exceeding permitted actuator, damaged closed throttle with B.U.D.S.
throttle valve position circuit wires, damaged Replace throttle actuator, repalce
ECM.
P16C9 ECM Monitoring detected Damaged D.E.S.S. Remove D.E.S.S. key and
non plausible D.E.S.S. key switch, damaged check system circuit B-82.
key state circuit wires, damaged Refer to the Service Manual for
ECM output pins.
P16CA ECM ECU detected faulty Damaged ECM. Replace ECM.

watch dog line ECU
defect
P16CB ECM ECU switch off Damaged ECM. Replace ECM.

through watch dog
line {hardware fault)
ECU defect
P2080 ECM Exhaust temperature Damaged sensor, Check for approximately 2280
not plausible damaged circuit to 2736 ohms at temperature of
wires. damaged 19 to 21°C {66 to 70°F) between
more details.
P2081 ECM Exhaust temperature lntremittent connection. Check for approximately 2280
sensor fault Damaged sensor, to 2736 ohms at temperature of
damaged circuit wires, 19 to 21°C (66 to 70°F) between
damaged connector or system circuits A-H4 and A-J4.
damaged ECM output Refer to the Service Manual for
pins. more details.
P212C ECM Electrical lower-range Damaged throttle Check system circuit, perform
violation TPS 2 actuator, damaged closed throttle with B.U.D.S.
circuit wires, damaged Replace throttle actuator, replace
connector or damaged ECM
ECM.
P212D ECM Electrical upper-range Damaged throttle Check system circuit, perform
circuit wires, damaged Replace throttle actuator. replace
connector or damaged ECM
ECM.
P2159 ECM TAS (Throttle

Accelerator sensor)
signal not plausible
P2245 ECM Lambda Sensor aging

catalyst Sensor Voltage
too low
248 smr2011·023
FAULT REPORTING SERVICE ACTION

DESCRIPTION POSSIBLE CAUSE
CODE MODU LE
P2246 ECM Lambda Sensor aging

catalyst Sensor Voltage
too high
P2279 ECM Air intake manifold leak

downstream of throttle
P2428 ECM High exhaust Exhaust overheat, Check cooling system for blockage.
temperature detected damaged sensor or Check if the exhaust injection
damaged circuit wires. valve is properly calibrated.
more details.
P2620 ECM TPS value not plausible Damaged throttle Check system circuit. perform
actuator, damaged closed throttle with B.U.D.S.
ECM.
P2621 ECM Electrical lower-range Damaged throttle Check system circuit, perform
ECM.
P2622 ECM Electrical upper-range Damaged throttle Check system circuit, perform
ECM .
U0129 ECM CAN communication iBR fault detected Check C.A.N. circuits wires.
error between ECM by ECM. Replace iBR.
and iBR module CAN. circuit failure, Refer to the Service Manual
iBR or ECM failure. for more details.
Disconnected
connector.
U0129 iS IBR CAN messages Warning only: the If fault ACTIVE, verify CAN
timeout or validity iS module lost connection between iBR and iS.
communication with
the iBR.
U016A ECM Loss of vehicle speed Instrument cluster fault Check CAN. circuits wires,
detected by ECM. replace instrument Cluster.
CAN. circuit failure, Refer to the Service Manual for
instrument Cluster or more details.
ECM failure.
U0300 ECM Exchange security - Incorrect ECM or cluster Install proper recommended ECM
Wrong ECM for engine. or cluster for vehicle.
U0401 iBR ECM CAN messages CAN. circuit failure, Check CAN. circuits wires.
timeout or validity ECM software failure. Replace ECM.
for more details.
U0401 iS ECM CAN messages Warning only: the If fault ACTIVE. verify CAN
timeout or validity iS module lost connection between ECM and iS.
communication with
the engine ECU.
smt2011-023 249
FAULT REPORTING
CODE MODULE
U0457 iBR Cluster CAN messages C.A.N. Circuit failure, Check C.A.N. circuits wires.
timeout or validity Cluster software failure. Replace instrument Cluster.
more details.
U0457 iS Cluster CAN messages Warning only: the If fault ACTIVE. verify CAN
timeout or validity iS module lost connection between Cluster and iS.
communication with
the Cluster.
U16A1 ECM Cluster CAN Timeout Cluster fault Check CAN. circuits wires.
error-Missing CAN ID detected by ECM. Replace instrument Cluster.
514h C.A.N. circuit failure, Refer to the Service Manual for
Instrument cluster or more details.
ECM failure.
U16A2 ECM Cluster CAN Timeout Cluster fault Check C.A.N. circuits wires.
230h C.A.N. circuit failure, Refer to the Service Manual for
ECM failure.
U16A3 ECM Cluster CAN Timeout Cluster fault Check C.A.N. circuits wires.
408h CAN. circuit failure, Refer to the Service Manual for
ECM failure.
U16A4 ECM iBR CAN Timeout iBR fault detected Check C.A.N. circuits wires.
error-Missing CAN ID by ECM. Replace iBR.
010h CAN. circuit failure, Refer to the Service Manual
Disconnected
connector.
U16A5 ECM iBR CAN Timeout iBR fault detected Check CAN. circuits wires.
error-Missing CAN ID by ECM. Replace instrument iBR.
012h C.A.N. circuit failure, Refer to the Service Manual
Disconnected
connector.
U16A6 ECM Cluster check sum Cluster fault Check C.A.N. circuits wires.
error - CAN ID230h detected by ECM. Replace instrument Cluster.
C.A.N. circuit failure, Refer to the Service Manual for
ECM failure.
250 smr201 l-023

FAULT RE PORTING
DES CRIPTION POSSIBLE CAUSE SERVICE ACTION
CODE MODULE
U 1 6A7 ECM Cluster check sum Cluster fault Check C.A.N. circuits wires.
error - CAN ID408h detected by ECM. Replace instrument Cluster.
CAN. circuit failure, Refer to the Service Manual for
ECM failure.
U16A8 ECM 1�H check sum error - iBR fault detected Check CAN. circuits wires.
CAN ID010h by ECM. Replace iBR.
CAN. circuit failure, Refer to the Service Manual
U16A9 ECM iBR check sum error - iBR fault detected Check CAN. circuits wires.
CAN ID012h by ECM. Replace iBR.
CAN. circuit failure, Refer to the Service Manual
smr2011·023 251
252
Section 04 FUEL SYSTEM
Subsection 01 (INTELLIGENT THROTTLE CONTROL OTC))
INTELLIGENT THROTTLE CONTROL

(iTC)
SERVICE TOOLS
DIAGNOSTIC HAHNESS . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . 529 036 188 ......................................... 280
. . .
FLUKE 115 MULTIMETER .. . . . . . . . . . . . .

. . . . . . . . . . ........... . ..... .. . ................ 529 035 868 ................................. 280, 285
SERVICE PRODUCTS
DIELECTRIC GREASE . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................... 293 550 004 ......................................... 285
GENERAL
SYSTEM DESCRIPTION
NOTE: Some functions or features described in
this section may not apply to every PWC model,
or may be available as an option.
The iTC is an electronic throttle control system
that includes a cableless throttle control located
on the RH side of handlebar, an electric throttle ac
tuator {ETA) located on the throttle body and the
engine control module (ECM). The iTC is often re
ferred to as a "throttle by wire" system.
TYPICAL
1. Throttle body
2. Throttle actuator
The throttle lever operates the throttle accelera

tor sensor (TAS). It is a double output hall effect
sensor. The redundancy is used for security pur
poses.
The throttle actuator (ETA) is a DC motor on the
throttle body that regulates the throttle plate via a
drive gear. Pulse width modulation (PWM) is used
to control the motor. In the throttle body, there is
sdd 2 009-001-031_ a
a double throttle position sensor {TPS). The redun
TYPICAL
1. Throttle lever dancy is used for security purposes. The TPS is
2. Throttle accelerator sensor (TAS) a potentiometer that supplies the ECM the actual
angle position of the throttle plate.
According to the torque demand from the TAS,
the ECM powers the ETA motor to rotate towards
open or close the throttl� plate. When the ECM
detects through the TPS that the throttle plate has
reached the targeted opening, the ECM stops the
throttle actuator.
smr2011-024 253
Subsection 01 (INTELLIGENT THROTILE CONTROL (iTC))
The iTC allows the throttle actuator to be moved ir Once the maximum cruise speed is set, the oper
respective of the accelerator sensor position since ator can vary the watercraft speed from idle speed
it is not directly linked by a throttle cable. up to the set cruise speed using the throttle lever.
While the throttle lever might be fully pulled in and The set cruise speed will not be exceeded even if
held, the ECM could close the throttle plate in the throttle lever is fully depressed.
stead of opening it if the iBR lever were pulled As you proceed under a constant cruising speed
in. Then, the ECM could open the throttle plate setting, keep your attention level up to maintain
to accelerate the engine to increase the braking good situational awareness.
effect. These different throttle plate movements Slowing down is a matter of releasing the throttle
could be achieved while the throttle lever was still lever further than the set point, or by pulling the
fully pulled in. This is one of the great flexibility of iBR lever in or decrease speed with the DOWN
the iTC. button.
The use of the iTC allows the following additional If the iBR lever is pulled in for braking, CRUISE
engine modes of operation. mode is overridden but not deactivated.
Touring/Sport Mode Once the iBR lever is released and the throttle is
pulled in to engage forward position, the cruise
Touring/Sport mode allows the operator to choose
function will reengage to limit the watercraft
between sport mode for instant throttle response,
speed as it was set before iBR lever activation.
or touring mode for progressive throttle response
at certain engine speed. Slow Speed Mode
In sport mode, maximum engine power is avail The Intelligent Throttle Control also allows for a
able throughout the engine operational range. Slow Speed Mode where the driver can adjust and
In touring mode, available engine power and set idle speed. This is useful when operating in
acceleration is reduced when accelerating from slow speed zones where the driver must be es
a complete stop and when operating in the low pecially attentive to possible obstacle avoidance.
engine power range under certain conditions. The throttle plate will open and close as necessary
When throttle is applied in touring mode, the en to maintain the set speed.
gine will progressively accelerate to an operating
range whereby full power eventually becomes Ski Mode
available as if operating in sport mode. If the Ski mode allows for repeated and precisely con
engine is throttled down sufficiently and for a trolled launches and a set towing speed, designed
long enough period of time, engine power and specifically for towing a skier or wake boarder.
acceleration will again be reduced.
RAMP Function
ECO Mode The RAMP function available in ski mode is a pre
When ECO mode is selected (fuel economy programmed function used for launching and ac
mode), engine RPM is limited whereby an op celerating the PWC when towing a skier or wake
timal cruising speed is maintained in order to boarder.
reduce fuel consumption.
TARGET SPEED Function
Cruise Control The TARGET SPEED function limits the maximum

towing speed.
Cruise mode is a function of iTC (intelligent Throt
tle Control) system that allows the operator to set
Learning and Rental Keys
the desired maximum watercraft speed.
Learning and Rental keys limit the watercraft ma
This is useful when cruising for long distances, op
ximum speed. The full stroke of the throttle lever
erating in limited speed zones, or towing a tuber,
is used while only a partial stroke of the throttle
skier or wake boarder.
plate is achieved. Therefore, greater throttle lever
Cruise mode only limits forward speed, the oper movement is used while a smaller engine speed
ator must keep the throttle depressed to maintain and torque variation is applied through the throttle
forward speed. actuator. This permits a more accurate and eas
ier throttle operation to control the engine within
a specified torque curve and maximum speed set
ting for a learner.
254 s.-rv20I 1-02A

O.T.A.S. TM System (Off-Throttle

Assisted Steering)
The O.T.A.S. (Off-Throttle Assisted Steering)
system provides additional maneuverability in
off-throttle situations. The O.T.A.S. system is
electronically activated and slightly increases en
gine speed under a pre-defined RPM when the
driver initiates a full turn. When the handlebar is
brought back to its center position, the throttle
reverts to idle.
The throttle plate will open and close as necessary
to assist the steering.
Limitations
The O.T.A.S. system cannot help maintaining con
trol or prevent collisions in all situations.
smr2011-024 255
OPERATING MODES (GTS, GTI AND WAKE SERIES)

GTS GTI GTISE GTI LIMITED WAKE
Touring mode x x x x x
Sport mode x x x x x
ECO mode N.A. N.A. x x x

Cruise mode N.A. Opt Opt x x
Slow speed mode N.A. Opt Opt x x
Ski mode N.A. Opt Opt Opt x
Learning and rental key modes x x x x x
X = Indicates a st a nda rd feature

Opt = Ind ica tes a feature available as an option
N.A. = I nd ica tes a function that is not applicable
Touring Mode Activating Sport Mode

(Quick Method)
By default, the watercraft is in TOURING mode of
operation when first started. To quickly activate sport mode while riding at
speed, carry out the following:
A TOURING mode indicator is ON in the multi
function gauge to confirm the active mode of op
eration.
AwARNING
When activating sport mode, be sure to
maintain situational awareness of other wa
tercraft, obstacles, or persons in the water.
1 . Depress and hold the SET button for at least 3

seconds.
TOURING MODE INDICATOR
Sport Mode
A SPORT mode indicator is ON in the multifunc
tion gauge to confirm the active mode of opera
tion.
l!t\'\020 11-00
3-0 19_
•
GTS MODELS
7. SET button
SPORT MODE INDICATOR
Once activated, SPORT MODE will remain active

until it is deactivated by the operator, or the engine
is shut down whereby it defaults back to TOUR
ING MODE.
256 smr2011-024
Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC))
sdd2 Q09.00 J-02•_f
GT/ SERIES AND WAKE

1. SET button
smo201C · 002-103
MESSAGE - SPORT MODE ACTIVATED

NOTE: The following important message will
scroll across the multifunction display: NOTE: After a few seconds, the gauge will revert
ENTERING SPORT MODE - INCREASED ACCEL to its normal display.
ERATION - INSTRUCT PASSENGERS TO HOLD -
PRESS_SET_BUTION.
3. Ensure the SPORT mode indicator is turned on.
NOTE: The SPORT mode indicator will come on

and stay on as long as sport mode is active.
Deactivating Sport Mode

(Quick Method)
smo2010·002 · 102 To quickly deactivate sport mode while riding at
MESSAGE - ENTERING SPORT MODE - speed, carry out the following:
INCREASED ACCELERATION - INSTRUCT PASSENGERS TO
HOLD - PRESS_SET_BUTTON
A WARNING
A WARNING When activating sport mode, be sure to
Ensure passengers are advised that sport maintain situational awareness of other wa
mode provides for increased accelerations tercraft, obstacles, or persons in the water.
and to hold on t i ghtl y .
1. Depress and hold the SET button for at least 3

2. Press the SET button again to activate sport seconds .
mode. NOTE: The following message will scr oll in the
A scrolling SPORT MODE ACTIVATED message multifunction display: SPORT MODE DEACTI
will momentarily confirm that sport mode has VATED.
been activated.
smr2011-024 257
:OE:Fll.T
smo2010-002· 10b s mo2010-002 -101
MESSAGE· SPORT MODE DEACTIVATED FUNCTION SELECTED· DRIVING MODE
NOTE: After a few seconds. the gauge will revert 2. Press the SET button to enter the driving mode
to its normal display. function.
2. Ensure the TOURING mode indicator is on. NOTE: The following important message will
scroll across the multifunction display ENTER
ING SPORT MODE - INCRE ASED ACCELERA
TION - INSTRUCT PASSENGERS TO HOLD -
PRESS_SET_BUTION.
Activating Sport Mode

(Through Information Center)
To activate sport mode through the gauge func
tions. carry out the following:
A WARNING
Activating sport mode through the informa
tion center should only be carried out with
the watercraft stopped and the engine run
ning at idle. The operator must ensure t o MESSAGE • ENTERING SPORT MODE -
maintain situational awareness o f other wa HOLD· PRESS_SET_BUTTON
tercraft, o b st ac les or persons i n the water.
,
A WARNING
1. With the engine running at idle, press the Ensure passengers are advised that sport
MODE button repeatedly until DRIVING MODE mode provides for increased accelerations
scrolls across the multifunction display. and to hold on tightly.
3. Press the SET button again to activate sport

mode.
A scrolling SPORT MODE ACTIVATED message
will confirm momentarily that sport mode has
been activated.
258 smr2011-024
Subsection 01 (INTELLIGENT TH R OTILE CONTROL OTC))
smo2 0 10--002-103 s m o201 0--0 02· 101
MESSAGE - SPORT MODE ACTIVATED FUNCTION SELECTED - DRIVING MODE
NOTE: A fter a few seconds, the gauge will exit 2. Press the SET button to enter driving mode
the function and return to its normal display. function.
4. Ensure the SPORT mode indicator is turned on. NOTE: The following message will scroll in the
multifunction display SPORT MODE ACTIVE -
PRESS_SET_TO_DISENGAGE.

and stay on as long as sport mode is active. If
the engine is not at idle and sport mode cannot
be activated, the following message will appear:
SPORT MODE- RETURN TO IDLE TO ACTIVATE.

(Through Information Center) •mo2010-0:12-10 4
MESSAGE - SPORT MODE ACTIVE

To deactivate sport mode, carry out the following:
-
PRESS_SET_TO_DISENGAGE
A WARNING 3. Press the SET button again to disengage sport

Deactivating sport mode through the infor mode.
mation center must only be carried out with N OTE: The following message will scroll in the
the watercraft stopped and the engine run multifunction display SPORT MODE DEACTI
ning at idle. VATED.
1. With the engine running at idle, press the

MODE button repeatedly until DRIVING MODE
scrolls across the multifunction display.
smr2011·024 259
FUEL ECONOMY MODI:
2. Press SET button to enter the function; the fol

lowing message will ap pear .
"""2 01 <>-002-105
MESSAGE· SPORT MODE DEACTIVATED
NOTE: After a few seconds, the gauge will exit

the fu nct ion and return to its n ormal display.
4. Ensure the TOURING mode indicator is on.
1. SET button
TOURING MODE INDICATOR FUEL ECONOMY MODE - HOLD SET TO ACTIVATE

OR MODE TO EXIT
Eco Mode 3. Press and hold SET button to activate fuel econ-
(Fuel Economy Mode) omy mode as instructed.
How to Activate Fuel Economy Mode Fuel economy mode activation will be indicated in
the following manner:
1. Pres s the MODE button repeatedly until the
following function appears in the multifunction - A fl ash ing ECO indicator will appear next to the
di splay . fuel tank symbol .
- A flashing smile will appear in the fuel tank sym

bol .
- The multifunction display will revert back to its

previous indication.
ECO MODE INDICATORS

&dd2009-00 HJ24.e
(Fuel Economy Mode)
1. MODE button
How to Deactivate Fuel Econo my M ode

1. Press the MODE button repeatedly until the
following function appears in the multifunction
display.
260 smr2011-024
MULTIFUNCTION DISPLAY MESSAGE
FUEL ECONOMY MODE
2. Press SET button to enter the function; the fol

lowing message will appear.
FUEL ECONOMY MODE - HOLD SET TO

CRUISE MODE _ SELECT SPEED _ PRESS SET
DEACTIVATE OR MODE TO EXIT
TO ACCEPT OR MODE T O EXIT
3. Press and hold SET button to deactivate fuel

3. Press the UP arrow button until the desired
economy mode as instructed.
cruise speed is indicated in the numerical dis
When activated, the following will occur: play.
- The flashing ECO indicator will disappear.
- The flashing smile will disappear.
- The multifunction display will revert back to its
previous indication.
Cruise Mode
NOTE: Cruise mode is not available if slow speed
mode, ski mode or ECO mode is engaged.
Cruise Mode Activation at Idle Speed

NOTE: This function is available up to approxi
mately 10 km/h (6 MPH).
To activate and preset CRUISE MODE at idle sdd 2 009-00 1 -024j
speed, carry out the following: 1. UP arrow button

2. DOWN arrow button
1. Tap the throttle lever to move the iBR to the
forward position. The following will be displayed in the multifunc
tion gauge.
2. Press and hold the cruise button.
1. CRUISE MODE SPEED ADJUSTING

2. CRUISE SPEED SET POINT INDICATION
4. Press the SET button to save the cruise speed

selected and engage cruise mode. The follow
ing scrolling message will appear in the multi
ENGAGING CRUISE AT IDLE
Step 1: Tap throttle to engage FORWARD
function display.
Step 2: Press cruise button
The following message will appear in the multi

function display.
smr2011·024 261
CRUISE MODE ACTIVE CRUISE MODE INDICATOR
A beep indicating that you are now in cruise mode Changing Set Cruise Speed
will sound. and a CRUISE indicator will come on in
To increase or decrease th e set cruise speed:
the multifunction gauge.
1. Hold the throttle lever all the way in to the han
dlebar.
2. On the RH handlebar, press UP/DOWN arrow
button. ·
CRUISE MODE INDICATOR
Cruise Mode Activation Above Idle Speed

To activate cruise mode above idle speed (10 km/h
(6 MPH)):
1 . Accelerate to the desired watercraft speed and
hold throttle lever steady.
2. Press and hold the cruise button for approxi
mately 1 second.
CHANGING SET CRUISE SPEED
1. Throttle lever
2. UP arrow button
While the UP/DOWN arrow is being pressed to

change the speed setting, the following will ap
pear in the multifunction gauge.
ENGAGING CRUISE AT SPEED

Step 1: Accelerate to desired speed and hold throttle steady 1. Sc rolli ng CRUISE MODE_ SPEED ADJUSTING
Step 2: Press cruise button
message
A beep indicating that you are now in cruise mode 2. Cruise speed setting indication
will sound. and a CRUISE indicator will come on in
the multifunction gauge. NOTE: Pressing the UP/DOWN arrow button re
peatedly will change the cruise speed setting in
single increments. Pressing and holding the but
ton will increase or decrease the speed until the
button is released.
262 SllV2011·024
Deactivating Cruise Mode The CRUISE indicator will come on in the multi
To deactivate cruise mode: function gauge to indicate cruise activation.
1. Release the throttle lever.

2. Press the cruise button.
Deactivation of cruise mode is indicated by:
- The CRUISE indicator in the multifunction dis-
play will go off.
- A BEEP will be heard.
NOTE: If the throttle lever is not fully released
when the cruise button is pressed to deactivate
cruise mode, the BEEP will not be heard and the
A scrolling message will appear in the multifunc
cruise light will remain on. The speed limiting
tion display to specify that slow speed mode. The
function of cruise mode will stay active until the
default slow speed set point of 1 will also come on
throttle is fully released, then the BEEP will be ·
for a few seconds in the numerical display.

heard and the cruise light will go out.
Slow Speed Mode

The operator can select an idle speed
set point (slow speed) between 1 and 5
(1.6 km/h to 11 km/h (1 MPH to 7 MPH)).
If you accelerate above approximately 14 km/h
(9 MPH). Slow Speed Mode will be deactivated
and the engine will return to its normal idle RPM
1. Scrolling SLOW SPEED MODE message
when the throttle is released.
2. Slow speed set point of "1" indication
Should a situation arise where the operator must
stop or accelerate quickly away from a hazardous NOTE: As a reminder, the scrolling SLOW SPEED
situation, pull in the iBR lever, or pull in on the MODE message repeats itself as long as slow
throttle lever to deactivate slow speed mode and speed mode is active. The numerical display re
regain normal control of the watercraft. verts back to the previous indication after a few
seconds.
Activating Slow Speed Mode
To activate slow speed mode of operation: Changing Set Slow Speed
1. Release the throttle lever to idle RPM. There are 5 slow speed set points available (1
2. Pull in and release the iBR lever to engage neu through 5), 1 being the slowest.
tral. To increase or decrease the slow speed set point,
3. Press and hold the CRUIDE button for approx press the UP/DOWN arrow button on the RH han
imately 1 second. dlebar once, or repeatedly.
sdd2009-00 1-024_g s dd2009-00 1 ·024 j
TYPICAL 1. UP arrow button to increase speed

1. CRUISE button 2. DOWN arrow button to decrease speed
smr2011·024 263
While the UP/DOWN arrow is being pressed to RAMP 5 provides for the quickest launch and
change the slow speed set point, the following most rapid acceleration. RAMP 5 also provides
will appear in the multifunction gauge. the highest TARGET SPEED range.
The RAMP setting that is selected by default
when entering ski mode may be changed to a
different setting.
TARGET SPEED Function

Once the RAMP has been selected, an average
PWC target speed for that RAMP will be visible in
the numerical display.
1. SLOW SPEED MODE - SPEED ADJUSTING The average speed displayed and the speed range
2. Slow speed set point indication available is dependent on the RAMP selected.
The higher the RAMP number, the higher the
The displays will revert back to their previous in speed range.
dication a few seconds after the last activation of
The operator may increase or decrease the tar
the UP/DOWN arrow button.
get speed to any value within the selected RAMP
NOTE: As a reminder, the following message will speed range.
scroll across the multifunction display periodically.
If the desired target speed cannot be set in the
MULTIFUNCTION DISPLAY MESSAGE selected RAMP, you must exit and reengage SKI
MODE, then select a different RAMP.
SLOW SPEED MODE ACTIVE
Engaging and Using Ski Mode
Deactivating Slow Speed Mode To engage ski mode, carry out the following steps:
Slow speed mode can be deactivated using any of 1. Press the MODE button repeatedly until SKI
the following methods: MODE is visible in the multifunction display.
- Pressing the cruise button
- Depressing the iBR lever
- Accelerating above the highest slow speed that
can be set (approximately 14 km/h (9 MPH)).
When deactivating SLOW SPEED MODE:
- By pressing the cruise button, the iBR system
maintains forward position.
- By pressing the iBR lever, the iBR system will
shift to neutral position.
SLOW SPEED MODE deactivation will be indi
cated in the following manner:
1. The CRUISE indicator will go out
2. The scrolling SLOW SPEED MODE ACTIVE TYPICAL
message will cease. 1. MODE button
Ski Mode
Ski mode is only available using a normal key, it
is not available when using a LEARNING key or a
RENTAL key.
R A M P Functi on
RAMP 1 provides for the smoothest launch and
most gradual acceleration. RAMP 1 also provides
for the slowest TARGET SPEED range.
264 smr2011 ·024

4. Press SET to lock in the ramp setting; the mul

tifunction display will change to the TARGET
SPEED setting function.
s mo20 1 0-002 11e
SELECTED FUNCTION - SKI MODE
2. Press SET to enter the function. The multifunc

tion gauge message will change to RAMP. The
RAMP setting number will be visible in the nu
SECOND SETTING AVAILABLE - TARGET SPEED
merical display. 1. TARGET SPEED setting
5. Press the UP/DOWN arrow button to increase

or decrease the target speed.
6. Press SET to lock in the target speed; the dis
play will switch to the following scrolling mes
sage.
•dd2009-001-02•.f
1. SET button
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SCROLLING MESSAGE - SKI MODE_pRESS_SET_TO START

OR MODE TO EXIT
NOTE: A BEEP will be heard every 5 seconds as

a SKI MODE engaged reminder.
7. Press SET again; the following confirmation
message will appear.
smo201 0-00 2·117 . o
FIRST SETTING AVAILABLE

1. RAMP setting
- RAMP
3. To change the RAMP setting, press the

UP/DOWN arrow button until the desired ramp
number is visible in the numerical display.
smr2011-02� 265
35.�
Ili4f1 TI'f 1f" T
ILJ .J.Jj : f1L..
sd<l2009-00l .0 2 4 11
1. Hold throttle lever in

2. Press UP arrow burton to increase speed
smo201 0-002- 1 20
3. Press DOWN arrow button co increase speed
SCROLLING MESSAGE - SKI MODE
ACTIVE]RESS_MODE_AND RETURN TO IDLE TO
CANCEL NOTE: If the throttle is partly released during a
ski run, the SKI MODE indicator light will start
NOTE: The SKI MODE indicator will also come to blink and the speed adjust function using the
ON and blink when ski mode becomes active. It UP/DOWN arrow button will be deactivated.
will be ON steady when the operator pulls and
10. To end a ski run or to pick up a fallen skier or
holds the throttle lever all the way in to the han
wakeboarder, fully release the throttle to re
dlebar.
gain normal throttle control.
NOTE: When the throttle is fully released during
ski mode operation, the system returns to ski
mode engaged status. The SKI MODE indicator
light will go out but, ski mode will remain engaged
and a message to that effect will reappear in the
multifunction display.
SCROLLING MESSAGE
SKI MODE INDICATOR
SKI MODE - PRESS SET TO START OR
MODE TO EXIT
NOTE: Ski mode cannot be engaged if the throt
tle is not fully released, and if CRUISE or SLOW 11. Press SET to reactivate ski mode and fully pull
SPEED mode is engaged. A message will appear in the throttle lever to start another ski run.
in the multifunction display advising you of the sit
uation. Follow the instruction in the display. Deactivating Ski Mode
8. To launch the PWC in ski mode, pull in and hold To exit ski mode at any given point during the ski
the throttle lever all the way to the handlebar mode setting process, press the MODE button.
grip. The PWC will accelerate to the set TAR To end a ski run and completely deactivate ski
GET SPEED and the SKI MODE indicator will be mode, release the throttle to idle. then press the
on steady. MODE button.
9. To increase or decrease the TARGET SPEED
during a ski run, press the UP/DOWN arrow Learning Key and Rental Key Modes
button. d o not release the throttle lever. There are 5 speed settings available for the rental
key mode. and 5 for the learning key mode. By
default, the key modes are preset to the highest
speed setting (5).
NOTE: Changing key settings is only available
when the engine is not running.
266 smr2011-024
Subsection 01 {INTELLIGENT THROTTLE CONTROL {iTC))
Changing Learning or Rental Key Speed 4. Press the SET button once to enable learning
Settings key mode setting function. The display will
change to L-Key.
GTS Models
NOTE: The default learning or rental key setting
of 5 cannot be changed on these models.
All Models Except GTS

To change learning or rental key settings, carry out
the following:
1. Press the START/STOP to wake up the electri
cal system and install the NORMAL key on the
engine cut-off switch.
2. Wait for the information center to complete its
self-test and display the key recognition mes
sage.
3. Press the MODE button repeatedly until KEY
MODE is visible in the digital screen of the in :;.mo2000-00-2 -114 _ c
formation center. EXAMPLE - LEARNING KEY SET TO 1
NOTE: Pressing the SET button twice will enable

the Rental key setting function. The display will
change to R-Key.
s. o d 2009-0 0 H l2•..J>
f�--f:E: V
TYPICAL - GAUGE CONTROL BUTTONS
1. MODE button
2. SET button
3. UP/DOWN arrow button
EXAMPLE - RENTAL KEY SET TO 5
5. Press the UP/DOWN arrow button to toggle

the key setting between 1 and 5. See table for
speed limitations according to setting.
1111r1 ·nc:. 6. Press the SET button once to save the setting,
I ILJ..UC� twice to exit the function, or simply wait for the
function to time-out. The change in key setting
will automatically be saved.
smo2009-0 02-1! 4_ b
FUNCTION SELECTED - KEY MODE
smr2011·024 267
NOTE: The key speed setting is applicable to any

key of the same type used on a specific water
craft. The same key type used on a different wa
tercraft may therefore have a different key speed
setting.
D.E.S.S. KEY SPEED APPROX. MAX.

KEY TYPE SETTING SPEED
5 58 km/h (36 MPH)
4 55 km/h (34 MPH)

LEARNING
3 50 km/h (31 MPH)
KEY
2 47 km/h (29 MPH)
1 42 km/h (26 MPH)
5 74 km/h (46 MPH}
4 69 km/h (43 MPH)

RENTAL
3 63 km/h (39 MPH)
KEY
2 58 km/h (36 MPH)
1 51 km/h (32 MPH)
268 smr2011-024
Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC})
OPERATING MODES (RXT, GTX AND WAKE PRO SERIES)

RXT-X
GTX GTX iS, WAKE GTX GTX
OPERATING MODE AVAILABLE as, RXT
LTD iS RXTiS PRO 215 155
RXT-X
Touring mode x x x x x x x
Sport mode x x x x x x x
ECO mode N.A. NA N.A N.A. N.A. NA x
Cruise mode x x Opt x x x x
Slow speed mode x x Opt x x x x
Ski mode Op t Opt Opt x Opt Op t Opt
Learning and re ntal key mode s x x x x x x x
X = In dicates a standard feature

Opt = Indicates a feature available as an option
N.A. = Not Available
Touring Mode
By default, the watercraft is set to TOURING
mode of oper?tion when started.
A TOURING mode indicator is ON in the multi
function gauge to confirm the active mode of op
eration.
•mo20 1 � 2-201_a
1. Sport mode indicator
Once activated, SPORT MODE will remain active

unti l it is deactivated by the operator, or the engine
is shut down whereby it defaults back to TOUR
ING MODE.

smo201 0-002· 1 00_• (Quick Method)
1. Touring mode indicator
To quickly activate sport mode while riding at
speed, carry out the following:
Sport Mode
NOTE: If using a LEARNING or RENTAL key, A WARNING
sport mode of operation is not available.
When activating sport mode, be sure to
A SPORT mode indicator is on in the multifunction maintain situational awareness of other wa
gauge to confirm the active mode o f operation. tercrafts, obstacles, or persons in the water.
1. Depress and hold the SET button for at least 3

seconds.
smr2011-024 269

scroll across the multifunction display: ENTER
ING SPORT MODE INCREASED ACCELERA
-
TION INSTRUCT PASSENGERS TO HOLD -

-
PRESS_SET_BUTTON.
•mo2010-00Vi01 JI
1. SPORT mode indicator

and stay on as long as sport mode is active.

(Through Information Center)
&mo2010-002·102 To activate sport mode through the gauge func

MESSAGE - ENTERING SPORT MODE - tions, carry out the following:
A WARNING
A WARNING Activating sport mode through the informa
Ensure passengers are advised that sport tion center should only be carried out with
mode provides for increased accelerations the watercraft stopped and the engine run
and to hold on tight ly .
ning at idle. The operator must ensure to
maintain situational awareness of other wa
tercrafts, obstacles, or persons in the water.
mode.
A scrolling SPORT MODE ACTIVATED mess age
will momentarily confirm that sport mode has
been activated.
"""' 201Q.()()2·101
FUNCTION SELECTED - DRIVING MODE

MESSAGE- SPORT MODE ACTIVATED
2. Press the SET button to enter the driving mode

NOTE: After a few seconds, the gauge will revert
function.
to its normal display.
270 smt2011-024
Subsection 01 {INTELLIGENT T H RO TT L E CONTROL OTC}}

scroll across the multifunction display ENTER
ING SPORT MODE - INCREASED ACCELERA
TION - INSTRUCT PASSENGERS TO HOLD -
PR ESS SET_BUTTON.
_
s rnc 20t 0..00 2-201_

a
1. SPORT mode indicator

and stay on as long as sport mode is active. If
the engine is not at idle and sport mode cannot
be activated, the following message will appear:
SPORT MODE - RETURN TO IDLE TO ACTIVATE.
smo2010-002· 102
MESSAGE - ENTERING SPORT MODE -

INCREASED ACCELERATION - INSTRUCT PASSENGERS TO (Through Information Center)
To deactivate sport mode, carry out the following:
A WARNING
A WARNING
Ensure passengers are advised that sport
mode provides for increased accelerations Deactivating sport mode through the infor
and to hold on tightly. mation center must only be carried out with
the watercraft stopped and the engine run
ning at idle.
mode.
A scrolling SPORT MODE ACTIVATED message
will confirm momentarily that sport mode has
been activated.
�if1[Jf�T
smo20 10·002· 1 1
0.
FUNCTION SELECTED- DRIVING MODE
MESSAGE- SPORT MODE ACTIVATED
2. Press the SET button to enter driving mode

NOTE: A fter a few seconds, the gauge will exit
function.
the function and return to its normal display.
smr2011-024 271
NOTE: The following message will scroll in the

multifunction display SPORT MODE ACTIVE -
PRESS_SET_TO_DISENGAGE.
smo201 (),.()()2-100_•
1. Touring mode indicator
ECO Mode
(Fuel Economy Mode)
•mo2010-00?-1()4 How to Activate Fuel Economy Mode
MESSAGE - SPORT MODE ACTIVE -
PRESS_SET_ TO_DISENGAGE 1. Press the MODE button repeatedly until the
following function appears in the multifunction
3. Press the SET button again to disengage sport display.
mode.
MULTIFUNCTION DISPLAY
NOTE: The following message will scroll in the
multifunction display SPORT MODE DEACTI FUEL ECONOMY MODE
VATED .
2. Press SET button to enter the function, the fol
FUEL ECONOMY MODE - HOLD SET TO

ACTIVATE OR MODE TO EXIT
3. Press and hold SET button to activate fuel econ

omy mode as instructed.
When activated, the following will occur:
- The multifunction display reverts back to previ
ous indication.
- A flashing ECO indicator will appear next to the
fuel tank symbol.
•mo201 0-002 · 105

- A flashing smile will appear in the fuel tank sym
MESSAGE - SPORT MODE DEACTIVATED bol.
NOTE: After a few seconds, the gauge will exit How to Deactivate Fuel Economy Mode
the function and return to its normal display. 1. Press the MODE button repeatedly until the
4. Ensure the TOURING mode indicator is on. following function appears in the multifunction
display.
FUEL ECONOMY MODE
2. Press SET button to enter the function, the fol

272 smr2011-024
MULTIFUNCTION DISPLAY MESSAGE MULTIFUNCTION DISPLAY MESSAGE
FUEL ECONOMY MODE - HOLD SET TO CRUISE MODE ACTIVE

DEACTIVATE OR MODE TO EXIT
Cruise Mode
3. Press and hold SET button to deactivate fuel
economy mode as instructed. Cruise Mode Activation at Constant Speed
When activated, the following will occur: All Models
- The multifunction display reverts back to previ-
1. Accelerate to the desired watercraft speed and
ous indication.
hold throttle steady.
- The flashing ECO indicator will disappear.
- The flashing smile will disappear.
mately 1 second.
Cruise Mode
Prerequisite for Cruise Mode Activation
GTX 155 Model

CRUISE MODE can be activated:
- At idle in forward thrust up to approximately
10km/h (6MPH)
- Whenever at constant speed above 10km/h
(6MPH).
All Models except GTX 155

CRUISE MODE can be activated at a constant
s dcl'l 009-00 1 ·024 .J
speed above approximately 3800 RPM.
ENGAGING CRUISE AT SPEED
Step 1: Accelerate to desired speed and hold throttle steady
Cruise Mode Activation at Id le Speed Step 2: Press CRUISE button
GTX 155 Only You will hear a beep indicating that you are now in
NOTE: This function is available up to approxi cruise mode, and a green CRUISE indicator light
mately 10km/h (6MPH). will be lit.
To activate and preset CRUISE MODE at idle
speed in forward thrust:
1. Press and hold the cruise button until the fol
lowing message appears in the multifunction
display.
CRUISE MODE_SELECT SPEED _PRESS SET

CRUISE MODE INDICATOR - GTX 155
TO ACCEPT OR MODE TO EXIT
2. Press the UP arrow button until the desired

cruise speed is indicated in the numerical dis
play. The following message will scroll in the
CRUISE MODE_SPEED ADJUSTING
3. Press the SET button to save the cruise speed

selected and engage cruise speed function.
The following message will scroll in the multi
function display.
smr2011-024 273
Deactivating Cruise Mode

To deactivate cruise mode:
1. Release the throttle lever.
2. Press the cruise button.
Deactivation of cruise mode is indicated by:
- The CRUISE indicator light in the speedometer
display will go off.
- A BEEP will be heard.
NOTE: If the throttle lever is not fully released
when the cruise button is pressed to deactivate
cruise mode, the BEEP will not be heard and the
cruise light will remain on. The speed limiting
function of cruise mode will stay active until the
CRUISE MODE INDICATOR LIGHT - OTHER MODELS throttle is fully released, then the BEEP will be
heard and the cruise light will go out.
NOTE: Activating cruise mode of operation only
limits the maximum speed available when de
Slow Speed Mode
pressing the throttle lever. The throttle lever
must be held in to maintain forward speed. Wa The operator can set idle speed between
tercraft speed can be varied from idle up to the 1.6 km/h to 11 km/h (1 MPH to 7 MPH).
set cruise speed using the throttle lever once the If you accelerate above approximately 14 km/h
cruise function is activated. Watercraft speed (9 MPH) , Slow Speed Mode will be deactivated
may vary depending on water conditions during and the engine will return to idle RPM when the
use. throttle is released.
Changing Set Cruise Speed Should a situation arise where the operator must
stop or accelerate quickly away from a hazardous
To increase or decrease the set cruise speed:
situation, pulling in the iBR lever, or pulling in on
1 . Keep throttle lever fully depressed. the throttle lever will deactivate slow speed mode
2. Press the UP/DOWN arrow button. and normal control of the watercraft will be re
turned to the operator.
Activating Slow Speed Mode

To activate slow speed mode of operation:
1. Release the throttle lever to idle RPM.
2. Pull in and release the iBR lever to engage neu
tral.
mately 1 second.
TYPICAL
1. CRUISE button
2. Throttle lever
3. UP arrow button
CRUISE MODE _ SPEED ADJUSTING
3. Press the UP/DOWN arrow button to adjust

speed accordingly. odd2009-00 1-024_Q
TYPICAL
7. CRUISE button
274 smr2011-024
All Models Except GTX 155

The green CRUISE indicator light will come on in
the speedometer or multifunction display to indi
cate cruise activation.
s mo2009-002� 1 l 4_
u
CONTINUOUS MESSAGE - SLOW SPEED MODE

7. Scrolling SLOW SPEED MODE message
2. Numerical display reverts to previous indication
Changing Set Slow Speed

NOTE: There are 5 slow speed settings available
(1 through 5). Adjust slow speed mode to desired
CRUISE MODE INDICATOR LIGHT
speed.
A message will scroll in the multifunction display To increase or decrease the set slow speed,
to specify that you are now in slow speed mode. press the UP/DOWN arrow button on the RH
MULTIFUNCTION DISPLAY MESSAGE handlebar once, or repeatedly.
SLOW SPEED MODE_ SPEED ADJUSTING MULTIFUNCTION DISPLAY MESSAGE
SLOW SPEED MODE_ SPEED ADJUSTING

The default slow speed setting of 1 will also come
on for a few seconds in the numerical display. The setting point indication in the digital screen
will come back on to indicate the slow speed set
ting change.
smo2009· 002·114 .z
SLOW SPEED MODE INDICATION

1. Scrolling SLOW SPEED MODE ACTIVATED message
2. The slow speed setting appears for a few seconds smo200 9·002·114_u
CONTINUOUS MESSAGE - SLOW SPEED MODE

NOTE: The scrolling SLOW SPEED MODE mes 1. Scrolling SLOW SPEED MODE message
2. Numerical display reverts to prevo
i us indication
sage repeats itself as long as slow speed mode is
activated. The numerical display reverts back to The displays will revert back to their previous in
the previous indication after a few seconds. dication a few seconds after the last activation of
the UP or DOWN arrow button.
smr2011-024 275
NOTE: As a reminder, the following message will The operator may increase or decrease the tar
scroll across the multifunction display periodically get speed to any value within the selected RAMP
as a reminder. speed range.
MULTIFUNCTION DISPLAY MESSAGE If the desired target speed cannot be set in the
selected RAMP, you must exit then reengage SKI
SLOW SPEED MODE ACTIVE
MODE, and select a different RAMP.
The displays will revert back to their previous in Engaging and Using Ski Mode
dication Cl few seconds after the last activation of To engage ski mode, carry out the following steps:
the UP or DOWN arrow button.
1. Press the MODE button repeatedly until SKI
Deactivating Slow Speed Mode MODE is visible in the multifunction display.
The slow speed mode can be deactivated using
any of the following methods:
- Pressing the cruise button
- Depressing the iBR lever
- Accelerating past the set slow speed.
When deactivating SLOW SPEED MODE by
pressing the cruise button, or accelerating using
the throttle lever, the iBR gate stays in the for
ward position.
When using the iBR lever, the iBR gate will move
towards the reverse position. then neutral when
the lever is released.
SLOW SPEED MODE deactivation will be indi 1. MODE button
cated in the following manner:
- The CRUISE indicator will go out
- The scrolling SLOW SPEED MODE ACTIVE
message will cease.
Ski Mode
RAMP Function 1t11r1 nc:
RAMP 1 provides for the smoothest launch and I ILJJJC�
most gradual acceleration. RAMP 1 also provides
for the slowest TARGET SPEED range.
RAMP 5 provides for the quickest launch and
most rapid acceleration. RAMP 5 also provides
the highest TARGET SPEED range.
The RAMP setting that is selected by default smo2010-002-116
SELECTED FUNCTION SKI MODE

when entering ski mode may be changed to a •
different setting. 2. Press SET to enter the function. The multifunc

TARGET SPEED Function tion gauge message will change to RAMP. The
RAMP setting number will be visible in the nu
Once the RAMP has been selected, an average
merical display.
PWC target speed for that RAMP will be visible in
the numerical display.
The average speed displayed and the speed range
available is dependent on the RAMP selected.
The higher the RAMP number, the higher the
speed range.
276 smr201 l-024

5. Press the UP or DOWN arrow button to in

crease or decrease the target speed.
6. Press SET to lock in the target speed, the dis
play will switch to the following scrolling mes
sage SKI MODE - PRESS_SET_TO START OR
MODE TO EXIT.
sdd 2009-001-0'24J
7. SET button 35-

JtJlfl nc:
I ILJJJC�
� 1
'
sm o2 010-002- 1 19
SCROLLING MESSAGE - SKI MODE_PRESS_SET_ TO START

OR MODE TO EXIT
NOTE: A BEEP will be heard every 5 seconds as

a SKI MODE engaged reminder.
7. Press SET again, the following confirmation
•
m o20Hl-002- 117 _a
message will appear SKI MODE ACTIVE - RE
TURN TO IDLE TO CANCEL.
FIRST SETTING AVAILABLE - RAMP
1. RAMP setting
3. To change the RAMP setting, press the UP or

DOWN arrow button until the desired ramp
mode number is visible in the numerical dis
play.
4. Press SET to lock in the ramp setting, the mul 35·�
1t11r1 nc: 1r·
tifunction display will change to the TARGET
SPEED setting function. I ILJJJC� F1L. T'
smo2010.002·120
SCROLLING MESSAGE - SKI MODE

ACTJVE_pRESS_MODE_AND RETURN TO IDLE TO
CANCEL
NOTE: The SKI MODE indicator light will also

blink on the speedometer or multifunction display
when ski mode becomes active.
srn o20 1 0-0 02- l 18
SECOND SETTING AVAILABLE - TARGET SPEED

1. TARGET SPEED setting
smr2011-024 277
NOTE: When the throttle is fully released during

ski mode operation, the system returns to ski
mode engaged status. The SKI MODE indicator
light will go out but, ski mode will remain engaged
and a message to that effect will reappear in the
SCROLLING MESSAGE
SKI MODE - PRESS SET TO START OR
MODE TO EXIT
11. Press SET to reactivate ski mode and fully pull

in the throttle lever to start another ski run.
TYPICAL -ALL MODELS EXCEPT GTX 155 Deactivating Ski Mode

To exit ski mode at any given point during the ski
NOTE: Ski mode cannot be engaged if the throt
mode setting process, press the MODE button.
tle is not fully released, and if CRUISE or SLOW
SPEED mode is engaged. A message will appear To end a ski run and completely deactivate ski
in the multifunction display advising you of the sit mode, release the throttle to idle, then press the
uation. Follow the instruction in the display. MODE button.
8. To launch the PWC in ski mode, pull in and hold

Learning Key and Rental Key Modes
the throttle lever all the way to the handlebar
grip. The PWC will accelerate to the set TAR There are 5 speed settings available for each
GET SPEED and the SKI MODE indicator will be learning and rental modes.
on steady. By default, the speed setting is 5 (highest).
9. To increase or decrease the TARGET SPEED Changing Learning or Rental Key Speed
during a ski run, press the UP or DOWN arrow Settings
button, do not release the throttle lever.
NOTE: Changing key settings is only available
when the engine is not running.
To change learning or rental key settings, carry out
the following:
1. Press the START/STOP to wake up the electri
cal system and install the NORMAL key on the
2. Wait for the information center to complete its
self-test and display the key recognition mes
sage.
3. Press the MODE button repeatedly until KEY
MODE is visible in the digital screen of the in
•dd2CI00-00 1 .024_h
formation center.
1 Hold throttle lever in
2 Press UP arrow button to increase Sf)6ed
3. Press DOWN arrow button ro increase speed

SKI MODE - SPEED ADJUSTING
NOTE: If the throttle is partly released during a

ski run, the SKI MODE indicator light will start to
blink and the speed adjust function using the UP
or DOWN arrow button will be deactivated.
10. To end a ski run or to pick up a fallen skier or
wakeboarder, fully release the throttle to re
gain normal throttle control.
278 smr201 l-024

TYPICAL - GAUGE CONTROL BUTTONS

1. MODE button smo2009-002-114 _cc
2. SET button
3. UP/DOWN arrow button TYPICAL - RENTAL KEY SET TO 5
5. Press the UP or DOWN arrow button to toggle

the key setting between 1 and 5. See table for
speed limitations according to setting.
6. Press the SET button once to save the setting,
twice to exit the function, or simply wait for the
function to time-out. The change in key setting
1t11r1 -nc: will automatically be saved.
I ILJJJC� NOTE: The key speed setting is applicable to any

key of the same type used on a specific water
craft. The same key type used on a different wa
tercraft may therefore have a different key speed
setting.
D.E.S.S. KEV SPEED APPROX. MAX.

s m o 2 -00S.002·114_ b KEV TYPE SETTING SPEED
FUNCTION SELECTED - KEY MODE
5 58 km/h (36 MPH)
4. Press the SET button once to enable learning 4 55 km/h (34 MPH)
key mode setting function. The display will LEARNING
change to L-Key. 3 50 km/h (31 MPH)
KEY
2 47 km/h (29 MPH)
1 42 km/h (26 MPH)
5 74 km/h (46 MPH)
4 69 km/h (43 MPH)

RE NTAL
3 63 km/h (39 MPH)
KEY
I f' c· ti 2 58 km/h (36 MPH)
l. -- 'c: ' 1 51 km/h (32 MPH)
smo2009·002 -11 d._c
TYPICAL - LEARNING KEY SET TO 1
NOTE: Pressing the SET button twice will enable

the Rental key setting function. The display will
change to R-Key.
smt2011-024 279
PROCEDURES All Models

5. Reach in under the steering support and discon
THROTTLE ACCELERATOR nect the 24-pin steering connector.
SENSOR (TAS)
General
The throttle accelerator sensor (TAS) is a double
hall effect sensor thrit sAnrls a signal to the ECM
which is proportional to the throttle lever angle.
obl2 0 1 0-034-01 9_c
7. 24-pin connector
6. Connect the DIAGNOSTIC HARNESS (PIN 529 036

1. Throttle lever
2. Throtrle accelerator sensor (TASJ 188) to make an in-line connection between the
disconnected connectors.
First ensure the throttle lever functions ade
quately. Pull the throttle lever fully in towards the
handlebar, then release it. It must reach the wide
open position and return to the idle position freely
when released. Otherwise, refer to STEERING
SYSTEMfor an inspection.
TAS Voltage Test

Check the voltage of the throttle accelerator sen �900 81 88
sor as follows.
NOTE: Use only the 24 pin connectors.
1 . Open the front storage cover and remove the
storage bin. 7. Install the tether cord on the engine cut-off
switch.
iS Models
8. Briefly press the START button to wake up the
2. Lift suspension using the iS UP button to gain ECM.
access.
9. Use the FLUKE 1 1 5 MULTIMETER (PIN 529 035
NOTE: If more height is required or if the iS can 868) and select Vdc.
not be used, manually lift suspension by the an
chor points close to handlebar and safely lock in 10. Measure the voltage readings on the installed
diagnostic harness connector as follows. Re
this position. Do not lift the watercraft from the
anchor points. fer to wiring diagram for details.
Models Without iS
3. As applicable, disconnect the top of the 2 front
air ventilation hoses for ease of access to steer
ing connector. Refer to BODY subsection.
4. As applicable. remove vertical panel in front
storage compartment.
280 smr2011-02-4
Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC}}
I
WIDE OPEN
24-PIN CONNECTOR IDLE POSITION
POSITION
PIN VOLTAGE (Vdc)
9 (VI/BU) 3 (BK) 4.9 - 5.,

3 (BK) 6 (Yl/BU) 0.15 0.35
-
I 1.4 - 1.6
10 (Vl/GN) 4 (BK) 4.9 - 5.1

4 (BK) 7 (Yl/GN) 0.4 - 0.6
I t.9 - 3.1
If voltage is as per specification, the TAS sensor

is functional.
If voltage is out of specification, check continuity
of wires between the ECM and the sensor. If con
tinuity is good. replace sensor.
11. Reinstall removed components.
TAS Replacement (Except X Package) 1. Align pin into hole
1. Remove steering cover. Refer to STEERING 7. Press sensor into position until locking tabs en
SYSTEM gage. Ensure it is properly locked in place.
2. Pry out sensor locking tabs and pull out sensor. 8. Route harness through the notched bracket.
5mf20()9.()3!). 100.o
, ,,.'2009-030 1 0 2.JJ
Step 1: Pry out
Step 2: Pull out sensor 1. Route hamess here
3. Pull up on the connector end of the TAS and 9. When installation is complete, ensure throttle
gently pull it out of the throttle handle. lever functions properly.
4. Remove connector from TAS sensor.
TAS Replacement (X Package Only)
5. For installation, reverse the removal procedure.
Pay attention to the following. TAS Removal
6. Align sensor pins in their holes. 1 . Remove the 2 screws in the front of the upper
handlebar housing.
smr2011·024 281
..... 201D-031-003_
a
Step 1: Remove these two screws Step 3: Hold on to this housing cover
Step 4: Unlock this tab
2. Remove the screw at back of the handlebar.

5. Remove the housing cover from the handlebar.
smf2010-03'-oo2 -•
Step 2: Remove this screw

smr201 0-031-004 _a
ffloi[iJj Do not try to pull the cover off the Step 5: Remove housing cover
housing at this time or damage to the cover will

6. Rele ase the two tabs that retain the TAS in the
occur.
handlebar housi ng.
3. Grab ho ld of the housing cover to prevent it
from falling off the handlebar when unlocking
the upper housing in the following step.
4. Using a small screwd rive r unlock the tab that
,
retains the upper housing and pull the upper

housing off.
l+f[,Ji[iJj As you remove the upper housing,

hold on to the housing cover to prevent it from
fall ing off the handlebar.
Step 6: Release TAS retaining tabs (21
7. Pull up on the connector end of the TAS.
282 smr2011 ·024

8. Gently pull TAS out of the throttle handle.
Step 1: Ensure proper wire routing
2. Insert the TAS in the throttle lever.

Step 7: Pull up at connector end
Step 8: Pull TAS out of throttle lever here 3. Align the TAS in the housing, then press it into
the housing until both locking tabs engage. En
9. Remove the connector from the TAS. sure it is properly locked in place.
4. Ensure wiring is not pinched.
5. Position the housing cover onto the handlebar
housing.
6. Ensure positioning of corrugated conduit.
Step 9: Remove TAS connector
TAS Installation
dure however, pay attention to the following.
1. Install connector on TAS and ensure wiring is s m r2 0 10-03 1-009_a
properly positioned in handlebar housing. Step 2: Insert TAS in throttle lever
Step 3: Ensure locking tab engagement
Step 4: Ensure wiring is not pinched
Step 5: Install housing cover
Step 6: Ensure proper corrugated conduit positioning
7. Position the upper housing on the handlebar

housing.
8. Ensure proper engagement of the upper hous
ing and cover tabs.
smr2011-024 283
smr'l010431 -01l_b
TYPICAL
7. Read Data
omt2010-031-0l 0J
2. Monitoring tab
Step 7: Ensure engagement of housing cover retaining tabs 3. Cluster tab
Step 8: Ensure engagement of upper housing locking tabs 4. Cruise indicator light
9. Install the three retaining screws for the upper

housing and torque them to 2 N•m (18 lbf•in). Switch inputs
10. Ensure there are no fault codes. Connect wa
tercraft to the latest B.U.D.S. software. refer 1 UP: e> Mode Button: i)
to DIAGNOSTIC AND FAULT CODES
Down: <C) Set Button: (it
11. Ensure proper operation of throttle lever and
TAS with engine running. Cruise:�
1
CRUISE SWITCH
Cruise Switch Test
If pressing the cruise switch does not engage the
TYPICAL
CRUISE or SLOW SPEED modes, test the cruise 7. Cruise indicator light
switch as per following procedure.
If the test succeeded, the switch and wiring are
1. Connect the watercraft to the latest B.U.D.S.
good and the problem may be related to the
software. Refer to COMMUNICATION TOOLS
information center or ECM. Check for related
AND 8.U.D.S subsection for details.
fault codes. Refer to DIAGNOSTIC AND FAULT
2. In B.U.D.S click the Monitoring tab then the
..
CODES
Cluster tab.
If the test failed, test the switch and wiring as de
3. Press the cruise button on the RH handlebar scribed in the following steps.
and look for the Cruise indicator light to come
4. Remove the gauge support cover. Refer to
on in the Switch inputs area.
GAUGE subsection.
5. Disconnect the gauge connector.
ti![eJDHj Pull connector lock out sideways.

Do not twist the screwdriver.
284 smr2011·024
10
snv2Q09.036003_ •
GAUGE CONNECTOR PIN-OUT
3. Attach a string approximately 1.2 m (4 ft) to the

s mr2009·042-00 l 3
end of the wires which will be used for draw

1. Gauge connector
2. Pull out to unlock connector ing the new switch wires through the harness
protective sheath.
6. Use the FLUKE 115 MULTIMETER {P/N 529 035
4. Remove steering cover. Refer to STEERING
868).
AND 0. T.A. S. subsection.
7. Select the n (ohm) function.
5. Remove the MODE/SET and UP/DOWN arrow
8. Test the cruise button switch as per following switches from its support.
table.
- NOTE: I t is not necessary to disconnect
CRUISE SWITCH TEST switches.
SWITCH
GAUGE CONNECTOR RESISTANCE
POSITION
Switch
OL
released
Pin 7 Pin 10
Switch
Close to 0 n
depressed
If the test failed, replace the cruise switch.

If the test succeeded, the problem may be internal
to the information center. Try a new one.
Cruise Switch Replacement

1. Disconnect information center connector.
1. MODE/SET and UP/DOWN arrow switches

2. Cruise switch
6. Remove the cruise switch by lifting it off its sup

port.
7. Cut the locking ties from the harness sheath as
necessary.
8. Carefully pull the wires out of the harness.
Ensure the string draws through the harness
sheath.
9. lie the string to the new cruise switch wire
ends and pull the new wires through the har
ness.
1. Gauge connecror
2. Pull out to unlock connecror 1 O. Install new switch terminals in the gauge con
nector.
2. Remove terminal 7 (GRAY wire) and 10 (BLACK
11. Apply a small amount of DIELECTRIC GREASE
wire) from the gauge connector.
(P/N 293 550 004) on switch terminals.
smr2011-024 285
12. Reconnect gauge connector.

13. Properly insert cruise switch wiring in slot in
switch support before installing MODE/SET
and UP/DOWN arrow switches.
am r2009-036-0t 4_a
SOME PARTS REMOVED FOR CLARITY

1 Cruise switch
2. Wmng in slot
3. MODE/SET and UP/DOWN arrow switch connector
14. Complete installation in reverse order of re

moval.
286 smr2011-024
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI))
ELECTRONIC FUEL INJECTION (EFI)

SERVICE TOOLS
DIGITAL INDUCTION TACHOMETER ........................................... 529 014 500 ......................................... 288

ECM ADAPTER TOOL..................................................................529 036 166 ........................ 292, 302, 31 0, .
314, 316, 318, 320

FLUKE 115 MULTIMETER .......................................................... . 529 035 868 ........ 292, 301-303, 308, 310, .
312, 314, 317-318

FUEL HOSE DISCONNECT TOOL ................................................ 529 036 037 ......................................... 297

FLUKE RIGID BACK PROBE ...... ... ........ . ........... . . .. .... ...... . .
.. .. .. . . ... . TP88 ......................................... 312
SERVICE PRODUCTS
LOCTITE 243 (BLUE) ........... .. ...... ..... .. . . .
.. . . . . .. . . . . . . . .. . . . . . . .. .
. . . .. . . . . . . . . 293 800 060 ................. 294, 298, 311, 321
LOCTITE 518 . . . . . . . . . . . . ................ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . 293 800 038 ......................................... 319
GENERAL A WARNING
Fuel lines remain under pressure at all times.
A WARNING Always proceed with care and use appro
Always disconnect battery prior to working priate safety equipment when working on a
on the fuel system. Always disconnect bat pressurized fuel system. Wear safety glasses.
tery exactly in the specified order, BLACK Do not allow fuel to spill on hot engine parts
(-) cable first. Electrical connections should and/or o n electrical connectors. Proceed with
be disconnected prior to disconnecting fuel care when removing or installing high pres
lines. sure test equipment, or disconnecting fuel
line connections. Wipe off any fuel spillage
A WARNING in the bilge. Never use a hose pincher on
Fuel vapors are flammable and explosive un high pressure hoses.
der certain conditions. Ensure work area is
well ventilated. Do not smoke or allow open When the repair is completed, ensure the hose
flames or sparks in the vicinity. from the fuel rail to the fuel pump is properly con
nected and secured in its support. Pe rform the
Use B.U.D.S. software to release the fuel pres FUEL SYSTEM HIGH PRESSURE LEAK TEST as
sure in the system prior to disconnecting a fuel described in FUEL TANK AND FUEL PUMP sub
line. Refer to FUEL TANK AND FUEL PUMP sub section.
section
A WARNING
Cover the fuel line connection with an absorbent
Always perform the fuel system high pres
shop rag before disconnecting them. Slowly dis
sure leak test if any component has been
connect the fuel hose to minimize spilling.
removed or disconnected.
If a gasoline leak and/or odor is present, do

not start the engine. Repair the leak.
smr201 l-025 287

SYSTEM DESCRIPTION Air for combustion is drawn in by the engine or by

a mechanically- driven supercharger. The air flows
The electronic fuel injection system (EFI} on through the throttle body and is controlled by a
this engine is based on the open-loop Bosch
throttle plate.
M E-Motronic system. It is comprised of various
sensors used for detecting ongoing operating Fitted on the throttle body, an electric throttle ac
conditions of the engine and watercraft, and in tuator (ETA) allows the ECM to electronically con
cludes all the actuators that perform the required trol the throttle plate opening which regulates the
adjustment to the engine. amount of air that enters the engine, and there
fore engine speed.
This system also introduces torque management
functions. There is no idle air control valve (IACV).
Electrical System Fuel System
ECM (Electronic Control Module) Fuel Rail
From input signals (e.g. throttle lever, iBR lever), A single fuel rail is mounted on the intake mani
the ECM acknowledges driver demands and fold. The fuel rail ensures that enough fuel can be
converts them to an engine torque requirement delivered to the fuel injectors throughout the en
through calculation of several variables. Then, the gine operating range.
ECM controls the iTC (intelligent Throttle Control), The fuel rail is fed by the fuel pump. The fuel pres
the injection system and the ignition system to sure applied to the fuel rail is regulated by the fuel
meet the torque requirement. pressure regulator located in the fuel pump mod
The ECM manages the engine torque require ule.
ments and controls engine operation to ensure it Fuel Injectors
is delivering optimum performance, fuel economy
Three fuel injectors are used to inject fuel into the
and meeting emission regulations. The ECM also
controls idle speed and limits maximum engine intake ports of the cylinder head. One injector is
used per cylinder.
speed.
Since the ECM manages several torque require Fuel Pump
ments at the same time including contradictory An electric fuel pump with an integrated pressure
demands (such as the throttle lever and the iBR regulator is used. For more details on the fuel
lever being fully pulled in at the same time), it pump unit, refer to FUEL TANKAND FUEL PUMP
must prioritize the most important requirement subsection.
according to predefined conditions and apply the
proper action.
ADJUSTMENT
EFI Sensors
The ECM reads the inputs from the sensors IDLE SPEED
which it compares to predetermined parameters
Idle speed is not adjustable. The ECM controls
stored in the ECM, makes computations. and ac
the idle speed of the engine through the iTC sys
tivates the outputs accordingly (injectors, ignition
tem by controlling throttle plate opening using the
coils etc.).
ETA (electric throttle actuator).
Signals from sensors are used by the ECM to de
If desired, the engine RPM can be measured fol
termine the injection and ignition parameters (ref
lowing this procedure:
erenced to fuel and ignition maps) as required to
maintain the optimum air-fuel ratio. 1. Use a DIGITAL INDUCTION TACHOMETER
(P/N 529 014 500).
Air Induction
Throttle Body
A 62 mm throttle body is mounted on the intake
manifold.
288 smr2011·025
2. Press the START button to wake up the ECM.

3. Install the tether cord on the engine cut-off
switch.
4. In B.U.D.S., click the ECM Setting tab, then
Cl t::I t:l t:l click on the Reset button.
ClCIOO
r---11111II\
�/
52901 4500
Closed Throttle,----- l
2. Wrap the tachometer's wire a few times
around the protruding part of the ignition coil. Throttle Opening: 1 0.0 1
,,,.,.
"-""="'
...
B.eset
==��__,,,
�
}("
'
.
:e:::::i ,__-,-.....,.
smr2009-030-002,..a
ECM SETTING PAGE IN B.U.D.S.

1. Click Reset button
The following message will confirm the operation.
Closed TPS was successfully

reset.
A32CCIA
TYPICAL
3. Start engine, read the engine RPM on the in- s mr200S-030-003
duction tachometer.
Reset is completed.
NOTE: If idle speed is not within specifica
tions, check if there is any occurred or active NOTE: It is not necessary to click on the Write
fault code(s}. If not, proceed with the CLOSED button in B.U.O.S.
THROTTLE RESET PROCEDURE If idle speed is Exit B.U.D.S.
still not adequate, there is probably a mechanical
NOTE: If the throttle valve was not within the al
problem.
lowed range when the Closed Throttle reset was
carried out. no error message would be displayed.
CLOSED THROTTLE RESET However, a fault code would be set when the en
gine is started.
General Information
5. Start engine and make sure it operates normally
This operation performs a reset of the TPS values
through its full engine RPM range.
of the throttle body in the ECM.
6. Check for fault codes using B.U.D.S. If a fault
Closed throttle reset must be carried out only
code related to the throttle actuator appears,
when:
clear it, then carry out another Closed Throttle
- Replacing the throttle body.
reset procedure. To clear faults, refer to DIAG
- Replacing the ECM. NOSTIC AND FAULT CODES subsection.
Closed Throttle Reset Procedure

1. Use the B.U.D.S. software to perform this set
ting. Refer to COMMUNICATION TOOLS AND
B.U.D.S. subsection.
smr2011-025 289
TROUBLESHOOTING PROCEDURES
DIAGNOSTIC TIPS ENGINE CONTROL MODULE
Engine problems are not necessarily related to the (ECM)
fuel injection system. ECM Access
It is important to ensure that the engine/propul Open/remove seat.
sion system, fuel delivery and electrical systems
are functioning normally. iS/llS Models
For diagnostics purposes, use B.U.D.S. software. 1 . Remove the rear ventilation box located over
See COMMUNICATION TOOLS AND 8.U.D.S. the engine. Refer to AIR INTAKE SYSTEM
subsection. 2. Remove deck extension. Refer to BODY.
After a problem has been solved, be sure to clear
All Models
the fault(s) in the ECM using the B.U.D.S. soft
ware.
A WARNING
All electrical actuators and electronic mod
ules are powered as soon as the START
button is pressed. Always disconnect the
battery prior to disconnecting any electrical
or electronic parts.
Never use a battery charger to temporarily substi

tute the battery as it may cause the ECM to func
tion erratically, or not at all.
Check related-circuit fuse solidity and condition
with an ohmmeter. A visual inspection could lead �5-•
to a false diagnosis. 1. ECM

2. ECM connectors
Electrical Related Problems

ECM Connector Identification
It is important to check the following in the elec
There are 2 connectors connected to the ECM.
trical system:
The engine harness female connector is con
- Battery voltage
nected to the ECM module male connector "A".
- Fuses
The vehicle system control harness female con
- Bus bar condition in fuse box
nector is connected to the ECM module male con
- Ground connections
nector ·s·.
- Wiring and connectors.
The ECM connectors have 48 pins.
Ensure that all electronic components are genuine
OEM. Any modification to the wiring harness may
lead to poor system operation or generate fault
codes.
Electrical Connections
Pay particular attention to ensure that terminals
and pins are not out of their connectors. corroded,
or out of shape.
When probing terminals, pay attention not to de
ECM CONNECTORS
form the terminals as this could cause a loose or
intermittent connection that would be difficult to
NOTE: For connector information, cleaning and
troubleshoot.
probing, refer to WIRING DIAGRAM subsection.
290 smr2011-025
ECM Power Supply Diagram ECM Wake Up Logic

With Tether Cord Installed
When the START button is pressed to start en
gine:
- ECM pin 8-01 receives current from battery via
the START switch. ECM is woken up.
- ECM pin B-H2 provides a ground to the relay
Relay coil in fuse box.
- The relay contacts close and provides main
12 Vdc power to the ECM at pin B-M4.
Lon - The relay also powers the other components in
the electrical system.
- ECM pin 8-E4 monitors for a tether cord in
stalled on the engine cut-off switch.
Signal
B·H2 - When a tether cord is installed, the magnet in
Wake up,�8=·01'------' the tether cord cap closes the reed switches
ECM in the engine cut-off switch and the ECM pin
B-F2 provides a ground. This tells the ECM the
tether cord is installed.
- ECM pin B-82 reads the D.E.S.S. key in the
-:- Engine tether cap and determines if it is valid. If so, the
$tTlr201 i -02s-001_aen engine can be started.
ECM Wake Up Validation Without a Tether Cord Installed
Press the START button. When the START button is pressed:

- The information center turns on, goes through
NOTE: Do not install the tether cord.
the self-test function, displays applicable mes
QUICK INDICATION THAT ECM IS POWERED sages and turns off a few seconds later.
(assuming the observed component is working) - The engine cannot be cranked.
- The ECM stays powered up until it removes
Information center turns on.
the ground to the relay coil after 3 minutes (pin
Fuel pump turns on for approximately 5 seconds. B-H2).
- Relay contacts open and power to the ECM is
NOTE: Since the tether cord is not installed, the removed.
information center will turn off a few seconds af - Power is also removed on all other electrical
ter the self-test, but the ECM and electrical sys systems except the GPS supply to the informa
tem will stay powered for approximately 3 min tion center.
utes longer.
ECM Shut Down Logic
If the ECM does not turn on, check the following:
- Fuses F8, F19 and F3 in fuse box When the engine is stopped by using the STOP
button or by removing the tether cord from the
- Battery voltage. Refer to CHARGING SYSTEM
engine cut-off switch, the following occurs:
- The 12 Vdc power bus bars in fuse box
- ECM stops the engine.
- The ground bus bar in fuse box
- After 5 seconds, the information center turns
- Relay and wiring. Refer to POWER DISTRIBU-
off.
TION
- After 10 seconds (130 and 155 engines) or 60
- ECM power supply wires and ground wires.
seconds (215 and 260 engines), ECM (pin B-H2J
See following procedure.
removes the ground to the relay coil.
smr2011·025 291
Subsection 02 {ELECTRONIC FUEL INJECTION (EFI))
- Relay contacts open and power t o the ECM is

removed.
- Power is also removed on all other electrical
systems except the GPS supply to the informa
tion center.
ECM Power Supply Test

1 . Remove cover from fuse box. Refer to POWER
DISTRIBUTION subsection.
2. Press the START button to wake up the ECM. cm12009 030-01 0
NOTE: Do not install the tether cord.

4. Use the FLUKE 115 MULTIMETER (PIN 529 035
3. Use the FLUKE 115 MULTIMETER (PIN 529 035 868) and select n.
868) and select Vdc.
5. Probe terminals as per following table.
4. Probe fuse F190 as illustrated.
ECM
NOTE: This will validate the fuse at the same FUSE BOX RESISTANCE
ADAPTER
time.
Terminal F1 Pin B-M4 Close to O S1
BATTERY
FUSE BOX VOLTAGE
POST
Fuse F190
terminal at Fl
Ground Battery voltage
Fuse F190
terminal at E1
omr2 009-030·
009_o
If an open circuit is measured, repair or replace

wiring and connectors.
If the ECM power circuit tests good, the problem
may be one of the following:
- Start switch circuit open to ECM, refer to
STARTING SYSTEM subsection.
If battery voltage is measured at E1 but not at F1, - ECM not providing a ground to relay in fuse box,
replace the fuse. refer to POWER DISTRIBUTION subsection.
If voltage is not measured at E1, check the wiring - ECM ground wire open circuit, refer to CONTI
and connections between the relay output and NUITY TEST OF ECM GROUND CIRCUITS in
F19 output. Refer to WIRING DIAGRAM this subsection.
If voltage is as per specification, carry out the - ECM internal problem.
CONTINUITY TEST OF ECM POWER CIRCUIT.
Continuity Test of ECM Ground
Continuity Test of ECM Power Circuit Circuits
1. Wait for electrical power to go off (approxi 1. Disconnect "B• connector from ECM.
mately 3 minutes). 2. Install ECM ADAPTER TOOL (P/N 529 036 166) on
2. Disconnect "B" connector from ECM. ECM connector.
3. Install ECM ADAPTER TOOL (PIN 529 036 166) on 3. Use the FLUKE 115 MULTIMETER (P/N 529 035
ECM connector. 868) and select n.
4. Probe adapter terminals as per following table.
292 smr2011-025
ECM BATTERY
RESISTANCE
ADAPTER POST
Pins B-L 1, Close to 0 n

Ground
B-M2 and B-M3 (continuity)
smr'2009-0 1 6-G26_b
LH SIDE OF ENGINE
1. Battery ground cable
2. Exhaust manifold warer inlet fitting
If everything tests good and ECM does not

sr
m2009·030·0 1 0_a power up, try a new ECM. Refer to ECM RE
PLACEMENT.
If measurement is out of specification, check
ground bus bar in fuse box and continuity of its
ECM Removal
wires and connections with the engine grounds.
Also check battery ground and engine grounds. NOTE: If a new ECM is to be installed, first read
the procedures in ECM REPLACEMENT in this
subsection.
1. Disconnect battery cables.
A WARNING
Always disconnect the BLACK negative (-)
battery cable first, then disconnect RED pos
itive (+) cable.
2. Disconnect both ECM connectors from ECM.

3. Unscrew all retaining screws and remove the
engine ECM fro m its support on the intake man
ifold.
TYPICAL
1. Ground bus bar in fuse box
smr'2009-030-025_b
$tll f2009-01 6.01 l _a 1 ECM

2. Retaining screws
FRONT OF ENGINE
1. Engine grounds
smr2011-025 293
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)}
ECM Installation
Reverse removal procedure however, pay atten
tion to the following.
1. Install ECM. Apply LbCTITE 243 (BLUE) (P/N 293
800 060) to mounting screws and torque to
5.5 N•m (49 lbf•in).
Rlni@j Always replace ECM by the same

part number or by a BRP approved equivalent.
Open
2. Reconnect ECM connectors. mm'1009-0Zl--0 B O
3. Reconnect battery cables. 3. Click once on the Folder Up button in the Open
box.
A WARNING
---
Always rec o nnect the RED po s i ti ve ( + ) battery Open -- r?l�
cable first, then reco nn ect BLACK negative(-)
look.in- lU Cuttomen
cable.
4. If a new ECM is installed, refer to ECM RE

PLACEMENTin this subsection.
ECM Replacement
Prior to replacing a suspected ECM, ensure that all
the recommendations in the general introduction nename; Im
of this section have been followed.
Fietolll'P« jMPEM '* ('.rmem)
When installing a new ECM, data must be entered
mm•2009-023-08 I _o
and a reset is required.
Double click on the AutoSave folder.
ECM Manual Data Entry
There are 2 possible methods to collect the re
quired information. The 1st bein g the easiest:
Open (1Jr><l
1. Use B.U.D.S. software and obtain the data
l.ookji: le 9UOSP2.3.19
t:)FRA
from a saved .mpem file on your PC com
puter.
2. Collect the information from the vehicle and
BOSSWeb.
1st Co l l ecti ng Method: Obtain i n g the Data

from a Saved .mpem File
Fie J)Mne: j•.mpem
1. Use the B.U.D.S. software.
Retol!>II« IMPEM lllet ('.mpem)
NOTE: It is not necessary to perform any connec
tion. The PC computer can be used alone.
2. In B.U.D.S., click on the Open button. NOTE: You may have to go to another AutoSave
folder from a previous version of B.U.D.S.
4. Choose the latest file saved for this specific ve
hicle.
294 smt2011-02S
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)}
Open f?lfXj 2nd Collect i n g Method: Collect the

Information from the Vehicle and BOSSWeb
1. Record engine serial number.
II
..P2.3.22. t2J8PSCX9959W0010l�-l01ss-t.mpem
P2,3,22,12_2flPS0(985911i)l{ll _20090206 _104558.mpem
.P2,3.22.12_VDV48580A909_20090206_t<f1803.11,,em
P2.3.22.I 2_28P5CX98S9V0100 0l_200902J01558,mpem
28
P2.3.ZZ. I2_2BPS<:X9659YOOOIO1,.200902_104558.mpem
29
>
P2.3.22. 12_28PSCX9BS91J0100 01_2009QZ?9_il4558.mpeln
�<, !EL
\ �-====================-::==
:: :=:�:
Fie� JP.2.:i21!.12_2BPSBKSCSWIXXl168_2009020 S'_
3
s mr2009-030-00 6
TYPICAL
IMPORTANT: Be sure to use the file that specifi

cally matches the vehicle you are servicing.
NOTE: The file name structure is as follows:
BUDS version_VIN_date read (yyyymmdd)_hour read

(hhmmss) mpem
Exampl e:
P2.3.22.12_2BPSBK8C68V000168_20090206_111640.mpem
Hence:
B.U.D.S. version: P2.3.22.12
VIN: 2BPSBK8C68V000168
Date: 2009 02 06
Hour: 11 h 16m 40s
5. Go in the Vehicle tab and record the following

L Engine serial number
information.
1. Vehicle serial number 2. Record the following numbers using
2. Engine serial number (without the leading BOSSWeb. Look in Service menu and
"M") choose Unit history.
3. Vehicle model number 1. Vehicle serial number
4. Customer name. 2. Vehicle model number

3. Customer name.
BOSS Web
)t tl. s \_' '· 'f s. "·() \\ .
L-
C•tt1pa1tnClaiiM
-�· - ...,
smr2009-030-0C7_a Cun:p•lvn MonKo-�9
¢1.,.!tn !t•WJ
VEHICLE TAB
6. Enter recorded data in ECM as detailed in

ENTERING THE COLLECTED INFORMATION
INTO THE ECM. mnv2009·118-011
SERVICE, UNIT HISTORY
smr2011·025 295
3. Enter the recorded data in the new ECM as de Vemtlt Mo*l Mtt't •fll -· • .,, . •.. . -� .
.
17
&.
tailed in ENTERING THE COLLECTED INFOR
BUDS CMtlOl d.rt·
MATION INTO THE ECM. rnnem...,,_ ot ,tta <lYy01hlfe C�to � lh9
.'thoc.t;, mocW" "'''""J n.. ....i.ci.. modoll mt!I �11har ba "S60Ar. an
�cdV\ltlll«onetr·re�1�nco)lvea.& Erurthe��wt'ldi
Entering the Collected Information into the 'node! In Illeeo1bot<�
ECM
1. Use the latest applicable B.U.D.S. software. l349A
Refer to COMMUNICATION TOOLS AND
B.UD.S. subsection.
r.mr2008-023 100 b
switch.
6. Click the Vehicle tab and enter the information
4. In B.U.D.S., click the Read Data button to read you recorded previously.
the new ECM. 1. Vehicle serial number
2. Engin e number (do not enter the "M" at the
file Y:iew Mfl® Module Iools .t!elp beginning of the engine number}
3. Customer name.
"*� Read Data

� ...
Write Data
vmr'2
006-0 • 2
- 100_Mn
The following window will pop up.
Y•h
lclt Mod tl M1nl"J _
11.J®
VEHICLE TAB
6uos c01100C dvwmtrn1tn. IYP9 Of�cl• \'OU ere connecied to �w.,

velwch!moJtl 11> rrowoq Tite Vtll•<ltt llllXfAf nlK! Riii"'' 00"SB0A1".an 7. Click on the following tabs:
elphoo.mencot Vlllw « on ontlret,-n1.rno�cotvalue ent.;rIlle epproplletDvelltt19
model In t� t<OltbOO(btlOW. - History
- Part Replacement
- Add Part in History.
8. Enter the old ECM serial number in the Add
Part In History window.
I I
5. Enter the vehicle model number. I I
M'1illll Do not enter SBOAT for a PWC. En
ter only the appropriate model number as ob PartTypo
tained when gathering the information. r Ellgtne
r t.f'EM
r. ECM
<' Ctus1er
�oncol J
&ml2009· 030-008
HISTORY, PART REPLACEMENT, ADDING PART IN HISTORY

TABS
296 smr2011·025
NOTE: The ECM serial number can be found on All Models

the ECM sticker that also identifies the part num 4. Pull out relay in fuse box to prevent fuel pump
ber. to turn on unexpectedly. Refer to POWER DIS
9. Click the Keys tab and click on the Erase All TRIBUTION.
Keys button.
Fuel Rail Hose Disconnection
1. Release fuel pressure. Refer to FUEL PUMPin
FUEL TANK AND FUEL PUMP subsection.
2. Place an absorbent shop rag under the fuel sup
ply hose fitting at the fuel rail to catch any fuel
leakage.
3. Disconnect fuel hose from fuel rail using the
FUEL HOSE DISCONNECT TOOL (PIN 529 036
037).
m mr2<J09.023·087
10. Program the desired D.E.S.S. key(s) to the wa

tercraft. Refer to D.E.S.S. SYSTEM subsec
529036037
tion.
NOTE: If you do not program at least one D.E.S.S.
key to the watercraft, you will not be able to write
the data to the new ECM, and will be prompted
to do so.
11. Briefly press the vehicle START button to
wake up the ECM. Engine must not crank.
12. Click on the Write Data button.
Read Data Write Data

NOTE: It may be necessary to rotate fuel hose fit
ting to align the tool ends with the openings of the
vmr2006-0 12· 1 00_1ien
locking mechanism.
13. Perform the Closed throttle reset. Refer
Fuel Rail Removal
to Closed Throttle Reset (TPS) in ADJUST
MENTS in this subsection. 1. Cut locking ties retaining engine harness to fuel
rail.
14. Reinstall remaining removed parts.
FUEL RAIL
Fuel Rail Removal
1. Open/remove seat.
iS/aS Models
2. Remove rear ventilation box. Refer to BODY
3. Remove deck extension. Refer to BODY.
srnr201 Hl26 297

Fuel Rail Installation

Reverse the removal procedure. However, pay at
tention to the following.
fuel rail retaining screws.
2. Torque fuel rail retaining screws to 9 N•m
(80 lbf•in).
smr1009 03!>0 I 1 _b
1. Cuc locking ties
2. Remove screws retaining the fuel rail.
1. Retaining screws
3. Properly install new locking ties to secure en

gine harness to fuel rail.
•mf.1009-0JO-O?G_•
1. Retaining screws
3. Gently pull fuel rail side to side {wiggle).
&m12000 -o:io 0 1 1_
b
I. New locking ties
Fuel Rail Hose Connection

1. Apply engine oil on 0-rings of fitting.
•""200a.o»o27 •
7. Fuel rail
4. Disconnect all injector connectors.

5. Pull fuel rail out with fuel injectors.
298 smr2011-025
Shutdown Cylinder·----,.,
---·� � � L.
�----··-----··--·- ---
mmt2 00S.1 20 -006_a
MONITORING AND ECM TABS

mmr2009-1 2 1-0Z!_a
1. Click on cylinder number lo be tested
1. Apply oil on 0-rings
If the engine RPM drops when clicking on a cylin
2. Connect fuel hose to fuel rail.
der, the injector and the ignition of this cylinder are
IMPORTANT: Push fuel hose fitting on fuel rail un functioning no rmally.
til you hear a "click". Try pulling fuel hose off fuel
If the engine RPM does not drop when clicking on
rail to ensure fitting is properly locked.
a cylinder, this cylinder is not functioning properly.
3. Pressurize the fuel system and check for a fuel Check the following:
leak. Refer to FUEL SYSTEM HIGH PRESSURE - Fuel injector operation. Refer to FUEL INJEC
LEAK TEST in FUEL TANK AND FUEL PUMP TOR OPERATION TEST.
subsection.
- Spark plug and ignition coil. Refer to IGNITION
SYSTEM
A WARNING
- Engine conditio n.
Failure to pressurize the fuel system may re
sult in severe injury or a life threatening situ
Fuel Injector Operation Test with
ation should a leak occur.
8.U.D.S. (Static)
4. Reinstall all remaining removed parts. IMoi@j After fuel injector activation using
B.U.D.S., always crank engine in drowned
FUEL INJECTOR mode to ventilate engine and prevent a poten
tial backfire due to fuel accumulation in the
Fuel Injector Operation Test with engine.
B.U.D.S. (Dynamic)
1. Connect watercraft to B.U.D.S. software.
1. Connect watercraft to B.U.D.S. software.
B.U.D.S.
B.U.D.S.
2. Start engine .
3. In B.U.D.S., click the following:
switch.
- Read Data button
- Monitoring tab.
- Read Data button
4. Using the B.U.D.S. software, shut down each
- Activation tab.
engine cylinder one at a time by clicking on the
button under the applicable cylinder. 5. On the ECM Activation page, energize the fuel
injector to be tested by clicking on it in B.U.D.S.
smr201HJ25 299
,,..,.....
• ,,._,., r Q•UC.i.f
..,..,,
,.... �... a.w I
r·w �
s mr2 0Q9.030.0 1 4_e
ACTIVATION AND ECM TABS

smr2009-031>-0 l 3_o 1. Fuel Pump activation button

7. Ine
j ctor of cylinder no. 1 shown 7. Fuel pressure must be within specification. Re
fer to FUEL TANK AND FUEL PUMP subsec
6. Listen to the injector. tion. Re-activate fuel pump as necessary.
If you can hear the injector, it validates its oper 8. In B.U.D.S., energize fuel injector no. 1.
ation. Carry out the FUEL INJECTOR BALANCE
TEST
If you do not hear the injector, carry out the INJEC
TOR.INPUT VOLTAGE TEST
Fuel Injector Balance Test with

B.U.D.S.
1it[1Jiljj After fuel injector activation using
8.U.D.S., alwa y s crank engine in drowned
mode to ventilate engine and prevent a po
tential backfire due to fuel accumulation in
engine.
1. Install a fuel pressure gauge as d es c rib ed in ACTIVATION AND ECM TABS

FUEL PUMP PRESSURE TEST of FUEL TANK 1. Injector of cylinder no.
1 shown
AND FUEL PUMP subsection.
9. R eco rd the fuel pressure drop for injector no. 1.
2. Con nect watercraft
to B.U.D.S. software.
Refer to COMMUNICATION TOOLS AND 10. In B.U.D.S., click the F uel Pump button to ac
tivate fuel pump.
B.U.D.S.
4. Instal l tether cord on engine cut-off switch. ,.
..
..

'-�� i
- Read Data button
_, ,....,. I
\
- Activation tab.
6. In B.U.D.S., click the Fuel Pump button to ac
tivate fuel pu m p.
1

1. Fuel pump
11. R epe at the procedure for fuel injectors no. 2

and no. 3 and record the pressure drop for
each injector.
300 smr20i 1-025

12. The maximum fuel pressure drop between in

jectors should not exceed the following spec
ification:
MAXIMUM FUEL PRESSURE DROP ALLOWED

BETWEEN FUEL INJECTORS
10 kPa (1.5 PSI)
If pressure drop of any fuel injector is greater than

the specification, replace that injector then repeat
the test.
13. Using the valve on the fuel pressure gauge,
release the pressure in the system (if so
equipped).
s mr2009-030-011_•
14. Remove fuel pressure gauge and reinstall re
1. Fuel injector connectors
moved parts.
Fuel Injector Input Voltage Test
5. Install tether cord on engine cut-off switch.
1 . Open/remove seat.
6. Use the F L U KE 115 MULTIMETER (PIN 529 035
iS/aS Models 868) and select Vdc.
2. Remove rear ventilation box. Refer to BODY. 7. Read input voltage to the applicable injector as
per following table.
All Models
PROBE INJECTOR
3. Disconnect fuel injector connectors. MEASUREMENT
CONNECTOR
NOTE: Push against tab underneath connector as
illustrated to unlock it. VIOLET wire with a tracer
Battery voltage
to battery ground
s mr2009-030.02$_a
If battery voltage is measured, carry out the IN

PUSH HERE TO UNLOCK
JECTOR CONTROL CIRCUIT TEST
If battery voltage is not measured, check continu
ity between fuse box and injector as follows.
Continuity Test of Injector Power

Circuit
1. Remove cover of fuse box. Refer to POWER
DISTRIBUTION subsection.
2. Remove the long bus bar.
smr2011-025 301
2. Install ECM ADAPTER TOOL (P/N 529 036166) on

ECM connector.
3. Use the FLUKE 115 MULTIMETER (P/N 529 035
868) and select n.
4. Probe terminals as per following table.
ECM
INJECTOR INJECTOR MEASUREMENT
ADAPTER
1 (rear) Pin A-83
BROWN
2 Pin A-Kl wire with Close to O n
a tracer
3 Pin A-J1
o mr20 1 l -02 7 -00 3.l
TYPICAL
1. Long bus bar
3. Use the FLUKE 115 MULTIMETER (PI N 529 035

868) and select n.
4. Read resistance of the applicable injector circuit
as per following table.
INJECTOR
INJECTOR FUSE BOX MEASUREMENT
CONNECTOR
1 (rear) Terminal 07
VIOLET wire
2 Terminal 06 Close to On
with a tracer If control circuit is at fault, repair or replace wiring
3 Terminal 05 and connectors.
If control circuit and all tests applicable to the in
jector are good, try a new ECM. Refer to ECM
Fuel Injector Resistance Test

(at ECM Connector)
1. Reconnect the injector connector.
2. Disconnect the ECM "A" connector.
3. Insta ll ECM ADAPTER TOOL (P/N 529 036 166) on
ECM connector.
4. Remove the long bus bar from fuse box.
• .,,, 2011.027.00 3_rr
If continuity is good, the fuse, wiring and connec

tors are functional.
If continuity is not obtained, first check the fuse
and replace as required.
5. If fuse is good, repair/replace wiring and con
nectors from fuse box to injector. Refer to
WIRING DIAGRAM subsection.
6. Reinstall bus bar and cover.
Fuel Injector Control Circuit Test omr101 l ·Ol7-000_l
TYPICAL
1. Disconnect ECM "A" connector. 1. Long bus bar
302 smr201 '-025


868) and select n.
6. Measure resistance value between terminals

as follows.
FUSE BOX ECM RESISTANCE @

INJ ECT O R
TERMINAL ADAPTER PIN 20°c (68°F)
1 07 A-83
2 06 A-Kl 11.4 - 12.6 n
3 05 A-J1
If readings are not as specified, replace injector.

If readings are as specified, repair or replace
wiring and connectors from ECM to injector.
Fuel Injector Removal

1. Remove fuel rail. Refer to FUEL RAIL in this
subsection.
2. Remove the injector clip .
smr2 0 1 1 -027-003_ m
If resistance values are as specified, injector coil

is in good condition.
If resistance value are not as specified, repeat test
at injector connector.
7. Reinstall bus bar and fuse box cover.
Fuel Injector Resistance Test (at

Component)
FUEL RAIL ASSEMBLY
1. Remove injector connector. 1. Fuel injector
2. Injector clip
2. Check resistance value between injector pins 3. 0-ring
as per followings table.
3. Pull the fuel injector out of the fuel rail.
RESISTANCE @
INJECTOR PIN
20°c (68°F)
Fuel Injector Installation
1
I 2 11.4 - 12.6 n
dure. However, pay attention to the following de
tails.
FUEL INJECTOR IDENTIFICATION

INJECTOR COLOR
ENGINE
CODE
130 Red
1 55/21 5/260 Blue
1. If you reinstall a used injector, carefully inspect

0-ring condition before reinstallation. Replace
0-ring with a new one if damaged.
smr2011-025 303
2. Apply a thin film of engine oil to 0-rings. ECM ENGINE THROTILE BODY
3. Insert the fuel injector in the fuel rail. Throttle actuator: Off.
4. Secure injector to fuel rail with a retaining cl ip. Throttle plate: Rest position. maintai ned
OFF S topped
opened at approximately 8° 111. This is
5. Install fuel rail on engine. Refer to FUEL RAIL
also the limp home position.
in this subsection.
Throttle actuator: On.
6. Pressurize the fuel system and check for a fuel
Throttle plate: Moves fro m the
leak. Refer to FUEL SYSTEM HIGH PRESSURE rest position to apprnximiitAly 14°. It
LEAK TEST in FUEL TANK AND FUEL PUMP then moves back to the rest position.
subsection. Not This is the diagnostic mode where the
ON
s tarted rest position, actuator o pening force to
overcome the return springs and the
Always carry out a fuel system high pressure motor return rate are monitored. If any
after working on the fuel system.
leak test of these parameters are out of range, a
fault code is initiated.
7. Reinstall all remaining removed parts, refer to Throttle actuator: On.

applicable subsections. Throttle plate: Moves from the
Started.
rest position t o idle position
Norma l
ON (approximately 1-3°) according to
THROTTLE BODY operation
ECM injection and ignition maps
at idle
.
Throttle plate is opened and closed as

Throttle Body Description
necessary to control the idle speed.
S tarte d
Throttle actuat or: On.
.
Normal
Throttle plate: Opens and closes
ON operation
according to ECM torque mana gemen t
at various
priorities.
RPM
!11 Degree values are given from the fully closed position.
Throttle-Body Faults and Effects

NOTE: Among other things, a weak or broken
spring and a sticky throttle plate (carbon build-up,
dried salt water etc) are validated by the throttle
body diagnostic mode.
2
1. Th rottle body
2. Throttle plate
3. Throttle actuator {electnc motor inside)
4. Throttle position sensor {TPSJ {inside)
Throttle Plate Operating Positions

Two torsional springs are connected to the throttle
plat�. A main spring and another one in a plunger
mechanism.
When there is no power to the throttle actuator
(ETA), the plunger mechanism maintains the throt
tle plate at a rest position. This also serves as the
limp home position.
When the throttle plate is opened by the ETA as
commanded by the ECM. 1t acts against the main
spring. If the ETA failed, the return spring would
bring the throttle plate back to the limp home po
sition.
304 smr2011-025
S ub sect ion 02 (ELECTRONIC FUEL INJECTION (EFI))
FAULT EFFECT A WARNING

Limp home mode. Engine speed limited to idle. Use the product in well ventilated area. Refer
ECM wi ll use the remaining TAS sensor. to product manufacturer's warnings. Wipe
Parti a l fa ilure
Fault code set and beeper off any product leakage in bilge.
of TAS sensor
activated to emit warning signals.
(one internal
Chec k engine light is turned ON. 5. To avoid getting dirt into engine, spray cleaner
sensor only)
Driveability could be reset by releasing
on a clean rag (outside the bilge) then rub rag
and reapplying the throttle.
against throttle plate and bore. A toothbrush
Complete Limp home mode. Engine works well too.
failure of speed limited to 2500 RPM
TAS sensor Fault code set and beeper A WARNING
( both in te rnal activated to emit warning signals.
First ensure ECM is off. Otherwise, i f ECM
sensors) Check engine light is turned ON.
should suddenly turn off, it would quickly
Ump home mode. Engine close the throttle plate which could cause
speed limited to 2500 RPM. serious finger injury.
Engine speed can still be increased up
Any throttle
to 3200 RPM using the throttle lever.
body failure 6. Manually open throttle and hold fully open to
Fault code set and beeper
activated to emit warni ng sign als.
reach all surfaces.
Check engine light is turned ON.
A WARNING
NOTE: When one of these faults is active. O.T.A.S. and iBR
Ensure nobody presses the START button.
will continue to monitor their input signals. However, since
The ECM would turn on and the throttle ac
the engine speed is limited, the O.T.A.S. will not be activated.
tuator (ETA) would cycle. This could cause
Also, since the ECM cannot control the throttle body, the iBR
may produce a fault since the ECM does not react to its serious finger injury as the throttle plate
specific torque requests. It all depends on the circumstances moves quickly.
when the iBR is applied. (vehicle and engine speed wi ll be
a factor). 7. To remove residual dirt, spray cleaner on throt
tle plate and on bore.
Throttle Body Lubrication 8. Reinstall removed parts.
No lubrication is required.
Throttle Body Inspection
Throttle Body Cleaning Always check for corroded terminals or damaged
1. Remove the parts required to access the throt wiring when diagnosing throttle body problems.
tle body, refer to THROTTLE BODY REMOVAL.
Throttle Body Dynamic Tests
2. Check throttle body cleanliness using a flash-
1. Remove the parts required to access the throt
light. Fully open throttle plate and verify:
tle body, refer to THROTTLE BODY REMOVAL.
- Throttle body bore
2. Remove the air inlet hose from the throttle
- Throttle plate edge.
body.
Look for: 3. Observe the throttle plate with the engine
- Dirt stopped.
- Oily surfaces
NOTE: The throttle plate should be in the rest po
- Carbon and salt deposits on throttle plate and sition (slightly opened).
the surrounding bore.
3. Clean as necessary. A WARNING
4. Use a throttle body cleaner such as GUNK IN- Keep your fingers out of the throttle plate
TAKE MEDIC or an equivalent. area while the ECM tu rns on. The throttle
actuator will cycle. This could cause seri
@t1Jit1Jj Only use an appropriate throttle ous finger injuries as throttle plate quickly
body cleaner that will not damage 0-rings and moves.
EFI sensors.
smr2011-025 305
4. As you observe the throttle plate, have some NOTE: The throttle plate must open fully and re
one press the START button to wake up the turn freely to the rest position (slightly opened)
ECM. when released.
NOTE: The throttle plate should cycle quickly 2. Push throttle plate closed as indicated in follow
from the rest position to a partially open position ing illustration. It must close completely and re
(approximately 14°), then back to the rest posi turn freely to the rest position (slightly opened)
tion. when released.
switch.
NOTE: The throttle plate should cycle again.
6. As you observe the throttle plate, have some
one gradually and evenly pull in the throttle
lever, then release it in the same way.
NOTE: The throttle plate should open then close
according to throttle lever position.
If any test failed, proceed with the STATIC TESTS.
Throttle Body Static Tests
A WARNING
First ensure the ECM is off. Otherwise, if
ECM should turn off, it would quickly close 1. Push here co close
the throttle plate which could cause serious
finger injury. If the throttle plate does· not move smoothly or
does not return freely to the rest position, the
problem is mechanical. Check for salt accumu
A WARNING
lation on throttle plate shaft. It may also be an
During the test ensure nobody presses the
,
actuator or gear problem. Replace throttle body
START button. The ECM would turn on and as necessary.
cycle the throttle actuator. This could cause
If throttle plate operates normally, the problem
serious finger injuries as the throttle plate
is electrical. Check throttle actuator (ETA) wiring
moves quickly.
continuity, throttle position sensor (TPSl and
throttle accelerator sensor (TAS).
1. Using your fingers, push in on the throttle plate
and ensure it opens smoothly within the throt
tle body.
Replace throttle body when throttle
does not return properly.
Th rattle Body Replacement

Throttle Body Removal
1 Open/remove seat.
.
iS/aS Models
2. Remove rear ventilation box. Refer to BODY.
iS Models
4. Lift suspension using the iS up button to gain
1
access.
1. Push here to open
306 smr2011·025
NOTE: If more height is required or if the iS can

not be used, manually lift suspension by the an
chor points close to handlebar and safely block in
this position. Do not lift the watercraft from the
anchor points.
All Models
5. Disconnect inlet hose from throttle body.
6. Disconnect throttle body connector.
To remove connector from throttle body, press
omrlOO!l O!O 0 22J
connector locking tab illustrated.
1. Throltle body
2. Screws
8. Pull throttle body off intake manifold.

Installation
Installation of the new throttle body is the reverse
of the removal procedure. However, pay attention
to the following.
1. Torque retaining screws in a criss-cross se
quence to 9 N•m (80 lbf•in).
2. Perform the Closed Throttle reset. See proce
dure in ADJUSTMENTS.
TPS (THROTTLE POSITION

SENSOR)
PRESS HERE TO UNLOCK
General
NOTE: The TPS is part of the throttle body.
The throttle position sensor (TPS) is a double po
tentiometer that sends a signal to the ECM that is
proportional to the throttle plate angle. The TPS is
located inside the throttle body.
TPS Wear Test

1. With the engine turned off. slowly pull in throt
tle lever and pay attention for smooth operation
without physical stops.
TYPICAL
1. Throttle body 2. Press the START button to wake up the ECM.
2. Inlet hose
3. Connector 3. Install the tether cord on the engine cut-off
switch.
7. Remove retaining screws from throttle body.
4. Connect watercraft to B.U.O.S. software.
8.U.D.S. subsection.
- Monitoring tab
- ECM tab.
6. Slowly and regularly depress the throttle lever.
7. Observe the Throttle Opening needle move
ment in B.U.D.S.
snr:zo11-02s 307
9. Check needle move m ent again.

- If needle moves as expected, check the throttle
accelerator sensor (TAS). Refer to THROTTLE
ACCELERATOR SENSOR (TAS) in this subsec
tion.
- If needle does not move as expected, perform
the TPS VOLTAGE TEST and the TPS RESIS
TANCE TESTin this subsection.
TPS Resistance Test
Throttle Opening 1. Remove the parts required to access the throt

tle body, refer to THROTTLE BODY REMOVAL
mmf1009· 120 001
in this subsection.
MONITORING AND ECM TABS
2. Ensure the throttle body connector is properly
NOTE: The needle should move gradually and connected.
regularly as you move the throttle lever. If the
3. Disconnect ECM connector "A" from the ECM.
needle "sticks", bounces or suddenly drops, it
may indi cate a worn TPS that needs to be re 4. Use the FLUKE 115 MULTIMETER (P/N 529 035
placed. An initial slight delay after the throttle 868) and select n.
lever is pulled and before the needle starts to 5. Probe circuit
as per following table while using
move is normal. a finger to manu al ly move throttle plate.
If the needle behavio r is not as expected, proceed
FULLY CLOSED FULLY OPEN
with the following steps.
ECM THROTTLE THROTTLE
8. Manually move the throttle plate in throttle ADAPTER PLATE (1l PLATE
body using a blunt tool (without sharp tip).
RESISTANCE (n)
A WARNING PIN MIN. MAX. MIN. MAX.
Do not move throttle plate with your fingers. A-A2 A-K4 875 1625 875 1625
Otherwise, if ECM should turn off, it would
A-A2 A-K3 954 1934 228 585
quickly close the throttle plate which could
cause serious finger injury. A-A2 A-F3 254 634 980 1983
A-K3 A-K4 228 585 954 1934
A-K3 A-F3 1385 2315 1385 2315
A-K4 A-F3 980 1983 254 634

11l To obtain the fully closed position,it is necessary
to push against the throttle plate in the throttle
body with a finger and hold it in this position for the
measurement.
oml1000 -030-0U l.J>
1. Push here
308 smr2011·025
If any resistance value is incorrect, check wire

continuity between ECM and throttle body before
assuming the TPS is at fault. Refer to WIRING
DIAGRAM subsection.
• m r2008 -023 0 I 6_a
TYPICAL

TPS CONNECTOR PIN-OUT 4. Install the tether cord on the engine cut-off
switch.
If the TPS resistance values are correct, try a new
ECM. Refer to ENGINE CONTROL MODULE 5. Pull the throttle lever completely in to the han
dlebar and hold (drowned mode).
(ECM) in this subsection.
6. While cranking the engine, probe CPS termi
CRANKSHAFT POSITION nals.
SENSOR (CPS) CPS CONNECTOR MEASUREMENT
PIN VOLTAGE
1
l 2 Approximately 2.3 Vac
TYPICAL
1. Crankshaft Position Sensor (CPS)
NOTE: Take into account that a CPS fault can imam&-011.(JQ2J
be triggered by a bent or missing trigger wheel TYPICAL
tooth. First check for fault codes, then test the

If voltage is not as specified, carry out a CPS RE
CPS as per following procedure. If it tests good,
SISTANCE TEST
check trigger wheel teeth condition. Refer to
PTO HOUSING AND MAGNETO in the ENGINE If voltage is as specified, check continuity of
section. wiring between CPS connector and ECM connec
tor. Refer to WIRING DIAGRAM
CPS Voltage Test
CPS Resistance Test
1. Remove the required parts to access the CPS,
refer to CPS REPLACEMENT 1. Disconnect CPS connector.
2. Disconnect CPS connector.
srv201 l-025 309

2. Using a FLUKE 115 MULTIMETER (P/N 529 035 ECM ADAPTER MEASUREMENT
868) set to n. probe CPS terminals as per fol
lowing table.
RESISTANCE n
PIN
@ 20°c (68°F)
CPS CONNECTOR MEASUREMENT
RESISTANCE n
A-H 1
I A-K2 100 - 900 n
PIN
@ 20°c (68°F)
1
I 2 700 - goon
v mr2008 022-005 _ 0
If resistance measured is as specified, check

ECM. Refer to ENGINE CONTROL MODULE
(ECM) in this subsection.
If resistance measured is not as specified, repair
or replace wiring and connectors between ECM
and the CPS.
l mr7006-02 1 -002.b
TYPICAL
CPS Replacement
If resistance is not within specifications, replace
the CPS. iS/aS Models
If resistance tests good, proceed with the follow 2. Remove rear ventilation box. Refer to BODY.
ing steps. 3. Remove deck extension. Refer to BODY.
3. Reconnect the CPS and disconnect ECM con
All Models
nector "A" from the ECM.
4. Remove air intake silencer. Refer to AIR IN
4. Install the ECM ADAPTER TOOL (P/N 529 036166)
TAKE SYSTEM
on ECM connector ·A".
5. Drain oil from PTO housing. Refer to PTO
5. Test circuit resistance through CPS as per fol
HOUSING AND MAGNETO.
lowing table.
NOTE: It is not necessary to drain oil from engine.
6. Disconnect CPS connector.
529035008
s m r2000-0'2�16_ a
TYPICAL
310 sml2011·025
7. Remove wire r etainin g clip (as applicable). CAPS Voltage Test (Harness Side)
8. Remove CPS retaining screw. 1. First check fuse F12 in fuse box. Replace as
required.
2. Re m ove the parts required to access the CAPS,
refer to CAPS REPLACEMENT.
3. Disconnect CAPS connector.
•mr2006-020- I OO
_b
1. Wire retaining clip

2. CPS retaining screw
9. Pull out CPS. smr200 9-030-034_•
7. CAPS connector
Installation is the reverse removal procedure.
However, pay attention to the following. 4. Press the START button to wake up the ECM.
10. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on 5. Install tether cord on e n gi n e cut-off switch.
CPS retaining screw threads, then torque to
6. Probe harness connector terminals as per fol
9 N•m (80 lbf•in).
lowing table.
11. Refill engine oil and check oil level, refer to
LUBRICATION SYSTEM subsection. CAPS CONNECTOR MEASUREMENT
PIN VOLTAGE
Trigger Wheel Inspection
Refer to PTO HOUSING AND MAGNETO in the
3
I 1 Battery voltage
ENGINE section.
CAMSHAFT POSITION SENSOR

(CAPS)
smt7009-030-0:nu1
If battery voltage is read, p roceed with CAPS DY..

NAMIC TESTfurther in this subsection.
If battery voltage is not read, probe circuit as per
smr2006-020-0!5 7 o
follo wi n g table.
TYPICAL
1. CAPS
smr201Hl25 311
CAPS CONNECTOR MEASUREMENT CAPS

FUSE BOX RESISTANCE
CONNECTOR
PIN VOLTAGE
TERMINAL PIN n
3 I Battery ground Battery voltage
Close to 0 n
08 3
(continuity)
If voltage is read to battery ground, check continu

smr2011 ·027-003_ a
ity of ground circuit between CAPS pin 1 and ECM
connector "A" pin 04. Repair or replace wiring and If continuity is good, wiring and connectors are
connectors. functional.
If voltage is not read to battery ground, carry out If a high resistance or an open circuit is measured,
a CONTINUITY TEST OF CAPS POWER CIRCUIT. check the short bus bar in fuse box, repair or re
place wiring and connectors from fuse box termi
Continuity Test of CAPS Power Circuit nal to CAPS connector.
1. Remove cover from fuse box. Refer to POWER 5. Reinstall bus bar and cover.
DISTRIBUTION.
2. Remove the long bus bar. CAPS Dynamic Test
1. Remove the parts required to access the CAPS,
refer to CAPS REPLACEMENT.
2. Remove CAPS sensor from engine.
3. Back-probe connector and read voltage as fol-
lows.
NOTE: To easily probe wire terminals through
the back of the connector, use FLUKE RIGID BAC K
PROBE (P/N TP88) or equivalent.
•mr201 l -027-003 . L
1. Pull out

vm r 2007·0!I0 ·004
868) and select n. FLUKE RIGID BACK PROBE PIN TPBB
4. Read resistance of the CAPS circuit as per fol
lowing table. They can be inserted at the end of the standard
probes of the FLUKE 115 MULTIMETER (P/N 529 035
868).
312 smr2011·026
If voltage is as specified, repair or replace wiring

and connectors between sensor and ECM.
If wiring is good, check ECM. Refer to ENGINE
CONTROL MODULE (ECM).
If battery voltage is not measured as specified, try
vmr2007-0S0-00 5
a new CAPS.
BACK PROBE INSTALLED ON MULTIMETER PROBE
CAPS CAPS
CAPS Replacement
VOLTAGE
CONDITION CONNECTOR 1 . Open/remove seat.
F ree 3
I 2 Close to 0 Vdc iS/aS Models
3. Remove deck extension. Refer to BODY
All Models
TAKE SYSTEM.
5. Detach CPS connector from its holder.
smr2007-021-010.•
CAPS CAPS
VOLTAGE
CONDITION CONNECTOR s m12008-02l-01 6_a
TYPICAL
Metallic object
3 2 Battery voltage
on sensor 6. Disconnect CAPS connector.
1. CAPS connector
smr2007-021-009.c
7. Unscrew the CAPS retaining screw.
7. Metallic object 8. Pull CAPS from engine.
9. Install the new CAPS.
smr2011-025 313
ll!Z•JifHj
Be sure to install new 0-ring on the
new CAPS.
10. Apply Loctite 243 (blue) on the CAPS retaining

screw threads.
11. Torque the CAPS retaining screw to 9 N•m
(80 lbf•in).
MANIFOLD AIR TEMPERATURE

SENSOR (MATS)
The resistance value measured should be as spec

ified in the MATS RESISTANCE CHARTthat fol
lows. Otherwise, replace the MATS.
If resistance value is as specified, carry on with
the following steps.
4. Reconnect the MATS and disconnect the ECM
connector "A" on the ECM.
5. Install the ECM ADAPTER TOOL (P/N 529 036 166)
on ECM connector "A" . •
1. Manifold air temperature sensor (MATS) 6. Probe adapter terminals as follows.
MATS Resistance Test ECM ADAPTER MEASUREMENT
1. Remove the parts required to access the MATS, PIN RESISTANCE f!
I
refer to MATS REPLACEMENT.
See MATS RESISTANCE
A J3 A-H3
2. Disconnect the MATS connector. CHART
-
1. MATS connector
3. Using the FLUKE 115 MULTIMETER (P/N 529 035

868) set to n, probe the MAPS sensor termi
nals.
314 srm201 l·025

MATS RESISTANCE CHART NOTE: Be sure to install a new thrust washer on

the MATS before installing it on the intake mani
TEMPERATURE RESISTANCE (OHMS)
fold.
oc OF NOMINAL LOW HIGH
- 30 - 22 12600 11800 13400 COOLANT TEMPERATURE
- 20 - 4 11400 11000 11800 SENSOR (CTS)
- 10 14 9500 8000 11,000
0 32 5900 4900 6900

10 50 3800 3100 4500
20 68 2500 2200 2800
30 86 1700 1500 1900
40 .104 1200 1080 1320
50 122 840 750 930
60 140 630 510 750
70 158 440 370 510

80 176 325 280 370
90 194 245 210 280
100 212 195 160 210
6-020-0- 5?_b
&mr200
110 230 145 125 160
TYPICAL
120 248 115 100 125 1. Coolant temperature sensor (CTSJ
NOTE: An overheat indication will come on in the

information center when the coolant temperature
reaches:
OVERHEAT
ENGINE
TEMPERATURE
All 1503 110°C (230°F)
CTS Resistance Test

1. Remove the parts required to access the CTS,
.
refer to CTS REPLACEMENT
2. Disconnect the connector from the CTS and
If resistance value is as specified, check ECM. Re
test the resistance of the sensor. Refer to the
fer to ENGINE CONTROL MODULE (ECMJ in this
CTS RESISTANCE CHARTfurther in this topic.
section.
If resistance value is not as specified, repair or
replace wiring and connectors between the ECM
and the MATS.
MATS Replacement
1 Open/remove seat.
.
iS/aS Models
All Models
3. Disconnect the MATS connector.
4. Unscrew the MATS from the engine.
5. Install a new MATS and torque to 17 N•m
(150 lbf•in).
smr2011-025 315
Subsection 02(ELECTRONIC FUEL INJECTION (EFI))
CTS RESISTANCE CHART

oc Of NOMINAL LOW HIGH
- 30 - 22 12600 11800 13400
- 20 -4 11400 11000 11800
- 10 14 9500 8000 11,000
0 32 5900 4900 6900
10 50 3800 3100 4500

20 68 2500 2200 2800
30 86 1700 1500 1900
40 104 1200 1080 1320
50 122 840 750 930
60 140 630 510 750
70 158 440 370 510
If resistance measured is not as specified, replace 80 176 325 280 370

the CTS. 90 194 245 210 280
If the resistance measured is as specified, pro 100 212 195 160 210
ceed with the following steps. 110 230 145 125 160
3. Reconnect the CTS connector and disconnect 120 248 115 100 125
ECM connector "A" from the ECM.
4. Using a multimeter and the ECM ADAPTER
TOOL (P/N 529 036 166). check the CTS circuit
resistance as per table.
CTS RESISTANCE TEST
ECM ADAPTER PIN RESISTANCE n
See CTS RESISTANCE

A-A1 A-J2
CHART
If the resistance value measured is as specified,

check ECM. Refer to ECMfurther in this section.
If the resistance value is not within specification,
repair or replace wiring and connectors between
ECM connector and the CTS.
CTS Replacement
1. Open/remove seat.
iS/aS Models
All Models
4. Disconnect CTS connector and remove CTS.
5. Install the new CTS and torque to 18 N•m
(159 lbf•in).
6. Reinstall remaining removed parts.
316 smr2011-025
MANIFOLD ABSOLUTE
PRESSURE SENSOR (MAPS)
1. Disconnect

TYPICAL switch.
1. Manifold absolute pressure sensor (MAPS)
5. Use the FLUKE 115 MULTIMETER (PIN 529 035
NOTE: This sensor is a dual function device. 868) and select Vdc.
When the engine is started and runs at idle speed, 6. Read voltage as per following table.
the sensor measures atmospheric pressure and
MAPS CONNECTOR VOLTAGE
stores it in the ECM. Thereafter, it measures
manifold absolute pressure at operating RPMs. Terminal 1 to battery ground Approx. 5V
Ensure sensor is correctly installed on intake Terminal 2 to battery ground Approx. ov

manifold. Otherwise, the MAPS could generate a
Terminal 3 to battery ground Approx. ov
fault code for an unexpected sensor range at idle
when it reads atmospheric pressure. Remove
sensor and check for oil or dirt on its end and
if problem persists, check throttle plate condi
tion/position and the wiring harness. Perform the
following tests.
MAPS Voltage Test

1. Remove the parts required to access the
MAPS, refer to CTS REPLACEMENT in this
subsection.
2. Disconnect connector from MAPS.
lrrv200S-021 -00
.6_ a
If voltage measured is as specified, replace the

MAPS.
If voltage measured is not as specified, refer
to CONTINUITY TEST OF MAPS WIRING HAR
NESS.
smr2011-025 317
Continuity Test of MAPS Wiring NOTE: An overheat signal will come on in the in
Harness formation center when the exhaust temperature
reaches.
1. Disconnect ECM connector "A" from the ECM.
2. Using a multimeter and the ECM ADAPTER ENGINE OVERHEAT TEMPERATURE
TOOL (PIN 529 036 166), test for circuit continu All 1503 110°C (230°F)
ity as per following table.
MAPS ECM
RESISTANCE
EGTS Resistance Test
CONNECTOR CONNECTOR
1. Remove the parts required to access the EGTS,
Pin 1 A-84 refer to EGTS REPLACEMENTin this subsec
Close to 0 n tion.
Pin 2 A-G4
continuity
2. Disconnect the connector from the EGTS.
Pin 3 A-H2
3. Set the FLUKE 1 1 5 MULTIMETER (P/N 529 035
3. I f wiring harness is good, check ECM. Refer 868) to n selection and measure the resistance
to ENGINE CONTROL MODULE (ECMJ in this of the sensor.
subsection.
4. If a high resistance or an open circuit is mea
sured, repair or replace wiring and connectors
between the ECM and the MAPS.
MAPS Replacement
iS/aS Models
All Models
4. Disconnect MAPS connector and remove the
MAPS.
5. Install the new MAPS paying attention to index
its tab into the adaptor notch.
6. Apply Loctite 243 (blue) on retaining screw and
torque to 10 N•m (89 lbf•in).
7. Reinstall remaining parts removed, refer to ap
plicable subsections.
EXHAUST GAS TEMPERATURE

SENSOR (EGTS)
"1 V2008· 023-018
.0
The resistance should be as per the EGTS RESIS

TANCE CHART that follows. Otherwise, replace
the EGTS.
If the EGTS resistance is within specifications,
proceed with the following steps.
4. Reconnect the EGTS and disconnect ECM con
nector "A" from the ECM.
s mr200<J-030·040_• 5. Using a multimeter and the ECM ADAPTER

1. Muffler TOO L (P/N 529 036 166), check the circuit resis
2. Exhaust gas temperature sensor (EGTSJ tance as per following table.
318 smr2011-026
Subsection 02 C
(ELE TRONIC FUEL INJECTION (EFI))
ECM ADAPTER MEASUREMENT GTX/RXT/Wake Pro Models

PI N RESISTANCE n 2. Remove the LH access panel on the boarding
platform.
I
See EGTS RESISTANCE
A-J4 A-H4 3. Disconnect the exhaust hose from the muffler.
CHART
All Models
EGTS RESISTANCE CHART
4. Disconnect the EGTS connector.
5. Unscrew EGTS from muffler.
oc OF NOMINAL LOW HIGH
- 22 12600 11800 13400
6. Apply LOCTITE 518 (PIN 293 800 038) on the mid
- 30
dle threads of the new EGTS.
- 20 - 4 11400 11000 11800
- 10 14 9500 8000 11,000

0 32 5900 4900 6900
10 50 3800 3100 4500
20 68 2500 2200 2800
30 86 1700 1500 1900
08 -01 3-04 l _o
sm110
40 104 1200 1080 1320
1. Apply Loctite 518 in this area
50 122 840 750 930
7. Install the EGTS.
60 140 630 510 750
440
8. Torque the sensor to 16 N•m (142 lbf•in).
70 158 370 510
80 176 325 280 370 9. Install the EGTS connector.
90 194 245 210 280 10. Install all other removed parts, refer to applica
ble subsections.
100 212 195 160 210
110 230 145 125 160
KNOCK SENSOR (KS)
120 248 115 100 125
vm 1200 � 22-00 5_a
If resistance value is as specified, check ECM. Re

fer to ENGINE CONTROL MODULE (ECM) in this
subsection. A1S03motr174A
If resistance value is not within specifications, re 1. Knock sensor (KSJ

pair or replace wiring and connectors between the
ECM and the EGTS. KS Dynamic Test
1. Connect watercraft to 8.U.D.S. software, refer
EGTS Replacement to COMMUNICATION TOOLS AND B.U.D.S.
iS/aS Models subsection.
1. Open the boarding platform and remove the LH 2. In 8.U.D.S., click the Faults tab and look for a
storage basket. Knock senso r fault.
smr2011-025 319
3. Start the engine and bring engine RPM above

5000 RPM.
4. Using the B.U.D.S. software. monitor the knock
sensor for a fault code.
If no fault occurs. the knock sensor is good.
If a fault occurs, carry out the following steps.
5. Ensure sensor and cylinder head contact sur
faces are clean.
6. Ensure the correct mounting bolt and washer
are used and are properly torqued.
NOTE: It is necessary to remove the intake man
ifold to inspect the contact surfaces. Refer to IN
TAKE MANIFOLD subsection.
KNOCK SENSOR RESISTANCE @ 20°C (68°F)
7. Check the knock sensor resistance, refer to KS
RESISTANCE TEST Approximately 5 Mn
KS Resistance Test If resistance is not as specified, replace knock

1. Remove the parts required to access the knock sensor.
sensor, refer to KS REPLACEMENT. If resistance is as specified, carry on with the fol
2. Disconnect the knock sensor connector. lowing steps.
4. Reconnect the knock sensor connector.
5. Disconnect connector "A" from the ECM.
6. Using a multimeter and the ECM ADAPTER
TOOL (P/N 529 036 166), check circuit resistance
through the knock sensor as per following ta
ble.
ECM ADAPTER MEASUREMENT

RESISTANCE
PIN
@ 20°c (68°F)
A-C3
I A-G2 Approximately 5 Mn
1. KS connector
3. Using a multimeter, measure the resistance be

tween the knock sensor terminals.
v�OOS.022-005_1
If wiring harness is good, check ECM. Refer to

ENGINE CONTROL MODULE (ECMJ in this sec
tion.
If an open circuit is measured, repair or replace
wiring and connectors between ECM and knock
sensor.
320 smr201l-025
KS Replacement
iS/aS Models
All Models
TAKE SYSTEM
5. Remove the intake manifold. Refer to INTAKE
MANIFOLD} subsection.
6. Disconnect KS sensor connector.
smr2010-032-002..•
TYPICAL - INTAKE MANIFOLD REMOVED

1. Knock sensor
2. Knock sensor connector
7. Unscrew and remove knock sensor from en

gine.
8. Clean contact surfaces.
9. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) in
threaded hole then install the new knock sen
sor.
10. Torque sensor retaining screw to 23 N•m
{17 lbf•ft).
1i+Z1JitijImproper torque might prevent sen

sor to work properly and lead engine to severe
damage of internal components.
1 1 . Reconnect knock sensor connector.
12. Reinstall remaining removed parts, refer to ap
plicable subsections.
smr2011-025 321
322
Subsection 03 (FUEL TANK AND FUEL PUMP)
FUEL TANK AND FUEL PUMP

SERVICE TOOLS
DIAGNOSTIC HARNESS .............................................................. . 529 036 188 ......................................... 342
ECM ADAPTER TOOL.................................................................. . 529 036 166 ......................................... 338
FLUKE 115 MULTIMETER ........................................................... . 529 035 868 ......................... 337, 342-343
FUEL HOSE ADAPTER................................................................. . 529 036 023 ......................................... 335
FUEL PUMP MODULE SOCKET .................................................. . 529 036 125 ......................................... 339
OETIKER PLIERS ..................... . . . . . . . . .............................................. 295 000 0 7 0 ......................................... 336
PRESSURE GAUGE ....................................................................... 529 035 709 ......................................... 335
SMALL HOSE PINCHER .............................................................. . 295 000 076 ................................. 332-333
VACUUM/PRESSURE PUMP ....................................................... . 529 021 800 ......................................... 331
srnr21)11·026 323
FUEL TANK AND FUEL PUMP

GTS and GT/ Series
IEm =Component must be replaced when removed.
;- -
1.7 N•m , \
(15 lbf.in) \
\"-,_ �
J
""'- 60 N•m
""'--,_ �lbfoft)
�
. .....__ �
� 22N•m
� (16 1bfoft)
� 3.5N•m
(31 lbfoin)
...... . ......
....._
......
- ......
324 smr2011-026
RXT 260, RXT X 260, RXT XRS 260, GTX 155, GTX 215 and WAKE PRO 215
1.7 N•m
(15 lbf.in)
""'
I
'
'
I
'
I
'
. I
1(·
�
60N•m
�
(44 lbf.ft}
,......__,.=--- 3.5N•m
J
(31 lbfoin)
10N
(89 !bf.in) '!fJ
10 N•m-t1
(89 lbf.in) � -3.5N•m
(31 lbfoin}
10 N·m�
(89 lbfoin) �
10N·m�
(89 lbf•in)
r::3
� (89 lbfoin)

smr2011·026-002 _a
smr2011-026 325
RXT iS 260, RXT as x 260, RXT as XRS 260, GTX iS 215 and GTX LTD iS 260
...._....,_,-3.5 N•m
(31 !bf.in)
� �
��
10 N·m
(89 lbf.in)
11l<f9./"l�
10N•m
·ff' t!�
a 1��T.. 1
"
(89 lbftin
10N·m�
'1 Jl
(89 lbfoin)
10 N•m
(89 lbf•in) iEm =Component must be replaced when removed.
326 sml2011·026
FUEL SYSTEM DIAGNOSTIC FLOW CHART
Fuel pump does not run I Press Start button I � Fuel pump runs
I I I
-
for 2 sec. then stops
t
Check fuses.
Check fuel pump operation.
Install fuel pressure gauge
fu
on el pressure line -
- I
Repair or replace if necessary.
.., neplace fuel
'� �
-I
Press Start button
I
-
� I pump module
'
)�
...
Fuel pump ru ns
t t t
Repair or Fuel pressure less Fuel pressure is Fuel pressure more
replace than 399 kPa (58 PSI) 399 kPa (58 PSI) than 399 kPa (58 PSI)
' •
Fails
,-
- Check fuel line/
rail for leaks
,,
Fails
'f OK Crank or start
I Perform fuel pump test engine
I
OK_J
t ,, t
Fast -
Fuel pressure less Fuel pressure more Fuel pressure is
pressure drop than 399 kPa (58 PSI) than 399 kPa (58 PSI) 399 kPa (58 PSI)
No ...
,, Yes
'�
OK c
Che k
'
Verify fuel
pump check ___...
valve
f uel l ine/
rail for leaks
-Fail� I Repair or
replace
r- FUEL SYSTEM OK
�
F ils
I OK- f
Fails
I It'
� Check fuel
OK Perform fuel
-
- Replace fuel
injector pump test pump module
�
l � Retest
OK
smr2011-026 327
GENERAL SYSTEM DESCRIPTION

A WARNING The fuel system is comprised of:
Fuel lines remain under pressure at all times. - A fuel tank

Always proceed with care and use appro - A non-vented fuel tank cap
priate safety equipment when working on a - A fuel pump module mounted inside the fuel
pressurized fuel system. Wear safety glasses. tank
- A fuel vent system, and
A WARNING - A variety of hoses.
Always disconnect battery prior to work The fuel pump module is ba s ically comprised of:
ing on the fuel system. Fuel vapors are - An electric fuel pump mounted inside a canister
flammable and explosive under certain con type pump reservoir
ditions. Always work in a well ventilated
- A lower inlet filter
area. Do not allow fuel to spill on hot en
- An upper outlet filter
gine parts and/or on electrical connectors.
Proceed with care when removing/installing - A pressure regulator
high pressure test equipment or disconnect - A float type fuel level sensor.
ing fuel line connections. Cover the fuel
line connection with an absorbent shop rag.
Wipe off any fuel spillage in the bilge.
A WARNING
When the repair is completed, ensure that
hoses and connections from fuel rail to the
fuel pump are properly secured. Then, pres
surize the fuel system. After carrying out a
fuel pump pressure test, use the valve on the
fuel pressure gauge to release the pressure
(if so equipped).
A WARNING • mr2 006·022-00 7 .•
FUEL PUMP MODULE

The fuel pump is energized for a few seconds 1. Fuel pump reservoir
2. Lower inlet filter
each time the START button is depressed. 3. Upper outlet filter
It builds fuel system pressure very quickly. 4. Fuel pressvre regulator
5. Float type fuel level sensor
Prior to pressing the START button, ensure
there are no disconnected or damaged fuel
Fuel Pump Operation
lines that may leak fuel. A high pressure
leak test must be carried out whenever a fuel When the pump is in operation, it draws fuel into
system component has been disconnected. the canister through a lower inlet filter and a disk
type valve.
A WARNING The pressurized fuel is pushed through an upper
outlet filter to the fuel rail.
Ensure wires and hoses are routed and se
cured away from any vibrating, rotating, Excess fuel pressure generated by the pump is
moving or hot components or sharp edges. routed from the upper filter back to the pump can
Use appropriate shields and fastening de ister reservoir by a pressure regulator mounted on
vices as per factory standards. the pump reservoir cover .
When the START button is pressed, the electrical
system is powered. The fuel pump will come on
INofllij Whenever repairing the fuel system, for approximately 2 seconds to pressurize the fuel
always check for water infiltration in the fuel
rail in preparation for the engine start.
tank. Replace any damaged, leaking or deteri
orated fuel line. The ECM supplies the ground signal to turn on the
fuel pump motor.
328 smr2011·026
The pressure regulator will ensure appropriate RXT iS, RXT aS and GTX iS Series
fuel pressure is supplied to the injectors.
When the ECM receives a signal to shut down
the engine (START/STOP switch, engine cut-off
switch, or T.0.P.S. switch) it removes the fuel
pump ground signal.
Fuel Level Indication

An electric float type fuel level sensor is mounted
on the side of the fuel pump reservoir. As the float
moves with changing fuel levels, it varies a resis
tance that changes the voltage signal coming from
the information center (multifunction gauge). This
signal is representative of the fuel level.
s m12009-031-003_ a
RH SIDE OF FRONT VENTILATION BOX

The information center interprets the fuel level 1. Inlet valve
voltage signal that comes back from the fuel level

RXT 260, RXT X 260, RXT XRS 260, GTX
sensor. It then displays the proper fuel level in
155, GTX 215 and WAKE PRO 215
the information center and a low fuel warning
message when required.
The information center will also trigger the beeper
which produces the appropriate beep signal to
warn the driver of a low fuel condition.
The fuel level sensor resistance is at its lowest
value when the fuel tank is full, and at its highest
value when the tank is empty.
Refer to the FUEL LEVEL SENSORin this subsec
tion for fuel level sensor testing procedures.
Fuel Tank Vent System Operation

5" 1201 0-004-002.. •
LH SIDE OF FRONT BODY MODULE

1. Inlet valve
4 GTS 130, GT! 130, GT/ 155 and WAKE 155
smr 2009.·1.002_
.Q3 a
TYPICAL
7. Fuel tank
2. Fuel tank cap
3. Inlet valve (check valve)
4. Outlet valve (fuel pressure relief valve) snv2011-02S-00 5_a
ON RH SIDE - BEHIND LATERAL TRIM PANEL

1. Inlet valve
smr2011·026 329
All Models
1
TYPICAL
1. Outlet valve
If pressure in the fuel tank builds up and exceeds

2.8 kPa 7.6 kPa (.4 PSI 1.1 PSI), the outlet valve
- -
RH SIDE OF HULL (BELOW BUMPER)

1 Our/et valve opens to let the excess pressure out of the fuel
2. Battery vent hose (GTS and GTI only) tank.
The inlet valve is located high in the watercraft to

prevent water entry in fuel tank.
The inlet valve is a check valve that allows air to
enter the fuel tank and prevents fuel starvation.
It also prevents fuel from flowing out of the fuel
tank.
TYPICAL
1. Outlet valve
INSPECTION
FUEL TANK LEAK TEST

TYPICAL 1. Fill up fuel tank.
1. In/er valve
2. Close fuel tank cap.
The outlet valve is a pressure relief valve that is 3. Open front storage compartment cover.
normally closed to prevent water entry in the fuel
tank. It also prevents air from flowing out until a
4. Remove storage bin or partitions. Refer to
given pressure is attained.
BODY subsection.
iS and aS Models
5. Remove front ventilation box.
330 smr2011-026
rnrnt 2009-1 2 1-004_•

s mr2 009-031-00B_&
1. Y-fitting (PIN 293 710 059)
1. Ventilation box
2. Check valve (P/N 275 500 505)
3. Apply compressed air here
6. Disconnect the top of the two front air ventila 10. Install the vacuum/pressure pump on the inlet
tion hoses, refer to BODY subsection. valve end.
S b l2010-004 -0l2
TYPICAL - FRONT AIR VENTILATION HOSES
All Models TYPICAL

1. Inlet valve end
7. Visually inspect condition of hoses and clamps. 2. Vacuum/pressure pump
3. Compressed air supply
8. Pull inlet valve out of its grommet. Refer to
FUEL TANK VENT SYSTEM OPERAT/ONfor in 11. Set vacuum/pressure pump to pressure.
let valve location.
9. Pressurize fuel tank.
REQUIRED TOOL
VACUUM/PRESSURE PUMP
(P/N 529 021 800)
NOTE: A Y-fitting and a check valve can be in

stalled to use compressed air for quick pressure
build-up when the fuel tank is not full.
1. Pressure selected
smr2011-026 331
fi![1lit1Jj
Do not exceed the specification
when pressurizing the fuel tank.
15. Bring the test pressure to the specification

by manually pumping the vacuum/pressure
pump.
FUEL TANK LEAK TEST

TIME WITHOUT
PRESSURE
PRESSURE DROP
"'"'2009 -03 1-1 01 21 kPa (3 PSI) 10 minutes

TYPICAL - PRESSURE TEST SETUP
If the pressure drops, locate fuel leak(s), repair/re
12. Slowly apply air pressure.
place leaking component(s) and carry out a new
NOTE: If pressure rises quickly within a few fuel system leak check to validate repair and en
strokes of the pump. the inlet valve is likely sure there are no other leaks.
clogged. Refer to INLET CHECK VALVE TEST in
Possible leak areas are:
this subsection.
- Inlet valve
When pressure has reached 2.8 kPa - 7.6 kPa
- Fuel tank
( 4 PS I - 1.1 PSI) the pressure relief valve should
- Fuel tank neck
.
open preventing a further increase in pressure.

When valve opens, pressure must drop at pump - Fuel tank cap
gauge. - Fuel pump gasket
If pressure increases above specification or gauge - Vent hoses

does not drop to zero (0). replace outlet valve. - Connections and valves
13. Block the vent hose near outlet valve (pres - Filler hose and connections
sure relief valve). - Fuel hose and connections
- Fuel rail and injector(s).
REQUIRED TOOL
To locate a leak, check for a fuel smell or leaking
SMALL HOSE PINCHER fuel.
(PIN 295 000 076)
If a fuel smell is detected but a leak is not visible,
spray a soapy water solution on components to
NOTE: To validate outlet hose, connection and ease locating the leak(s); bubbles will indicate the
valve altogether, a test cap (P/N 293 000 105) or leak location(s).
an equivalent hand made plug (such as a capped
NOTE: If the pressure drops and no leak has been
vent hose) can be installed on the outlet nipple of
found. it is likely a leaking fuel injector. Refer to
the valve.
ELECTRONIC FUEL INJECTION (EFI).
ffl•)itJJj When the fuel system leak test is

1 completed, thoroughly rinse all components
of the soapy water solution with clear water.
J A soapy water residue may cause premature

deterioration and must be rinsed away.
A WARNING
If a leak is found, do not start the engine.
Wipe off any fuel that leaked and ventilate
the hull thoroughly to remove any accu
�l· IOU>
mulated fuel vapors. Do not use electric
-
TYPICAL PRESSURE TEST SETUP
powered tools on watercraft unless system
1. Hose pincher
has passed the leak test .
14. Slowly apply pressure until it nearly attains the
pressure specification. 16. Open fuel tank cap to release pressure in fuel
tank.
332 smr2011-026
Check Valve and Pressure Relief Valve

Test
Pressure Relief Valve Function Test
The pressure relief valve is checked when per
forming the FUEL TANK LEAK TEST.
A WARNING
If the pressure relief valve is stuck, the pres
sure in the fuel system will build up and pos
sibly cause fuel leakage in the eng i n e com
partment.
� m r2009.o31·013_a
1. Vacuum selected
When replacing the pressure relief valve, always
install it with the arrow pointing away from the 3. Block the vent hose near outlet valve (pressure
vent hose. relief valve).
REQUIRED TOOL
SMALL HOSE PINCHER

(P/N 295 000 076)
4. Connect vacuum/pressure pump to the vent

hose.
• m r200 9 -031-01 6_a
Install the valve end the arrow is po1nt1ng to

through the grommet in the hull, towards outside
1
ambient air pressure.
Inlet Check Valve Test J

1. Disconnect vent hose from fuel pump.
s m r2009-031-01 S_ c
TYPICAL VACUUM TEST SETUP

-
1. Hose pincher
5. Squeeze the vacuum/pressure pump handle

several times to draw air in through the inlet
valve.
Air should be drawn in freely and the vacuum indi
cation on the pump gauge should remain at zero
(0). If the indication does not remain at zero (0),
= • 2 009 -03 1 - 0 1 4_ 3 replace the inlet check valve.
TYPICAL
6. Set vacuum/pressure pump to pressure.
1. Disconnect here
2. Set the vacuum/pressure pump to vacuum.
smr2011·026 333
Subsection 03 (FU E L TANK AND FUEL PUMP)
FUEL SYSTEM HIGH PRESSURE

LEAK TEST
A WARNING
A high pressure leak test must be carried
out before starting the engine anytime a fuel
system component has been disconnected
for maintenance or replacement.
1. Visually inspect fuel system to ensure all fuel

system connections are properly made.
2. Lightly pull on hoses at each connection to en
omr2009·03 1 -01 U
sure they are properly locked at the quick con
nect fittings.
7. Squeeze the vacuum/pressure pump handle 3. Remove tether cord from the engine cut-off
several times to apply air pressure to the inlet switch to prevent engine starting.
valve.
4. Press the START button to turn on the fuel
pump for a few seconds and pressurize the
fuel system.
5. Check for fuel odor and visually inspect hoses,
fittings and components for leaking fuel.
6. If a leak is detected, repair or replace the leaking
component and repeat leak test after the repair.
7. If no leak is found, engine can be started.
FUEL PUMP PRESSURE TEST

Preparation
The pressure test will show the available pressure
TYPICAL PRESSURE TEST SETUP
at the fuel pump outlet. It validates the pressure
-
1. Hose pincher
regulator, the fuel pump and tests for leaks in the
The valve should hold 34.5 kPa (5 PSI) without system.
leakage. Otherwise, replace inlet check valve.
1. Ensure the battery is fully charged, refer to
When replacing the valve, always reinstall it with CHARGING SYSTEM
the black side towards the hose.
2. Open front storage compartment cover.
3. Remove the storage bin or partitions. Refer to
BODY subsection.
iS and aS Models
8. Reinstall valve in its grommet.

9. Reinstall remaining removed components.
334 smr2011-026
•m r2()()9,031 0 1 7,JI
$\'\r2000-031-00B.o
TYPICAL
1. Ventilation box
1. Outlet hose
Models Without iS and aS 9. Install pressure test tools between discon

5. Disconnect the top of the two front air ventila nected hose and fuel pump fitting (in line
tion hoses, refer to BODYsubsection. installation).
REQUIRED TOOLS
b
PRESSURE GAUGE
(P/N 529 035 709)
FUEL HOSE ADAPTER

.-·r --
(P/N 529 036 023)
l
•bi20 1 0-004 ·002
TYPICAL - FRONT AIR VENTILATION HOSES
All Models
6. Ensure hoses and fittings are not leaking. Re
pair any leak.
7. Ensure there is enough gas in the fuel tank.
8. Di scon ne ct the pressure outlet hose from the
fuel pump.
A WARNING
$fflf 2Q09 -03 l .O l 8••
Cover the fuel line connection with an ab
TYPICAL
sorbent shop rag. Wipe off any fuel spillage 1. Connect to fuel pump
inside the bilge. 2. Connect to outlet hose
Test when Engine Is Stopped

switch to prevent engine starting.
2. Press the START button and observe fuel pres
sure.
3. Release pressure in system using the valve on
the pressure gauge between each test so that
the reading returns to zero (0).
smr2011-026 335
4. Repeat test twice and compare readings to A WARNING

specifications in following table.
Wipe off any fuel spillage in the bilge. Fuel
is flammable and explosive under certain
conditions. Always work in a well ventilated
area.
5. Reinstall all other removed parts, refer to appli

cable subsectiC1ns.
PROCEDURES
FUEL HOSES AND OETIKER

CLAMPS
Fuel Hose Inspection
1. Inspect all fuel hoses for wear, kinks, cracks or
any other types of damages.
FUEL PUMP PRESSURE TEST
1. Valve on gauge 2. Inspect all clamps for tightness.
FUEL PRESSURE
Fuel Hose Replacement
MODELS (WHEN PRESSING THE
START BUTTON) When replacing fuel lines on all Sea-Doo water
craft models, be sure to use "A1 type hose
All
"
386 kPa - 414 kPa (56 PSI - 60 PSI)

approved by BRP for pressurized hoses, and
"81" type hose approved by BRP for ventilation
Test when Cranking or Starting Engine hoses. These hoses available from BRP meet our
1. Crank or start engine and observe fuel pres system requirements and will ensure continued
sure. The fuel pressure should be the same as proper and safe operation.
in previous test.
A WARNING
If pressure is good, fuel pump and pressure regu
lator are functioning correctly. Use of fuel lines other than those recom
mended by BRP may compromise fuel sys
2. Stop the engine.
tem integrity.
A rapid pressure drop indicates leakage either
from the fuel rail or from the fuel pump check A WARNING
valve. Check fuel rail for leaks.
Whenever removing a hose in the fuel sys
If a pressure drop occurs when pressing the tem, always use new Oetiker clamps at as
START button and the fuel rail is not leaking, then sembly. Then validate fuel tightness of sys
replace the fuel pump module. tem by performing a fuel tank leak test o r a
A slow pressure drop indicates leakage either high pressure leak test as applicable.
· from a fuel injector or from the fuel pressure
regulator in the fuel pump module. To check Oetiker Clamp Replacement
fuel injectors for leaks, refer to the ELECTRONIC
To secure or cut Oetiker clamps on fuel lines, use
FUEL INJECTION (EFI) subsection. If injectors
OETIKER PLIERS (PIN 295 000 070).
are not leaking, then replace fuel pump.
3. Release fuel pressure in system using the valve
on the pressure gauge.
4. Remove pressure gauge and reinstall fuel hose
on fuel pump module.
336 smr2011·026
5. If the fuel pump does not run:

- Ensure ECM is powered. Refer to ELEC
TRONIC FUEL INJECTION (EFIJ subsection.
- Check fuse F18. If fuse is faulty, replace it
and repeat test. If fuse is good, carry out the
FUEL PUMP INPUT VOLTAGE TEST in this
subsection.
Reconnect throttle body connector.
Fuel Pump Pressure Test

Refer to INSPECTION in this subsection.
Fuel Pump Input Voltage Test

1. Cutting clamp
1. Ensure the fuel pump fuse (F18) is in good con
dition.
2. Disconnect fuel pump harness connector. Re
fer to FUEL PUMP REMOVAL.
868).
4. Select Vdc.
5. Press the START button.
F01804A 1 6. Read voltage at fuel pump harness connector

as per following table.
1. Securing clamp
INPUT VOLTAGE TEST
TEST PROBES VOLTAGE
Battery
Pin B
ground Battery voltage
(+probe)
(- probe)
Fo1006A
1. Securing clamp in limited access
FUEL PUMP
Fuel Pump Operation Test
switch to prevent engine starting.
2. Press START button.
""'2 008-022-01 7-�
3. The fuel pump should run for 2 seconds to build FUEL PUMP INPUT VOLTAGE TEST
up fuel system pressure.
If battery voltage is read, power circuit is good.
4. If fuel pump runs, carry out the FUEL PUMP
Test the fuel pump circuit. Refer to FUEL PUMP
PRESSURE TEST as described in INSPECTION
CIRCUIT TEST.
in this subsection.
smr2011-026 337
If battery voltage is not read, power circuit 1s

faulty. Test continuity of power circuit wiring
between fuse box and fuel pump. Refer to FUEL
PUMP CIRCUIT TESTin this subsection.
Fuel Pump Circuit Test

1. Reconnect the fuel pump harness co n necto r.
2. Remove cover of fuse bo x.
3. Remove the long bus bar.
12------1
smr2011-026·001_a
6. If test succeeded, the fuel pump, its fuse and

its w iring harness are good.
7. If test failed, test w iring continuity as per table.
FUEL PUMP HARNESS CONTINUITY

TEST (WIRING ONLY)
RESISTANCE@
TEST PROBES
20°c (68°F)
Pump harness Fuse
smr201 1 -02 6-006 _• connector pin B box te rm inal F2
1. Long h11s har Close to On
ECM (continuity)
Pump harness
4. Remove ECM connector "B' and install it on the connector B
connector pin A
ECM ADAPTER TOOL (P/N 529 036 166). pin B-M1
!!29036166
5. Set multimeter ton and test pump circuit as per

following table.
...,.. , 2011-026-008..D
PUMP CIRCUIT TEST THROUGH FUEL PUMP
RESISTANCE@
TEST PROBES
20°c (68°F)
Fuse box ECM connector B

Approx. 12 n
terminal D2 pin B-M1
338 smr2011·026

5. Disconnect the top of the two front air ventila
tion hoses, refer to BODY subsection.
smr2009-03t -021 _ b
If there is an open circuit to FB-F2, repair

wiring/connector between fuel pump and fuse
FRONT AIR VENTILATION HOSES
box.
If there is good continuity to FB-F2 and fuel pump All Models
fuse (F18) is good, check continuity of the wire 6. Disconnect the negative battery terminal, refer
jumper between D2 and E2. Repair or replace to CHARGING SYSTEM subsection.
wiring as required.
7. Disconnect fuel pump electrical connector.
If every test succeeded and fuel pump still does
not work, try a new ECM. Refer to ELECTRONIC
8. Disconnect the vent tube from the fuel pump.
FUEL INJECTION (EFI) subsection. 9. Wrap shop rags around the high pressure fuel
hose fitting, then press on the release button
Fuel Pump Removal of the quick connect fitting and disconnect the
1 . Open front storage compartment cover. hose.
2. Remove storage bin or partitions. Refer to

BODY subsection.
iS and aS Models
om12009-0::l l -0 1 7_
b
TYPICAL
1. Quick connect fitting (high press ure fuel hose)
2. Vent hose
3. Harness connector
10. Unscrew the fuel pump retaining nut.

smr2009-031·00B_o
REQUIRED TOOL
1. Ventilation box
•
FUEL PUMP MODULE SOCKET
4. Lift suspension to gain access.
(PIN 529 036 125)
NOTE: If more height is required or if the suspen
sion cannot be used, manually lift suspension by
the anchor points close to handlebar and safely
lock in this position. Do not lift the watercraft from
the anchor points.
smr2011 ·026 339

A WARNING
Always wipe off any fuel spillage from the
watercraft. When working with fuel or fuel
system and its components, always work in
a well ventilated area.
Fuel Pump Installation

Reverse the r e111ovol procedure however, pay at
tention to the following.
1. Carefully insert fuel pump module in fuel tank
so as not to bend float arm.
111'1\12 009-031-022..a 2. Install a NEW fuel p um p module gasket each
1. Fuel pump module socket time the module is reinstalled.
2. Fuel pump retaining nut
NOTE: Wipe off parts to prevent fuel pump from
IM1)1li1j While pulling out the fuel pump turning while torquing fuel pump nut.
module, pay attention to the corrugated tubes
3. Align arrow on top of fuel pump module with
and fuel sensor float arm. Float arm can get
index mark on top of fuel tank or fuel sensor
caught up and bend which will reduce fuel sen
accuracy will be affected.
sor accuracy. If fuel pump module is dropped
or damaged, it must be replaced. NOTE: Index mark and arrow locations are high
lighted for clarity in following illustration.
11. Slowly pull fuel pump module up through
opening until corrugated tubes contact sides
of opening. lilt the fuel pump module as you
slowly pull the pump upwards.
AwARNING
The upper filter and fuel pump reservoir on
t h e fuel pump module contain fuel which will
drain out when fuel pump module is not in a n
upright position.
12. Carefully pull fuel pump module out.
s mr20IJ9-03 l-02 4 _1
FUEL PUMP MODULE INDEXING

1. Align marks
4. lighten fuel pump nut.
TORQUE
Fuel pump nut
5. Carry out a FUEL TANK LEAK TESTand a FUEL

SYSTEM HIGH PRESSURE LEAK TEST See
procedures in this subsection.
1mr2009-031-023.• FUEL FILTER

iS MODEL SHOWN
1 Pull out fuel pump module Fuel Filter Inspection
Inspect fuel filter. If dirty, partially clogged or dam
aged, replace it.
340 smr2011-026
2. Press new filter on by hand. Ensure it is fully

seated and locked onto the pump reservoir
housing.
3. Reinstall fuel pump as per procedure in this sub
section.
4. Carry out a FUEL SYSTEM HIGH PRESSURE
LEAK TESTas described in this subsection.
5. In stall or other removed parts, refer to applica
1 ble subsection.
FUEL LEVEL SENSOR

$ mr2009
-03 1·02 _o
5
Fuel Level System Overview
7. Fuel filrer
A float type fuel level sensor mounted on the fuel
Fuel Filter Removal pump module sends a signal to the information
center.
NOTE: The lower fuel filter on the fuel pump mod
ule does not require replacement under normal
operating conditions. Replace only if permanently
clogged or damaged.
1. Remove fuel pump. Refer to FU EL PUMP in
this subsection.
A WARNING
the fuel pump module contain fuel which will
drain out when fuel pump module is not in an
upright position.
2. Turn fuel pump upside down.

3. Using a small flat screwdriver, pry up the filter TYPICAL- FUEL PUMP MODULE
1. Fuel level sensor
locking tabs.
The information center interprets this signal and
turns on the appropriate number of segments of
a bar type fuel level indication in the lower RH side
of the digital screen in the information center.
Fuel Level Troubleshooting

FUEL LEVEL TROUBLESHOOTING
SYMPTOM POSSIBLE CAUSE
- Wiring/connectors
Fuel gauge always
- Fuel level sensor
display EMPTY
- Float stuck in low position
- Water in fuel pump
Fuel gauge always
connector
display FULL
7. Fuel filter locking tab (x2) - Float stuck in full position
2. Filter locking pin (x2)
Fuel level sensor fault - Wiring/connectors
4. Pull filter off fuel pump reservoir housing. code - Fuel level sensor
Fuel gauge displays - Low battery voltage
Fuel Filter Installation wrong level - Fuel level sensor fault
1. Align new filter with pump reservoir housing.
srnt2011-026 341
Use B.U.D.S. to check for a fault code. Refer to 5. Connect the DIAGNOSTIC HARNESS (P/N 529 036
DIAGNOSTIC AND FAULT CODES 188) to make an in-line connection between the
disconnected connector.
Fuel Level Sensor Voltage Test
1. First ensure battery is fully charged.
iS Models
2. Lift suspension using the iS up button to gain
access.
NOTE: On AXT aS 260 model, if more height is

required , manually lift suspension by the anchor
points close to handlebar and safely lock in this po 52900 6 1 88
sition. Do not lift the watercraft from the anchor

6. Briefly press the START button to wake up the
points.
ECM.
Models Without iS and aS 7. Install the tether cord on the engine cut-off
3. Disconnect the top of the two front air ventila switch.
tion hoses, refer to BODYsubsection.
868) and select Vdc.
9. Measure the voltage at the test connector of

the diagnostic harness as follows.
TEST
FUEL TANK CONNECTOR
VOLTAGE
LEVEL OF DIAGNOSTIC
HARNESS
Full 0.14 Vdc

Pins 5 and 17
Empty 2.7 Vdc
All Models
4. From under the steering support area, discon
nect the 24-pin connector.
smr2010-038003. b
TEST CONNECTOR OF DIAGNOSTIC HARNESS
NOTE: Voltage could be slightly different depend

ing on battery voltage but should remain relatively
close to this range. If fuel tank is not full or empty,
the voltage value will be proportional to the fuel
level (somewhere in-between).
24-PIN STEERING CONNECTOR DISCONNECT If voltage is as per specifications the fuel level cir
Step 7: Pull our safety lock cuit and sensor are good. If fuel level does not
Step 2: Press in on release tab
Step 3: Pull locking collar down work in information center, try a new one.
342 smr2011-026
If voltage is out of specifications, perform the RESISTANCE (n) FLOAT HEIGHT (MM)
FUEL LEVEL SENSOR RESISTANCE TEST AT 4.8 ± 2.2 268.9 ± 3.0 (FULL)
INFORMATION CENTER as described in this sub
17.8 ± 2.2 240.6 ± 3.0
section.
27.8 ± 2.2 219.1 ± 3.0
Remove diagnostic harness and reconnect con
37.8 ± 2.2 193.8 ± 3.0
nector.
47.8 ± 2.2 161.9 ± 3.0 (HALF)
Fuel Level Sensor Resistance Test at 57.8 ± 2.2 128.3 ± 3.0
Information Center 94.1 ± 3.0
67.8 ± 2.2
1. Disconnect information center (multifunction 77.8 ± 2.2 60.6 ± 3.0
gauge) connector. Refer to GAUGE subsection.
89.8 ± 2.2 28.8 ± 3.0 (EMPTY)
l1fZ1JmJj Pull connector lock out. Do not twist
the screwdriver.
A. Float height
NOTE: If fuel tank is not full or empty. the resis

tance value will be proportional to the fuel level
(somewhere in-between).
If readings are as per specifications, the fuel level
circuit and sensor are good. If fuel level does not
smr2009-042-00<..;l
work in information center, try a new one.
1. GBuge connector If readings are out of specifications, perform the
2. Pull out to unlock connector
FUEL LEVEL SENSOR RESISTANCE TEST AT
2. Use the FLUKE 115 MULTIMETER (PIN 529 035 FUEL PUMP
868) and select n. If an open circuit is measured, carry out a conti
3. Alternately drain then fill fuel tank and measure nuity test of the wiring from the information cen
the sensor resistance between pins 19 and 20 ter to the 24-pin steering connector, and from the
as follows. 24-pin steering connector to the fuel pump mod
ule connector. Refer to WIRING DIAGRAM.
If the wiring is good, carry out a FUEL LEVEL SEN
SOR RESISTANCE TfST AT FUEL PUMP
4. Reconnect information center (multifunction
gauge) connector.
Fuel Level Sensor Resistance Test at

Fuel Pump
1. Disconnect fuel pump module connector.
smr2011·02S 343
Fuel Level Sensor Removal
TYPICAL FUEL PUMP MODULE

-
7. Fuel pump module connector

FUEL LEVEL SENSOR
2. Alternately drain then fill fuel tank and measure
1. Remove· fuel pump module from fuel tank, see
the sensor resistance between pins "C" and "D"
FUEL PUMP REMOVAL in this subsection.
of the fuel pump connector. See table in FUEL
LEVEL SENSOR RESISTANCE TEST AT INFOR A WARNING
MATION CENTER.
the fuel pump module contain fuel which will
drain out when fuel pump module is not in an
upright position.
2. Drain all fuel from the upper fuel filter and fuel
pump reservoir in an appropriate container.
NOTE: Note routing of fuel level sensor wires
prior to disconnecting the sensor from the fuel
pump module flange.
3. Disconnect the fuel level sensor connector
from the fuel pump module upper flange.
smr200S.022-018_t
TYPICAL - FUEL LEVEL SENSOR RESISTANCE TEST
If readings are out of specifications, replace sen

sor.
When everything else has been tested and fuel
level is still not working, try a new information
center.
smr2008-022-021 _a
1. F(le/ level sensor connector
4. Disconnect the ground wire from the pressure

regulator. Be careful not to bend the ground
contact on the pressure regulator.
344 smr2011-026
6. Once the pressure regulator is rotate oyer the

locking tab, pull up on it to remove it from the
pump reservoir cover.
1. Pressure regulator
2. Ground wire contact on pressure regulator
3. Ground wire disconnected
5. Using a flat screwdriver, press down on the

srnt2008-022-026_a
locking tab just below the pressure regulator
1. Pressure regulator alignment tabs
to release it from the pump reservoir cover, 2. Fuel pump reseNoir alignment tabs
and rotate it clockwise simultaneously so that
it slips over the locking tab. NOTE: The pressure regulator cover must not be
removed from the pressure regulator housing as
sembly.
1. Pressure regulator
2. Pressure regulator locking tab
srrv200B-022-028_ a
7. Do not remove pressure regulator cover at locking tabs

2. Pressure regulator cover
3. Pressure regulator housing
7. Push in on the release tabs at the top of the

fuel level sensor to unlock it from the fuel pump
reservoir housing, and simultaneously pull up
on the fuel level sensor to remove it.
snv2008-022-024_a
1. Pressure regulator locking tab •
2. Pressure regulator rotated clockwise over locking tab
smr2011-026 345
2. Align the fuel pressure regulator tabs into the

pump reservoir cover and turn it counterclock
wise until it locks properly.
1. Fuel level sensor release rabs

2. Locking pins
smr2008-022-02 5..I>
PRESSURE REGULATOR INSERTION INTO PUMP RESERVOIR

COVER
1. Pressure regulator alignmenr tabs
2. Fuel pump reservoir alignment tabs
1. Pull up on fuel level sensor
Fuel Level Sensor Installation

TAB UP WHEN PRESSURE REGULATOR PROPERLY LOCKED
1 . Ensure fuel level sensor locking pins are prop 1. Pressure regulator locking tab
erly engaged into the fuel pump reservoir.
3. Reconnect the ground wire onto the pressure
regulator.
cm1 2008-022-026_b
1. Ensure engagement of sensor locking pins smr:? OOB-022 -031_1
1. Pressure regulator ground wire installed
346 smr2011-026
4. Ensure fuel level sensor connector is locked All Models

into the module flange connector. 5. Inspect fuel tank retaining straps for wear,
cracks or any other damages. Inspect strap
clip anchors and bolts.
6. Inspect fuel tank for wear caused by any ab
normal contact or rubbing with other compo
nent(s).
7. Disconnect fuel filler hose from fuel tank.
8. Inspect fuel tank filler hose for wear, cracks or
other damages.
9. Visually inspect the inside and outside of the
fuel tank filler necks for crack(s). If crack(s) are
found, replace fuel tank.
10. With your fingers, feel the inside and outside
surfaces of fuel tank, especially near the filler
s m r2 008-022-02 t_ a
neck.
1. Fuel level sensor connector
11. Flex fuel tank neck to ensure there are no hid-
5. Carry out a FUEL LEVEL SENSOR RESISTANCE den cracks.
TESTas described in this subsection.
NOTE: A fuel tank is comprised of 2 components:
6. Reinstall the fuel pump module. Refer to FUEL the tank and the filler neck. The filler neck is in
PUMP INSTALLATION in this subsection. jection molded and the tank is then blow molded
over the neck. During the molding process, a
FUEL TANK small molding seam may appear on the inner
side of the neck at approximately 4 mm (5/32 in)
Fuel Tank Inspection from the base of the neck. It is normal to have a
1. Open front storage compartment cover. molding seam and it should not be confused with
2. Remove storage bin or partitions. Refer to a crack.
BODY subsection.
4 2
1S and aS Models
3 A 5
F07F06A
1. Tank upper surface area

2. Inspect outer upper surface at filler neck
3. Normal molding seam
4. Inspect upper surface area inside filler neck
5. Base of filler neck
A Approx. 4 mm (5/32 in)
12. Install filler hose and torque retaining clamps.

1. Ventilation box

4. Open or remove seat for access to aft end of
fuel tank.
smr2011-026 347
Subsection 03 {FUEL TANK AND FUEL PUMP)
smr2009-031-017_
b
TYPICAL
smr2009-03 t-02d_b 1. Quick connect fitting (high pressure fuel hose)
INDEXING WITH FUEL TANK 2. Vent hose
1. Align mark wirh the writing on hose 3. Harness connector
TORQUE 3. Disconnect filler hose from fuel tank.
Filler hose retaining

clamps
I 3.5 N•m (31 lbt•in)
NOTE: Re movi ng retaining screws of the filler
neck may help t o disconnect hose from fuel tank.
13. Reinstall all other removed parts. Refer to ap

propriate subsection.
Fuel Tank Removal

GTS, GT! and WAKE 155
1. Remove engine. Refer to ENGINE REMOVAL
AND INSTALLATION
2. Remove the air intake silencer. Refer t o AIR IN
TAKE SYSTEM (EXCEPT 1S AND as MODELS)
subsection.
RXT 260, RXT X 260, RXT XRS 260, GTX

155, GTX 215 and WAKE PRO 215 smr2009-031-026_
1
1. Rem ove the front body module. Refer to BODY TYPICAL

1. Filler hose
subsection. 2. Retaining clamp
2. Remove the air intake silencer. Refer to AIR IN
NOTE: Take note of wiring harness, hose and
TAKE SYSTEM (EXCEPT tS AND aS MODELS)
cable routing for proper reinst all atio n. Also note
subsection.
method used for securing with lock ing ties.
RXT iS 260, RXT as x 260, RXT as XRS 260, 4. Detach fuel tank retaining straps.
GTX iS 215 and GTX LTD iS 260
5. Remove fuel t an k from the vehicle.
1. Remove moving deck. Refer to BODYsubsec
tion. 6. Remove fuel pump as necessary. Refer to
FUEL PUMPin this s ub se ctio n.
2. Remove engine. Refer to ENGINE REMOVAL
AND INSTALLATION 7. Ins pect hull and flotat io n foams for wear.
3. Remove suspension base. Refer to SUSPEN- Fuel Tank Installation

SION
NOTE: Apply torque values as specified in th e ex
All Models ploded view.
1. Siphon fuel tank. 1. Reinstall fuel pump if it was removed. Refer to
2. Disconnect fuel pump connections. FUEL PUMPin t his su bsection .
2. Ensure flotation foams are properly po sit ion ed
under fuel tank.
348 smr2011-026
3. Insert fuel tank in hull. 9. Reinstall all other removed parts. Refer to their
subsections.
4. Place fuel tank retaining strap ends in anchoring
clips. Temporarily use tape to hold straps on the 10. When vehicle reassembly is complete, carry
top of fuel tank. out a FUEL TANK LEAK TEST and a FUEL
SYSTEM HIGH PRESSURE LEAK TEST as
described in this subsection.
smt2009431-021_t
TYPICAL
I. Fuel tank retaining strap
2. Clip anchor securing strap to hull
5. Secure retaining strap ends on top of fuel tank.

6. Properly secure wire harness, cables and hose
as prior to removal using appropriate locking
ties.
7. Install fuel tank filler hose as illustrated.
omr2009·03H i24_b
INDEXING WITH FUEL TANK

1. Align mark with the writing on hose
TORQUE
I
Filler hose retaining
3.5 N•m (31 lbf•in)
clamps
8. Tighten clamp retaining vent hose to pump

module.
TORQUE
Vent hose clamp I 1.7 N•m (15 lbf•ln)
smr2011-026 349
350
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Section 05 ELECTRICAL SYSTEM
Subsection 01 (POWER DISTRIBUTION AND GROUNDS)
POWER DISTRIBUTION AND GROUNDS

GENERAL
POWER DISTRIBUTION DIAGRAM
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F12 3Ai----
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F13 10A >---�-------i FUEL I NJECTOR

IGNITION COIL No. �I
F15 lOA FUEL INJECTOR
IGNITION COIL No. 2
FUEL INJECTOR
IGNITION COIL
No. 3
F16 SAt--...._-----1 STARTER SOLENOID

SA � --- - - --------------- ---·----- -------------- ---- ..
;...1F-8--OAl I-- I FUEL PUMP I
F19 15Al----'7---'
��---< n
---
--
1
-
--
-
-- ;:::
==
= o. = .
= TA.= .S
==
---- '
1 - ==; -
u ____i
CAPS
ttnr201 1 -021 -00 1 _ae11
NOTE: Component shown in doted lines are not offered on all models.
ACRONYM DESCRIPTION
CAPS: Camshaft position sensor iS: Intelligent suspension
ECM: Engine control module O.T.A.S.: Off throttle assisted steering
iBR: Intelligent brake and reverse
smr2011-027 351
FUSE BOX
Fuse Box Location (GTS and GTI
Series)
To access the fuse box, open the front storage
cover an remove the access panel.
.... 200!>-002 .0 0 2 •
1. Boarding platform
FUSE BOX ACCESS

1. Access panel
7. Storage bin
To access the fuse box, open the starboard access
panel on the rear deck.
smo2011-000 -oos..1 1
TYPICAL
1. Fuse box
2. Fuel tank
3. Front storage compartment (access panel removed)
Fuse Box Location (RXT, GTX and

Wake Pro Series)
'""2011.() 29-009•
1S and aS Models 1. Starboard access panel
To access the fuse box, open the boarding plat

form and remove the RH storage bin.
352 smr2011-027
Fuse Identification NO. DESCRIPTION
Through relay:
F1 5A
1 -------12 - iBR control
Direct power {through F8):

ii- IJ l.J i..J t; � u u 3 tl cl ila F2 15A
- Diagnostic connector
Ai11.Jl..J6GuurlrlcliJ
Direct power {through F8):
a.( t(J I() /:l ir::J rJ rJ --:t, :-f :-f :f F3 3A
If I() c(I n:J LJ 1 3 t J J J I 4 START/STOP
� .Li L L � i;..; i:l .J. r4 .& Direct power {through F8):
• �, .I: J..IU ,... _. ,.{""' ,a.
.. F4
- Gauge constant power
3A
' a1-;f � � � � .:t .., ,. �

Direct p o wer:
A -« .. � If llil llii � .. " .A ill F5 30 A
- iBR power
1 -------11 Direct power:
F6 30 A
- Voltage rectifier/regulator
FUSE BOX PIN IDENTIFICATION Direc t power:

F7 30 A
- iS power
NOTE: This fuse box has rows of 11 or 12 cavi
ties. See table below for details. - F2
NUMBER OF CAVITIES BY ROW - F3

F8 30 A
- F4
ROW NUMBER OF CAVITIES
- Relay
A-B 11
Through relay:
F11 3A
C-D 12 - Depth sounder
E-F 11 Through relay:

- O.T.A.S.
G-H 12 F1 2 3A
- Gauge start u p
- CAPS
Through relay:
F13 - Fuel injector cyl. 1 10 A
- Ignition coil cyl. 1
Through relay:
Through relay:
Through relay:
F16 5A
- Starter solenoid
11m 201 1 ..o27-003_1
Through relay:
F17 5A
- iBR control
Thr ough relay:

F18 10 A
- Fuel pump
Thro ugh relay:

F19 15 A
- ECM power
smr2011·027 353
RELAY
Relay Pin Identification
The relay is on the fuse box. Refer to FUSE BOX
LOCATION
RELAY PIN IDENTIFICATION
FUNCTION FUSE BOX PIN CONDITION
Direct battery
12-volt input at
89 power
winding
from fuse F8
Grounded
by ECM B
Control A11 pin H2 once
START/STOP
is depressed
Direct battery
12-volt input at
A9 power
contacts
from fu se F8
12-volt output 811 -
GROUNDS
Ground Location
All the ground terminals are located on the front
of engine.
There is no splice in the ground wiring, the inter
connections are made through a bus bar in the
fuse box.
l'TV'2011--027-0>4._•
S-
FRONT OF ENGINE
1. Battery ground
2. Electrical compon9nts grounds
3. Exhaust manifold
354 smr2011-027
Subsection 02 (IGNITION SYSTEM)
IGNITION SYSTEM
SERVICE TOOLS
ECM ADAPTER TOOL................................................................... 529 036 166 ......................................... 358
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ................................. 357-358
SERVICE PRODUCTS
DOW CORN ING 111 ......... ............................................................ 413 707 000 ......................................... 360
GENERAL
AwARNING
Hoses, c ables or locking ties removed during a

procedure must be r ein stal led as per factory stan
dards.
A WARNING sm r2009-032-0 D 7_ e
1. Ignition coils
an open coil and/or spark plug as spark may
Ignition Timing
cause potential fuel vapors to ignite. Always
use an approved spark tester. Ignition timing is not adjustable.
The ECM is programmed with data (ignition map
SYSTEM DESCRIPTION pings) that it uses to establish optimum ignition
timing under all engine operating conditions.
The ignition system is a digital inductive type sys
It receives signals from a variety of sensors that
tem.
it compares with the ignition mappings and uses
Ignition system parameters such as ignition tim it to control the ignition spark timing, duration and
ing, spark duration, and firing order, as well as firing order.
many other engine related functions are con
The fir ing of each spark plug is independent of the
trolled by the e ngine management system (EMS)
ot hers.
in order to meet engine operational requirements.
The EMS can detect many abnormalities includ Engine RPM Limiter
ing a short circuit in the primary winding of the
ignition coils as well as its associated circu it s. The ECM wi ll limit the maximum engine speed by
cutting off ignition spark and fuel at a predeter
Three separate ignition coils receive power from
mined engine RPM.
three separate fuses.
ENGINE RPM LIMITER
When a ground signal is provided by the ECM to
an ignition coil primary winding, a high volta ge is 130 and 155 HP 7750 RPM
ind uce d in the coil secondary winding that is used
215 and 260 HP 8300 RPM
to produce a spark at the spark plug electrode.
smr2011·028 355
Knock Sensor ENGINE WILL NOT START (ENGINE

A knock sensor is mounted on the cylinder block TURNS OVER)
behind the intake manifold. It detects specific vi 1. Fouled or defective spark plug
brations that would typically be generated by en
- Check spark plug condition. Replace if necessary.
gine detonation.
2. Defective CPS
If detonation occurs, the knock sensor detects
it and the ECM goes into a specific operating - Test CPS, refer to ELECTRONIC FUEL INJEC
TION (EFI) subsection.
mode whereby it temporarily retards the ignition
advance until detonation stops. 3. Defective trigger wheel
The ECM is able to identify in which cylinder the - Check. Refer to PTO HOUSING/MAGNETO sub
knocking occurs and modifies the ignition advance section.
on that cylinder only. 4. Defective ignition circuit
Refer to the ELECTRONIC FUEL INJECTION (EFI) - Check fuses, ignition coils, wiring and connec
section for testing and replacement procedures. tors.
ENGINE HARD TO START

TROUBLESHOOTING
1. Faulty, fouled or worn out spark plug
It is good practice to check for fault codes using
the B.U.D.S. as a first troubleshooting step. Refer
to DIAGNOSTIC AND FAULT CODES subsection.
ENGINE MISFIRES, RUNS IRREGULARLY
Refer to POWER DISTRIBUT/ONfor fuses and re
lay information. 1. Fouled, defective, worn spark plugs
Always refer to the WIRING DIAGRAM when
troubleshooting an electrical circuit. 2. Defective T.O.P.S. sensor
- Test T.O.PS. Refer to LUBRICATION subsection.
IGNITION SYSTEM TESTING 3. Damaged trigger wheel/loose CPS
1. Ensure fuses F13, F14 and F15 are powered - Check. Refer to PTO HOUSING/MAGNETO sub
and in good condition. section.
2. If a fuse is burnt, test for a short circuit or faulty 4. Defective ignition circuit
component on that fuse circuit before replacing - Check fuses, ignition coils, wiring and connec
the fuse. tors.
A WARNING 5. Poor engine grounds

- Check ground condition. refer to POWER DISTRI
Due to the possibility of flammable vapors ac
BUTION AND GROUNDS subsection.
cumulating in the bilge, you should always
test for a short circuit which may produce a ENGINE CONTINUALLY BACKFIRES
spark and ignite the vapors before replacing
a burnt fuse. 1. Fouled, defective spark plugs
3. If there is no active fault code, start diagnos
2. Damaged trigger wheel/defective or loose CPS
tic by carrying out IGNITION COIL TEST USING
Check, refer to PTO HOUSING/MAGNETO and
B.U.D.S
-
ELECTRONIC FUEL INJECTION (EF!) subsec

4. If a primary winding of an ignition coil or a cir tions.
cuit is at fault, a fault code will be set. Refer to
DIA GNOSTIC AND FAULT CODES subsection. ENGINE DETONATION OR PINGING
1. Faulty or disconnected knock sensor
DIAGNOSTIC GUIDELINES - Check, refer to ELECTRONIC FUEL INJECTION
(EFIJ subsection.
probable cause of a problem. It is a guideline and
should not be assumed to list all possible causes.
356 smr2011-028
ENGINE LACKS ACCELERATION OR -J

·-.. -----·----·,---··------
M�
POWER �
1. Weak spark 3
1
- Check spark plugs, coifs, wiring and connections.
PROCEDURES
IGNITION COILS
A WARNING
2
--�.:��: ..::
�
compartment as a spark may cause fuel va
...-
,.�
..-;-:
J.'c
��--.
J
� _�
� 1� __
==_
pors which may have accumulated in the ..
.. �
__
_ _=
=
__
__
smr2009-032-00 U
bilge to ignite.
IGNITION COIL ACTIVATION
1. Activation tab
Ignition Coil Access 2. ECM tab
3. Click on the desired ignition coil
1 . Open or remove seat.
You should hear the spark occurring. If in doubt,
iS and aS Models use a sealed vapor proof spark tester or an induc
2. Remove the rear ventilation cover. tive spark tester as available from tool suppliers,
to prevent a spark from occurring in the bilge.
All Models
If there is no ignition at one or more coils, c a rry
Ignition coils are located on top of the valve cover. out a IGNITION COIL INPUT VOLTAGE TEST.
NOTE: Some models have an engine cover that If spark is weak. try a new spark plug. If spark is
has to be removed to access the ignition coils. still weak, try a new ignition coil.
NOTE: The voltage required to produce a spark in
Ignition Coil Test Using B.U.D.S.
the combustion chamber is higher when the en
1. Connect to the latest applicable B.U.D.S. soft gine is running.
ware. Refer to COMMUNICATION TOOLS
AND B.U.D.S. section. Ignition Coil Input Voltage Test
2. Select the Activation and ECM tabs. Make sure fuses F13, F14 and F15 are good be
3. Energize the ignition coil to be tested by clicking fore testing.
on the corresponding illustration. 1. Disconnect the applicable ignition coil connec
tor.
switch.
3. Set the FLUKE 115 MULTIMETER (PIN 529 035
868) to Vdc.
4. Press the START button to activate the ECM.
NOTE: Pressing the start button without the
tether cord installed on the engine cut-off switch
will turn on electrical power without starting the
engine; the information center will cycle through
a self-test function and shut off its display after a
few seconds. However, the electrical system will
stay powered up for approximately three minutes
after the START button was pressed.
5. Measure voltage as per following table.
smr2011-028 357
TEST PROBES VOLTAGE 3. Read resistance of the desired ignition coil cir
cuit.
VIOLET/BLUE wire
(ignition coil no. 1) IGNITION IGNITION FUSE
MEASUREMENT
COIL COIL WIRE BOX
VIOLET/GREEN wire Battery Battery
(ignition coil no. 2) ground voltage 1 Termi nal
VI/BU
(rear) F7
VIOLET/ORANGE wire
(ignition coil no. 3) Terminal
2 VI/GR C:ln�A to Q ,Q
E6
Terminal
3 VI/OR
F5
1 ----
,.....,
--12
smr 2008-0 2•-005 .

b
IGNITION COIL INPUT VOLTAGE TEST
s rn Wl 1 -027--00
2 _•
If test succeeds, carry out an IGNITION COIL RE r
FUSE BOX PIN IDENTIFICATION

SISTANCE TEST
If test fails, carry out an IGNITION COIL POWER If test fails at any ignition coil, test the following
CIRCUIT CONTINUITY TEST items separately and repair/replace wiring or ter
minals from fuse box to the applicable ignition coil.
Ignition Coil Power Circuit Continuity - Wiring from fuse box to engine C04-4POS con-
Test nector
1. Remove fuses F13. F14 and F15. - Wiring from C04-4POS connector to ignition
coil.
Refer to WIRING DIAGRAM for details.
Ignition Coil Control Circuit Continuity

Test
1. Disconnect ECM connector "A". For connector
identification, refer to WIRING HARNESS AND
CONNECTOR subsection.
2. Connect ECM connector to the ECM ADAPTER
TOOL (P/N 529 036 166).
s rm 20 1 l-027-003 _g
7. Fuse F73
2. Fuse F14
3. Fuse F15

868) and select n.
358 smr2011-028
2. Perform a visual inspection of the ignition coils.

Check for corrosion, bent pins, loose or burnt
contacts, and cracked or torn insulator.
3. Using a multimeter, test the resistance in both
primary and secondary windings.
3. Disconnect ignition coil connector.

4. Test for continuity of circuit as per following ta
ble .
smrOS -0 1 5-00 2 .JI
IGNITION PRIMARY WINDING

ECM
COIL COIL RESISTANCE
ADAPTER
WIRE RESISTANCE @
CIRCUIT TERMINAL
20°c (68°F)
Cyli nder
BR/BK A-M4
1 (rear) Primary
1 and 2 o.85 - 1.15 n
winding
Cyl i nder Close to 0 n
BR/OR A-M2
2 (continuity)
Cylinder
BR/YL A-M1
3
smrO S- 0 1 5-002 .Jl
SECONDARY WINDING
RESISTANCE @
CIRCUIT TERMINAL
20°c (68°F)
Secondary 1 and spark

9.5 13.5 kn
windi ng plug terminal
-
If any test fails, replace ignition coil .
If test succeeds, carry out an IGNITION COIL

•mr2D07-0l3-003 _d
CONTROL CIRCUIT CONTINUITY TEST.
IGNITION COIL CONTROL CIRCUIT TEST
Ignition Coil Removal
If test fails, repair the connector or replace the en 1. Disconnect ignition c oil connector.
gine wiring harness.
IW1)ilitj Do not remove the ignition coil be
Ignition Coil Resistance Test fore disconnecting the input connector or the
An ignition coil with a good resistance measure wires may be damaged. Do not pry up ignition
ment can still be faulty. Current leakage can occur coil with a screwdriver to avoid damage.
at high voltage levels which is not detectable with
NOTE: Twist ignition coil in both directions as you
an ohmmeter. Replacing the ignition coil may be
pull it up to ease removal.
necessary as a test.
2. Remove ignition coil from spark plug.
1. Remove ignition coil. Refer to IGNITION COIL
REMOVAL in this subsection.
smr2011·028 359
Subsection 02 (IGNITION SYSTEM}
Ignition Coil Installation

Prior to inserting the ignition coil on its spark plug,
apply sealant as described in following procedure:
1. Pull rubber seal down.
1
sbs2009'011-0 03_o
1. Correctly shaped excess of product
5. Apply DOW CORNING 111 (PIN 413 707 000) on

rubber seal contact area.
m.2009-01 1 -00 2 ...1
1. Rubber seal pulled down
2. Apply DOW CORNING 111 (P/N 413 707 000) to

rubber seal seat as shown.
1. Apply product here
6. Install coil in cylinder head hole.

7. Push the ignition coil down to securely install it
on the spark plug tip.
8. Ensure the seal seats properly with top surface
of engine valve cover.
s bs2009'0 1 1-001-0
1. Apply product here
3. Pull rubber seal back on its seat making sure the

tabs on the ignition coil and the slots in the seal
properly match together.
4. Leave a ring of grease on top of the seal as
shown to act as a water barrier. Wipe off the
excess.
smt2CXB-03 2 -004_.
1. Seal properly seated
SPARK PLUGS
Spark Plug Removal
1. Remove ignition coil. Refer to IGNITION COIL
REMOVAL in this subsection.
360 srnr201 l-028

A WARNING Troubleshooting a Fouled Spark Plug

Never remove an ignition coil from a spark Fouling of the spark plug is indicated by irregular
plug without disconnecting it from the wiring running or misfiring of the engine, decreased
harness. Flammable vapors may be present engine speed due to misfiring, reduced perfor
in the bilge. Should the tether cord be in mance, and increased fuel consumption.
stalled on the engine cut-off switch, a spark Other possible causes are: use of an incorrect
could be generated at the spark plug end of or bad fuel, defective ignition system, incorrect
the coil possibly resulting in an explosion. spark plug gap, loss of compression, or lubric a t ing
oil entering the combustion chamber.
2. Using a spark plug socket, release the torque The plug face of a fouled spark plug has either a
applied to the spark plug. wet or dry black carbon deposit. Such coatings
form a conductive connection between the center
electrode and the ground electrode.
Spark Plug Analysis
AOOEOAA 1 2 3
7. Approved socket TYPICAL

2. Improper socket 1. Overheated (light gray, white)
2. Normal (light brown, brown)
3. Fouled (black, wet or dry, dark deposits, gray, melted coating)
3. Clean the spark plug and cylinder head with
pressurized air. The plug face reveals the condition of the engine,
4. Unscrew spark plug then use the ignition coil to operating condition, method of driving and fuel
take spark plug out of spark plug hole. mixture. For this reason it is advisable to inspect
the spark plug at prescribed intervals, examining
the plug face (i.e. the part of the plug projecting
into the combustion chamber) .
Spark Plug Installation

Prior to installation, ensure the contact surfaces of
the cylinder head and spark plug are free of grime.
1. Using a wire feeler gauge, set electrode gap as
specified in the following chart.
SPARK GAP
ENGINE TORQUE
PLUG mm (in)
Hand tighten
NGK
1503 + 1 /4turn with 0.75 (.030)
DCPRBE
a socket
1. Ignition coil 2. Apply anti-seize lubricant over the spark plug

2. Spark plug
threads to prevent possible seizure.
3. Hand screw spark plug into cylinder head.
Then, tighten the spark plug clockwise an ad
ditional 1 /4 turn with an approved spark plug
socket.
smr2011 ·028 361

4. Install ignition coil. Refer to IGNITION COIL IN

STALLATION in this subsection.
5. Complete the installation in the reverse order of
the removal.
362 srnr2011-028
Subsection 03 (CHARGING SYSTEM)
CHARGING SYSTEM
SERVICE TOOLS
VACUUM/PRESSURE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529 021 800 ......................................... 378

ELECTRO SPECIALTIES BATIERY LOAD TESTER . . . 710 . ..... . . . . . . . . . . . . . . ......................................... 372
EXTECH INDUCTIVE AMMETER ...... . .... . .. ........... ......... .. .. 380941
... .. . . . . . . . ......................................... 364
GENERAL Voltage Regulator/Rectifier

The rectifier receives AC current from the mag
ijfZ1)iliJj When performing a test on iS mod
neto and transforms it into direct current (DC).
els with the engine running above approxi
mately 4500 RPM for 3 seconds, be aware that The voltage regulator, included in the same unit,
the suspension will move to its predefined up limits voltage to a maximum level to prevent any
position and then stop in that position. Wait damage to electrical components.
until suspension is stopped before working on
the watercraft. Keep away from moving parts.
SYSTEM DESCRIPTION
The purpose of the charging system is to maintain
the battery at a full state of charge and to provide
the electrical system with the required electrical
power for normal vehicle operation.
Magneto
The magneto is the primary source of electrical
energy. It transforms a magnetic field into an elec
tric current (AC).
The magneto has a 3 phase, delta wound, 18 pole
smr2 01 1-0Z9-00· 1 _a
stator that is rated at 380 watts.
1. Voltage regulator/rectifier
Battery
The battery supplies DC power to the electric
starter for cranking the engine. During engine
starting, it also supplies DC power to every elec
trical and electronic system in the vehicle as well
as all accessories.
At low engine RPM operation and high current
load conditions, it supplements the magneto
output and helps to maintain a steady system
voltage.
F 18HIRA
TYPICAL
smr2011-029 363
INSPECTION Output Voltage Test Using a

Multimeter
CHARGING SYSTEM OUTPUT GTS and GT/ Models
First ensure that battery is in good condition prior For battery access, refer to BATTERY ACCESS in
to performing the following tests. this subsection.
NOTE: It is good practice to check for fault codes 1. Set multimeter to Vdc.
using the 8.U.D.S. as a first troubleshooting step.
2. Connect multimeter to battery posts.
Refer to DIAGNOSTIC AND FAULT CODES sub
section.
Output Voltage Test Using B.U.D.S.

1. Connect to the latest applicable 8.U.D.S. soft
ware. Refer to COMMUNICATION TOOLS
AND B. U.D.S. subsection.
2. Select the Monitoring and ECM tabs.
3. Start engine.
NOTE: Connect a garden hose to cool exhaust
system. Refer to EXHAUST SYSTEM subsection.
4. Increase engine RPM as specified in the follow
ing table and read voltage in B.U.D.S. smf'2009-0330_01 a
TYPICAL - CHARGING SYSTEM VOLTAGE TEST AT BATTERY

OUTPUT VOLTAGE TEST USING B.U.D.S. POSTS
TEST ENGINE SPEED VOLTAGE (DC) 3. Start engine.

5500 RPM 14.5 ± .5 Vdc NOTE: Connect a garden hose to cool exhaust
ing table and read voltage with the multimeter.
OUTPUT VOLTAGE TEST USING A MULTIMETER

TEST ENGINE SPEED VOLTAGE (DC)
5500 RPM 14.5 ± .5 Vdc
If voltage is above specification, replace voltage

regulator/rectifier.
If voltage is below specification, check stator
amf1009·033-001 _a output and wiring harness prior to concluding that
TYPICAL voltage regulator/rectifier is defective. Refer to
1. Monitoring tab
PTO HOUSING AND MAGNETO subsection.
2. ECM tab
3. Battery voltage
Output Current Test with an Inductive
If voltage is above specification, replace voltage Ammeter
regulator/rectifier.
For fuse box access, refer to the appropriate BAT
If voltage is below specification, check stator TERY ACCESS in this subsection.
output and wiring harness prior to concluding that
1. Detach fuse box from its support.
voltage regulator/rectifier is defective. Refer to
PTO HOUSING AND MAGNETO subsection. Use an inductive ammeter such as the EXTECH I N
DUCTIVE AMMETER (P/N 380941) or equivalent.
2. Turn on the ammeter and select 40 Ade.

3. From underneath the fuse box, clamp the am
meter around the DC output (RED/BLUE) wire.
364 smr2011-029
Su b section 03 (CHARGING SYSTEM)
3. Connect probes to fuse holder terminals.
sm r2
0 1 l-029· 002 _
a
1. Fuse box
2. DC output !RED!BLUEJ wire
3. Ammeter clamp
4. Start engine.
NOTE: Zero set the ammeter before use or read
ing may be erroneous. NOTE: Connect a garden hose to cool exhaust
4. Start engine.
NOTE: Connect a garden hose to cool exhaust ing table and read current with the multimeter.
5. Increase engine RPM as specified in the follow OUTPUT CURRENT TEST
ing table and read current with the ammeter.
TEST ENGINE
CURRENT (DC)
TEST ENGINE SPEED
CURRENT
SPEED
Approx. 10 A (while
Approx. 10 A (while 5500 RPM
5500 RPM suspension does notmove)
suspens ion does not move)
NOT� : Initial current reading will be higher than
NOTE: Initial current reading will be higher than . due to the battery drain from the engine
spec1f1ed
specified due to the battery drain from the engine .
start. This proves the charging system works.
start This is an indication that the charging sys
. Current load will come down as the battery re
tem 1s operating normally. Current load will come
covers its charge.
down as the battery recovers its charge.
If current is below specification, carry out a STA
If current reading is far below specification, test
TOR OUTPUT VOLTAGE TEST prior to concluding
�tator output and wiring harness prior to conclud the voltage regulator/rectifier is faulty.
ing the voltage regulator/rectifier is faulty.
NOTE: If the battery is in poor condition or is not TROUBLESHOOTING
at a full state of charge, current reading will be
above specification. Refer to BATTERY in this DISCHARGED OR WEAK BATTERY
subsection for battery testing.
1. Battery posts and/or cable terminal oxidized.
Output Current Test with a Multimeter - Clean _battery terminals, posts, and coat with di
electric grease.
W,JlllJj Charging current may rise over mul
2. Loose or bad connections.
timeter current reading capacity (usually 10 A)
possibly causing test equipment damage. It is - Check for wiring and connector tightness' frayed
or broken wires. Repair or replace cables or con
preferable to use an inductive ammeter to test
nectors.
the charging system current.
For fuse box access, refer to BATTERY ACCESS

in this subsection.
1. Remove charging system fuse.
2. Set multimeter to Ade.
smr2011-029 365
3. Worn or faulty battery (sulfated, fretting, 3. Cracked, leaking or improperly sealed battery.
shorted plates or cell, damaged casing, loose - Ensure battery cell caps are properly installed and
post). not leaking.
- Carry out a BATTERY VOLTAGE TEST (LOAD AP - If battery is cracked or leaking electrolyte, re
PLIED). place battery and clean surrounding area as
- Replace battery. recommended in BATTERY further in this sub
section.
4. Burnt fuse(s) or faulty rectifier.
- First check fuse(s). If in good condition, check PROCEDURES
voltage regulator/rectifier.
5. Faulty stator. VOLTAGE

- Test stator and replace as required . REGULATOR/RECTIFIER
6. Parasitic or "Key Off" current loads.
Voltage Regulator Continuity Test
- Isolate, reduce or eliminate such loads.
Due to internal circuitry, there is no static test
- Recharge battery as recommended if vehicle is
available to check continuity.
not used for extended periods of time.
NOTE: "KeyOff" or parasitic loads may be loads Voltage Regulator/Rectifier Access

due to installed accessories. Parasitic loads may (GTS and GTI Series)
also be due to water infiltration in connectors, or
partial short circuits that slowly drain a battery Open the front storage cover an remove the ac
without causing a fuse to burn. cess panel.
LOW OR NO CHARGING SYSTEM

VOLTAGE
1. Blown F6 fuse.
- Check F6 fuse.
2. Defective stator.
- Test stator. Refer to PTO HOUSING AND MAG
NETO subsection.
3. Defective charging system wiring or connec

tions.
- Check for damaged wiring.
- Check for damaged or loose connections.
REPETITIVE BLOWN F6 FUSE

.smo2011-0l3-01 1 _c
1. Voltage regulator/rectifier internal circuit I. Access panel

shorted to ground.
- Refer to VOLTAGE REGULATOR/RECTIFIER
TEST FOR BLOWN F6 FUSE in this subsection.
FREQUENT LOW ELECTROLYTE LEVEL

REQUIRING ADDITION OF DISTILLED
WATER
1. High charging system voltage.
- Carryout a CHARGING SYSTEM VOLTAGE TEST.
2. Old battery with reduced current storage capac

ity.
- Carryout a BATTERY VOLTAGE TEST (LOADAP
PL/ED.)
- Replace battery.
366 smr2011-029
smr201 1·02 9-00 4 _a 1. Regulator/rectifier

1. Regul<Jtor/rectifier
Voltage Regulator/Rectifier Access Remove the starboard access panel on the rear
(RXT, GTX and Wake Pro Series) deck.
iS and aS Models - --
1 . Open the boarding platform.
&>12009-002-002.•
1. Bo<Jrding platform
2. Remove the starboard storage bin.
5 mr2 0 1 l-029-006_ a
1. Regulstor/rectifier
ssi2009 -002-003_a
1. Storage bin
Voltage Regulator/Rectifier Test for
Blown F6 Fuse
1. Detach the voltage regulator/rectifier from the
electrical component support.
smr2011-029 367
2. Disconnect the voltage regulator/rectifier

2-wire connector.
3. Install a new fuse.
If the fuse still burns, check for a shorted wire or
connector pin.
If fuse does not burn, replace regulator/rectifier.
Voltage Regulator/Rectifier
Replacement
Voltage Regulator/Rectifier Removal
1. Detach the electrical component support from
the battery holder: s m,2011-02�8-•
Step 7: Push tab

1.1 Unhook the top of electrical component Step 2: Pull off
support.
Voltage Regulator/Rectifier Installation
1.2 Pull electrical component support up.
dure. However, pay attention to the following.
1. Insert the top of voltage regulator/rectifier be
hind the component support upper tab.
2. Push the bottom of voltage regulator/rectifier to
lock it.
smr2011-029-0G7_a
Step 1: Unhook
Step 2: Pull up
1. Electrical component support
2. Disconnect the two connectors from the volt

age regulator/rectifier.
3. Detach the voltage regulator/rectifier from the Step 1: Insert behind the tab
electrical component support: Step 2: Push to lock
3.1 Push the lower tab down to release the 3. Wiggle it to make sure it is safely locked.
bottom of voltage regulator/rectifier.
4. Reinstall remaining removed components.
3.2 Pull the bottom of voltage regulator/recti
fier off the electrical component support.
BATTERY
Battery Access {GTS and GTI Series)
Open the front storage cover an remove the ac
cess panel.
368 smr2011-029
3. Remove the starboard access panel on the rear
deck.
smo20 1 1-00 3-01 1 _c
FUSE BOX ACCESS

1. Access panel
Battery Access (RXT, GTX and Wake smr201 1 .029 -009 •
Pro Series) 1. Starboard access panel
iS and aS Models Battery Removal

A WARNING
The BLACK negative battery cable must al
ways be disconnected first and reconnected
1 last. Never charge or boost battery while in
stalled in watercraft.
1. Remove the diagnost ic connector from its

holder.
SS>200!Ml02.00 2 _.
2. Remove the starboard storage bin.
7. Diagnostic connector
2. Disconnect the BLACK (-) battery cable.
A WARNING
Always disconnect battery cables exactly in
the specified order, BLACK (-) battery cable
first then the RED (+) cable last.
1. Storage bin
3. Discon nect the RED (+) cable.
smr2011-029 369
ssi2009-0 02
.cD9_•
TYPICAL
1. BLACK(·) cable 7. Retaining screws
2. RED (+) cable 2. Battery holder
4. Detach the electrical component support from 6. Disconnect vent hose from the battery.
the battery holder:
4.1 Unhook the top of electrical component
support.
snv2009-0J�.Jl
TYPICAL
1. Disconnect here
7. Install a piece of hose (same type as vent hose).

with a cap or small hose pincher, onto the bat
tery vent to prevent electrolyte spillage when
Step 7: Unhook
Step 2: Pull up removing the battery.
1. Electrics/ component support 8. Remove battery with battery holder from vehi-
cle.
5. Remove and discard both screws securing bat
tery holder to battery holder base.
A CAUTION Be careful not to disconnect the
hose from the battery vent and cause an elec
trolyte spill in the watercraft.
370 smr2011·029
smr2 000.0 33 «>S •
TYPICAL 11 . Remove battery holder from battery .
1. Venr plugged for removal
A WARNING
Electrolyte is poisonous and corrosive. Avoid
contact with eyes, skin and clothing. Wear a
suitable p air of non-absorbent gloves when
removing the battery by hand. Rinse any
affected area with clear running water for
at least 15 minutes, then seek p rofessional
medical at tention.
lm'•Jitllj Should any electrolyte spillage oc

cur, im mediately wash off area with a solution
of baking soda and water, then rinse thor
oughly.
Battery Cleaning
9. Unlock the upper tabs then slightly open battery
holder. Cl ean t he battery casing, cap s ca bles and bat tery
,
posts using a solution of baking soda and water.
UZoitilj Do not allow cleaning solution to en

ter battery .
Remove corrosio n from bat tery cable terminals

and battery posts using a firm wire brush. Rinse
with clear water then dry well.
Battery Inspection
Visually inspect battery casing for cracks or
other possible damages. If casing is damaged
or shows signs of acid leaking, replace battery
and thoroughly clean battery holder, holder base
s mr2 009-005-00S _a and surrou n di ng area with a solut ion of water and
1. Unlock here ba k i ng soda .
10. Separate lower tabs to unlock them. I nspect batt ery posts for corrosion and security of
mountin g .
Inspect for cracked or damaged battery caps, re

place defective cap s .
smr2011-029 371
NOTE: Hand tighten caps then tighten an ad Battery Voltage Test {No Load)
ditional 1/4 turn using a 20 mm {3/4 in) socket. NOTE: Be aware that the voltage test can indi
Using any other tool could damage the plastic cate that the battery is in good condition even
battery caps. though the battery does not have enough stored
energy to crank the engine. A load test gives a
A WARNING more accurate indication of the condition of the
Battery electrolyte is caustic. To prevent battery.
spillage, ensure battery cell caps are suffi
If the battery has just received a charge. wait 1-2
ciently t ig ht to properly seal each cell.
hours before taking a voltage reading.
Battery Electrolyte Level Set multimeter to Vdc and measure voltage at bat
tery terminals.
Check electrolyte level in each cell, add distilled
water up to the upper fill level line. FULLY CHARGED BATTERY VOLTAGE (NO LOAD)
12.6 Vdc minimum

l!l[1JitiJj Add only distilled water in an acti
vated battery.
Battery Electrolyte Reading
Battery Testing NOTE: Do not top up cell electrolyte level with
There are 3 types of battery tests. distilled water prior to taking an electrolyte read
ing.
TEST
COMMENT Check charge condition of each cell using a hy
METHOD
drometer.
A dynamic voltage test with a load
NOTE: A hydrometer measures the charge of a
applied gives an accurate indication
Volta ge test battery in terms of specific gravity of the elec
of the condition of the battery.
(load applied) trolyte.
This is the most recommended
method.
BATTERY ELECTROLYTE SPECIFICATION
A static voltage test is carried out
BATTERY CONDITION SPECIFIC GRAVITY
without discharging current. It is
Voltag e test
the simplest and most commonly Fully charged 1 .265 - 1 .280
(no load)
used but the most likely t o give
false results.
Battery
Gives an accurate indication of the
e lectr ol yte
charge condition of ea ch cell.
read ing
Battery Voltage Test (load Applied)

Use a load testing device such as the ELECTRO
SPECIALTIES BATIERY LOAD TESTER (P/N 710). It
has a 500 A carbon pile adjustable load.
Follow battery load tester instructions.
Apply a load of 3 times the ampere-hour rating
of the battery for 14 seconds, then check battery A17£0JA
voltage. 7. Hydrometer
BATTERY VOLTAGE TEST (LOAD APPLIED)
Most hydrometers give a true reading at 21°C
TIME TO MEASURE VOLTAGE (70°F).
INTO TEST (with load applied)
In order to obtain the correct value, adjust the ini
14 seconds 10.5 Vdc min. tial reading by adding or subtracting the number
indicated in the following table.
If battery voltage has dropped below specifica
tion, the battery storage capacity has decreased
appreciably and the battery should be replaced.
372 smr2011-029
ELECTROLYTE Check electrolyte level in each cell.

TEMPERATURE OPERATION TO
PERFORM
Add distilled water up to upper level line as nec
oc OF essary.
38 100 . 012
Add to the
W•Ji[IJj Do not overfill.
32 90 .008
reading:
The battery must always be stored fully charged
27 80 . 004
.
If required, recharge until the recommended spe

21 70 CORRECT READING cific gravity is obtained prior to storage.
16 60 . 004
10 50 Subtract .008
Ol•JmJj Battery electrolyte temperature
from the must not exceed 50°C (122°F) during charging.
4 40 .012 The battery casing should not feel hot to the
reading:
-1 30 .016 touch.
EXAMPLE NO. 1 Clean battery terminals and cable connections us

ing a wire brush.
TEMPERATURE BELOW 21°C (70°F):
Apply a light coat of dielectric grease on terminals.
Hydrometer reading: 1.250
Electrolyte temperature: -1 •c (30°F) Clean battery casing and caps using a solution of
Subtract: .016 baking soda and water.
Corrected: 1.234
EXAMPLE NO. 2
l+![.JmJj Do not allow cleaning solution t o en
ter battery.
TEMPERATURE ABOVE 21°C (70°F):
Hydrometer reading: 1.235 Rinse battery with clear water and dry well using
Electrolyte temperature: 38°C (100°F) a clean cloth.
Add: .012
Store battery in a cool dry place. Such conditions
Corrected: 1.247
reduce self-discharging and keep fluid evaporation
to a minimum. Keep battery away from dew, high
STATE OF CHARGE AS PER HYDROMETER
moisture and direct sunlight.
READING (CORRECTED)
During the storage period. recheck electrolyte
STATE OF SPECIFIC GRAVITY
level and specific gravity readings at least every
CHARGE @ 27°C (80°F) @ 4°C (40°F) month. If necessary, top up the electrolyte level
with distilled water, then recharge (trickle charge).
100% 1 26 - 1 .27 1.27-1.28
Recharge frequency depends on battery condi
.
75% 1.21 - 1.22 1.22 - 1.23 tion and storage temperature. Maintain battery
1.16 -1.17 1.17-1.18 as per following table.
50%
25% 1.12-1.13 1.13-1.14 AMBIENT C H ARGING

TEMPERATURE FREQUENCY
0% 1.10 or less 1.11 or less
Below 16°C (60°F) Every month
Battery Storage Above 16°C (60°F) Every 2 weeks
Disconnect and remove battery from watercraft

as explained in BATTERY REMOVAL.
Batteries must always be stored out of reach
fi![1)i[IJjBattery storage is critical for battery of children.
life. Regularly charging the battery during
storage will prevent cell sulfation. Keeping the
Activation of a New Battery
battery in vehicle for storage may lead to con
tacts degradation/corrosion and case damage
if freezing occurs. A discharged battery will
freeze and crack in areas where freezing condi Never charge or boost battery while installed
tions are experienced. Electrolyte leakage will in watercraft.
damage surrounding parts. Always remove
battery from vehicle for storage and regularly
recharge it to keep an optimal condition.
smr201 l-029 373

Perform the following operations whenever a new

battery is to be installed.
- Remove the sealing tube from the vent fitting.
Failure to remove the sealing tube could re

sult in an explosion.
1. Remove caps and fill battery to UPPER LEVl::L

line with electrolyte (specific gravity: 1.265 at
21°C (70°F)).
NOTE: This battery may fill slower than others A17EOR8
due to the anti-spill check ball design. 1. Battery electrolyte

2. Upper level /me
4. Connect a 2 A battery charger for 3 to 5 hours.
Step 1: Connect + lead to battery + post

A17EOFB
Step 2: Connect - lead to battery - post
Step 3: Connect battery charger to AC outlet
1. Sealing tube removed
2. Battery electrolyte
3. Upper level line A WARNING
NOTE: Place the cell caps over the cell openings Gases given off by a battery being charged
engaging only the first thread to prevent cell are highly explosive. Always charge in a well
contamination and acid splatter during charging. ventilated area. Keep battery away from cig
Do not screw caps on tightly. arettes, open flames, welding operations and
any other types of ignition. Always turn bat
2. Allow the battery to stand for 30 minutes MIN
tery charger off prior to disconnecting cables.
IMUM to allow the electrolyte time to soak
Otherwise, a spark will occur possibly caus
through the battery cells plates.
ing the battery to explode.
ffltJitjj If charging rate increases above

2.4 A reduce it immediately. If cell tempera
ture rises above 50°C (122°F) or if the casing
feels hot, discontinue charging temporarily or
reduce the charging rate.
5. Disconnect battery charger.
A17EOGA
1. 30 minutes
3. Readjust the electrolyte level to the UPPER

LEVEL line.
374 smr2011-029
For best results, battery should be charged when

it is at room temperature. A battery that is cold
may not accept current for several hours after
charging has begun.
Do not charge a frozen battery. If the battery
charge is very low, the battery may freeze. If
you suspect the battery to be frozen, move it to a
heated area for about 2 hours (or more if required)
to let it tha w out before charging.
Step 7: Disconnect battery charger from AC outlet

Step 2: Disconnect lead
- Always charge a battery in a well ventilated
Step 3: Disconnect + lead
6. Test battery state of charge. Use a hydrometer.

The time required to charge a battery will vary de
pending on several factors. such as:
- Battery temperature: The charging time is in
creased for a cold battery as charging current
accepted by a cold battery will be lower than
for a warm battery. As the battery warms up,
it will accept a higher rate of charge.
- State of charge: As a battery discharges. it
gives up its stored energy. The greater the dis
charge, the longer it will take to fully recharge
it.
- Type of charger: Battery chargers vary in the
amount of voltage and current that they can
A17EOJA
supply.
1. Hydrometer
Charging a Very Flat or Completely
7. If electrolyte level has dropped after charging, Discharged Battery
fill with distilled water to UPPER LEVEL line . The battery charger used should have an ad
After water is added. continue charging for 1 to justable charging rate. A unit which can be
2 hours to mix water with electrolyte. adjusted in small increments is acceptable.
8. Reinstall caps and clean any electrolyte spillage The battery charger must be equipped with an am
using a solution of baking soda and water. meter capable of accurately measuring current of
NOTE: Hand tighten caps then tighten an ad less than 1 ampere.
ditional 1 /4 turn using a 20 mm (3/4 in) socket. Unless this procedure is properly followed. a good
Using an other tool could damage the plastic battery may be needlessly replaced.
battery caps.
1 . Measure the voltage at the battery posts with
an accurate voltmeter. If it is below 10 volts,
A WARNING
the battery will accept current at very low rate.
Battery electrolyte is caustic. To prevent It could be some time before the charging rate
spillage, battery cell cap should be suffi increases. Such low current flow may not be
ciently tight to properly seal. detectable on some charger ammeters and the
battery will not seem to accept the charge.
Charging a Used Battery 2. Exceptionally for this particular case, set the
charger to a high rate.
Never charge battery while installed in water

craft.
smt2011-029 375
NOTE: Some chargers have a polarity protec

tion feature which prevents charging unless the
charger leads are connected to the correct battery
terminals. A completely discharged battery may
not have enough voltage to activate this circuitry,
even though the leads are connected properly.
This will make it appear that the battery will not
accept a charge. Follow the charger manufac
turer's instruction on how to bypass or overrirlA
this circuitry so that the charger will turn on and
charge a low-voltage battery.
3. Since battery chargers vary in the amount of
voltage and current they provide, the time re
s mr2QOO.C 3 3-009_ o
quired for the battery to accept a measurable
TYPICAL
charger current may be up to 10 hours or more. 1. Connect here
4. If the charging current is not up to a measurable

6. Attach the electrical component support to the
amount after 1 O hours, the battery should be
battery holder:
replaced.
6.1 Engage the electrical component support
5. If the charging current is measurable before
lower tabs in the battery holder openings.
the end of the 10 hour period, the battery is
good and charging should be completed at a 6.2 Push the top of electrical component sup
lower rate as specified in ACTIVATION OF A port towards the battery holder until it
NEW BATTERY. clips.
6. It is recommended that any battery recharged

using this procedure be tested under load prior
to returning it to service.
Battery Installation
1. Install battery in its holder and lock holder.
2. Install the battery in the watercraft using new
screws.
3. lighten battery holder screws to 14 N•m
(124 lbf•in).
4. Remove the temporary hose used to plug the
battery vent.
5. Reconnect the watercraft vent hose to the bat
tery vent outlet. Make sure vent hose is not
pinched or bent.
$1>120 1 H
l02 -00 i _•
Vent hose must be free and open. Avoid skin 7. Electrical component support lower tabs
2. Battery holder openings
contact with electrolyte.
3. Battery holder
4. Elecrricaf components support
376 smr2011·029
Subsection 03 (CHARGING SYSTEM}
..
sm r'2011-029-007 c
PUSH TOWARDS BATTERY RACK smo201 1-003-011-<
1. Electrical component support 1. Access panel
7. Wiggle the assembly to make sure it is properly Reach the check valve on starboard side of the hull
secured. just in front of the fuel tank vent.
AwARNING
Always connect battery cables in the spec
ified order, RED positive cable first, BLACK
negative cable last.
8. Connect RED {+) cable.

9. Connect BLACK {-) cable last.
sm1 2011-02 9 -0l O_e
FRONT STARBOARD OF HULL - DECK NOT SHOWN

1. Vent hose
Battery Vent Hose and Check Valve

Access {RXT, GTX and Wake Pro
Series)
smt2 009-033 -002_o

iS and as Models
1. BLACK (-) cable 1. Open the boarding platform.
2. RED (+)cable
10. Apply dielectric grease on battery posts.

11. Verify cable routing and attachments.
1
12. Insert diagnostic connector in its holder.
13. Install remaining removed components.
BATTERY VENT CHECK VALVE

Battery Vent Hose and Check Valve
Access {GTS and GTI Series)
cess panel. ssi2009-002-002_o
smr2011·029 377
2. Remove the starboard storage bin. Battery Vent Check Valve Test
A WARNING
Battery caps do not have vent holes. Ensure
vent line is not obstructed and check valve is
functioning properly.
1. Check vent hose condition.

2. Make sure the check valve and grommet are
not plugged.
3. D isconnect vent on LH side of the battery.
Ul 2009-<102-003_a
1. Storage bin
Remove the starboard access panel on the rear
deck.
omr2 �_a
TYPICAL
1. Disconnect here
4. Use the vacuum/pressure pump in the VAC

UUM/PRESSURE PUMP (P/N 529 021 800).
omr2011-02 9-009_ a
1. Starboard access panel
All models
Reach the check valve on starboard side of the
hull.
529021800
5. Set vacuum/pressure pump to PRESSURE.
TYPICA L REAR STARBOARD OF HULL

- - DECK NOT SHO WN
. 1 . Vent hose
378 smri<ll1-029

several times to draw air in through the check
valve.
NOTE: The check valve must not let air in, and
must be able to hold 10 in Hg (-34 kPa) of vacuum
without leaking.
smr2009 ·031-012_a
6. Connect vacuum/pressure pump to the vent

hose end.
several times to push air out through the check
valve.
NOTE: The check valve must let air flow out.
sm r 2009-033--0 1 O_ b
MUST HOLD VACUUM IN THIS POSITION
If any test failed, check the vent hose. If the vent

hose is good, replace check valve.
Battery Vent Check Valve Replacement

1. Pull vent check valve out of grommet in hull.
2. Cut locking tie retaining vent hose to check
valve.
3. Remove hose from valve.
4. Install a new check valve on vent hose with
black end towards vent hose, and secure with
a locking tie.
smr2009-0 33-010_o 5. Push check valve through grommet in hull.
AIR MUST FLOW OUT FREELY
l1f!1)j@j At installation, be sure to position
8. Set vacuum/pressure pump to VACUUM. the check valve with the black side connected
to the vent line, and ORANGE side inserted
through the grommet protruding outside of
the hull.
s m'2009-031-013_a
1. Vacuum selected
smr2011-029 379
""'2COS023-0_
0 a
380 srrv20l1-029
Subsection 04 (STARTING SYSTEM)
STARTING SYSTEM
SERVICE TOOLS
DIAGNOSTIC HARNESS ............................................................... 529 036 188 ......................................... 385
ECM ADAPTER TOOL.................. : ................................................ 529 036 166 ................................. 384, 388
FLUKE 115 MULTIMETER ....... ...... ...... ..................................... 529 035 868 ................. 384-385, 387-388
. . . .
SERVICE PRODUCTS
DIELECTRIC GREASE ................................................................... 293 550 004 ......................................... 393
ISOFLEX GREASE TOPAS NB 52 ..... ......... .. . .. .......... ........ .... 293 550 021 ......................................... 392
. . .. . . . .
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ......................................... 393
smr2011·030 381
mm
7 N•m
(62 lbf-in)
• fi '
-
&
lsoflex grease
& Topas NB 52
Loctite
243
382 srn(.201 I·030

GENERAL NOTE: This subsection assumes the problem is

related to an electrical component of the starting
system. If the starting system tests good, ensure
BASIC STARTING SYSTEM
engine and jet pump integrity. Refer to applicable
O PERATION subsection.
Engine Cranking Conditions
The following conditions must be met to allow en
DIAGNOSTIC GUIDELINES
gine cranking: NOTHING HAPPENS WHEN START/STOP
1. START/STOP button pressed and released to BUTTON PRESSED
activate the ECM.
1. Battery not connected
2. The tether cord securely installed on the en
- Connect battery
gine cut-off switch and the D.E.S.S. key recog
nized by the ECM as valid (2 short beeps) 2. Burnt fuse
3. START/STOP button pressed and held. - F3 fuse: (START/STOP button circuit).
- FB fuse: (main DC power fuses).
Starting System Logic
- F19 fuse (ECM power fuse).
If the ECM recognizes a valid D.E.S.S. key, it al
3. Defective relay or related circuits
lows engine cranking by providing the ground to
the starter solenoid when the START/STOP but - Test relay and circuits.
ton is pressed and held. 4. Defective START/STOP switch
If the START/STOP button is activated while the - Test START/STOP switch, wiring and connec
throttle lever is depressed more than 60%, the en tions.
gine will crank but will not start (engine drowned
mode). ENGINE DOES NOT CRANK
If the START/STOP button is held after engine has 1. D.E.S.S. not functional or wrong D.E.S.S. key
started, the ECM automatically stops the starter if - If 2 short beeps are not heard when pressing
engine speed reaches at least 1400 RPM. the START/STOP button, refer to DIGITALLY EN
CODED SECURITY SYSTEM subsection.
If the START/STOP button is pressed when the
engine is running, the engine will shut down. 2. Burnt fuse
- F16 fuse: (starter solenoid power) Carrv out a SO
TROUBLESHOOTING LENOID INPUT VOLTAGE TEST (Solenoid Coil).
3. Discharged battery
DIAGNOSTIC TIPS - Recharge and test. Refer to CHARGING SYSTEM
subsection.
NOTE: I t is a good practice to check for fault
codes using B.U.D.S. as a first troubleshooting 4. Battery connections
step. Refer to DIAGNOSTIC AND FAULT CODES - Check/clean/tighten.
subsection.
5. Poor/bad or corroded ground contacts (engine,
Starting system failures are not necessarily re battery ground cable, starter etc.)
lated to the starter but may be due to one the - Check/clean/repair, refer to POWER DISTRIBU
following: TION AND GROUNDS subsection.
- Starter solenoid fuse F16
6. Starter solenoid
- Battery, refer to CHARGING SYSTEM
- Test solenoid, wiring and connections.
- START/STOP switch
7. Damaged starter or ground cables
- Starter solenoid
- Carry out SOLENOID DYNAMIC TEST
- Engine cut-off switch
- ECM 8. Obstructed starter drive gear assembly
- Wiring/connections. - Check/repair, refer to PTO HOUSING AND MAG
NETO.
Check these components before removing the
starter. 9. No ground provided by ECM to starter solenoid
- Refer to CONTINUITY TEST OF START/STOP
SWITCH CONTROL CIRCUIT in this subsection.
smr2011·030 383
10. Engine cannot be rotated (possibly seized) ENGINE START/STOP SWITCH

- Refer to ENGINE subsection.
START/STOP Circuit Continuity Test
ENGINE CRANKS SLOWLY 1. Remove START/STOP button fuse (F3).
1. Loose, corroded or dirty battery cable connec For fuse box access, refer to POWER DISTRIBU
tions TION AND GROUNDS subsection.
- Check/clean/tighten. Disconnect connector "8" from the ECM, refer to
2. Discharged/wcok bottcry
WIRING HARNESS AND CONNFCTOR subsec
tion.
- Recharge and test. Refer to CHARGING SYSTEM
subsection. Install ECM ADAPTER TOOL (P/N 529 036 166) on
ECM harness connector "8".
3. Low voltage from starter solenoid
- Carry out a SOLENOID DYNAMIC TEST.
4. Damaged starter or ground cables

- Carry out SOLENOID DYNAMIC TEST
5. Worn starter
- Check.
STARTER TURNS, BUT STARTER DRIVE

DOES NOT MESH WITH RING GEAR
1. Worn starter drive gear/starter gear/ring gear
5200361 60
- Replace worn parts_ Refer to STARTER GEAR in
this subsection and PTO HOUSING AND MAG
Set the FLUKE 115 MULTIMETER (P/N 529 035 868)
NETO subsection.
ton.
2. Defective drive
Press and hold the START/STOP switch and test
- Replace starter drive. Refer to PTO HOUSING for continuity of the switch circuit as per following
AND MAGNETO subsection.
table.
STARTER KEEPS RUNNING CONTINUITY TEST OF START /STOP SWITCH

CIRCUIT (BUTION PRESSED AND HELD)
1. Shorted solenoid winding
ECM
- Replace solenoid. FUSE BOX RE S I S TANCE
CONNECTOR B
2. Melted solenoid contacts
Close to 0 n
- Replace solenoid. Pin A6 8-01
(continuity)
3. Sticking or defective starter drive
2. If the reading is as specified, the START/STOP
- Lubricate or replace. Refer to PTO HOUSING
AND MAGNETO. switch and its wiring are good.
3. If a high resistance or an open circuit is mea
PROCEDURES sured, carry out s START/STOP SWITCH CON
TINUITY TEST.
A WARNING
When carrying out any kind of maintenance START/STOP Continuity Test
on the starting system, always disconnect the 1. Rem ove START/STOP button fuse (F3).
battery ground cable. This will eliminate the 2. Disconnect the 24-pin steer i ng co n nector :
possibility of shorting out a power cable, and
generating a spark which could result in a fire GTS, GT/ and Wake 155 Models
or and explosion. Do not place any tool on Open the front storage cover an remove the ac
the battery. cess panel.
384 smr201 l-030

All Models
s mo201 1 -003-0 1 1 _ c
1. Access panel
RXT, GTX and Wake Pro Models s bl2010-034-0 1 9_c
Without iS or aS 1. 24-pin steering connector
Open front storage compartment cover. 3. Connect the DIAGNOSTIC HARNESS (P/N 529 036
Remove front storage bin. 188) to make an in-line connection between the
disconnected connector.
Disconnect the top air ventilation hoses.
5290361 88
NOTE: Use the 24 pin connectors only.

868) and select n.
s b1201 0-004-002

5. Measure resistance through switch as per fol
lowing table.
RXT, GTX and Wake Pro iS Models
CONTINUITY TEST OF START/STOP
Open front storage compartment cover. SWITCH CIRCUIT
Remove front storage bin. DIAGNOSTIC
SWITCH
For easier access, rise the moving deck using the HARNESS RESISTANCE
POSITION
iS "UP" button. CONNECTOR
Released Infinite (OU

Pressed and Pins 2 and 23
Close to 0 !1
held
smr2011-030 385
&m1 2011-03 0.001-o
VIEW FROM BEHIND BATTERY

1. Fuse box
smr20 I D-03&003_1 2. Starter solenoid
If the switch does not test as specified, replace Starter Solenoid Access (RXT, GTX
the engine START/STOP switch. and Wake Pro Series)
If the switch tests as specified, check for an open The starter solenoid is located underneath the
circuit: fusebox.
- Between fuse box pin A6 and steering connec
tor pin 23. iS and aS Models
- Between steering connector pin 2 and ECM Open the boarding platform and remove the RH
connector 8, pin 01. storage bin.
STARTER SOLENOID
Starter Solenoid Access (GTS and GTI 1
Series)
The starter solenoid is located underneath the
fuse box.
cess panel.
FUSE BOX ACCESS

1 Access panel
I. Storage bin
386 smr2011-030
2. Set the FLUKE 115 MULTIMETER (P/N 529 035

868) to Vdc.
3. Install tether cord on the engine cut-off switch.
4. Press the START/STOP button to activate ECM.
the battery holder:
support.
s mr201 l .o30--01
0 _a

1. Fuse box
2. Starter solenoid
Open the starboard access panel on the rear deck.
- --
s rnm>11 · 019-00 7_a
Step 1: Unhook
Step 2: Pull up
6. Disconnect solenoid connector, refer to

STARTER SOLENOID ACCESS in this sub
section.
smr2011 -029-009 _a
1. Starboard access panel
smr2011-030-001_e

1. Fuse box
2. Starter solenoid
1. Battery holder
2. Electrical componenrs support
Solenoid Input Voltage Test 3.
4.
Starter solenoid
Solenoid connector
(Solenoid Coil)
1. Make sure F16 fuse is powered and in good 7. Measure voltage as per following table.
condition before testing.
smr2011·030 387
Subsection 04 {STARTING SYSTEM)
SOLENOID INPUT VOLTAGE TEST

(SOLENOID COIL)
VOLTAGE
TEST PROBES
READING
Pin A (VIOLET} I Battery ground Battery voltage
If test failed, repair or replace wiring/connectors.

If test succeeded, carry out a SOLENOID COIL
RESISTANCE TEST.
Solenoid Coil Resistance Test

1. Set multimeter to n.
2. Disconnect solenoid connector.
3. Measure solenoid coil resistance as per follow
If test succeeded, carry out a SOLENOID CON
TROL CIRCUIT TEST.
If test failed, carry out a START/STOP SWITCH
ing table.
CIRCUIT CONTINUITY TEST. SOLENOID COIL RESISTANCE TEST
SOLENOID CONNECTOR RESISTANCE

Solenoid Control Circuit Continuity
Test Pin A (Vil I Pin B (BK/YL) 4.5 to 5.5 n
1. Set the FLUKE 115 MULTIMETER (PIN 529 035

868) to n.
If test fails, replace solenoid.
2. Disconnect connector "B" from ECM, refer to Solenoid Dynamic Test

WIRING HARNESS AND CONNECTOR subsec 1. Ensure fuse F16, battery, and starter solenoid
tion. are properly connected.
3. Install ECM ADAPTER TOOL (PIN 529 036 166) on 2. Make sure the battery ground cable is securely
ECM harness connector. connected to the engine. Refer to POWER DIS
4. Test continuity of wiring from solenoid to ECM TRIBUTION AND GROUNDS.
as per following table. 3. Set ECM in engine drowned mode: Depress
SOLENOID CONTROL CIRCUIT TEST throttle lever and install a rubber band to hold
lever in full throttle position.
4. Set multimeter to Vdc.
SOLENOID ECM
RESISTANCE
CONNECTOR CONNECTOR B
5. Crank engine.
Close to 0 n
(con ti n uit y) 6. As engine is cranking, measure the voltage as
Pin B !BA/YU B-L4
per following tables.
SOLENOID DYNAMIC TEST (ENGINE CRANKING)
TEST PROBES VOLTAGE (DC)
Solenoid
battery post
I s
attery ground Battery voltage
388 smr2011-030
Subsection 04 (STARTING SYSTEM}
If test failed, replace solenoid.

If all solenoid dynamic tests are as specified, re
place starter.
11. Remove rubber band from throttle lever.
12. Reinstall removed parts.
Solenoid Removal
s mr2009-03&-01 o_a
1. Disconnect battery. Refer to CHARGING SYS
1. Starter motor
TEM subsection.
2. Starter solenoid
7. If test failed, check battery positive cable (from

Always disconnect the BLACK (-) battery ca
battery to solenoid).
ble first and reconnect last.
8. If test succeeded, continue with next step.
2. Remove diagnostic connector from battery
SOLENOID DYNAMIC TEST (ENGINE CRANKING}
holder.
TEST PROBES VOLTAGE (DC)
Solenoid the battery holder:
Battery ground Battery voltage
battery post
support.
1 3.2 Pull electrical component support up.
1. Starter motor
2. Starter solenoid
9. If test failed. carry out a SOLENOID INPUT

VOLTAGE TEST (SOLENOID COIL).
10. If test succeeded, continue with next step.
smr2011-029-00 7_a
SOLENOID DYNAMIC TEST (ENGINE CRANKING}
Step 1: Unhook
TEST PROBES VOLTAGE (DC) Step 2: Pull up
I
Solenoid Solenoid
0.2 Vdc max.
battery post starter post 4. Disconnect voltage regulator/rectifier connec
tors.
5. Disconnect starter solenoid connector.
1
6. Push starter solenoid back against locking tab.
smr2009·034-0 10_c
1. Starter motor
2. Starter solenoid
smr2011·030 389
2. Connect cables to solenoid as shown.
smr 2009-034-00 3 _c
1. Locking tab
7. When the solenoid mounting flanges are clear

of the electrical components support, slide so
lenoid up and out of the support. 7. Cable from battery
2. Cable to starter motor
3. Insert solenoid in components support by push

ing in against the locking tab, then down so
the solenoid mounting flanges insert under the
flanges on the electrical components support.
1. Solenoid mounting flange
8. Disconnect solenoid cables.
omr2009-034 004 c
1. Insert solenoid under the components supporr flanges
4. Push the solenoid into the support until a

"click" is heard (locking tab engagement).
smr2009.()34- 005J
7. Cables
Solenoid Installation
1. Reverse the removal procedure and pay atten
tion to the following. Js nr2009 03 4 003b
1. Solenoid locked here
390 smr2011·030
NOTE: It may be necessary to pull retaining tab to A WARNING

ensure proper locking.
Always use an external battery for this test t o
5. Wiggle solenoid to ensure it is securely locked .
prevent any electrical sparks from occurring
6. Reinstall remaining components. within the hull. Always make the final con
nection to the external battery negative(-) ter
7. Reconnect battery and test starter solenoid op
minal using the BLACK booster cable clip. Do
eration.
not short starter solenoid contacts across the
main power connections on the relay with a
STARTER tool that would cause electrical sparks. Fail
ure to follow this procedure may result in an
Starter Quick Test
explosion.
To easily bypass the starter solenoid and the start
control circuits, proceed as follows.
- Use a fully charged 12 V battery with a capacity
of at least 30 A-h.
- Use a set of booster cables to power the
starter.
This procedure tests the following:
- Electric starter
- Starter power cable
- Battery to engine ground cable.
A WARNING
Fuel, oil, or electrolyte vapors are flammable
and may become explosive if certain con
ditions are met. These vapors may collect s m r2009-034-011_8
near the bottom of the hull when present. All Step 1: Connect cable to solenoid starter post
Step Connect cable to vehicle battery positive post
types of ignition including electrical sparks 2:
Step 3: Connect cable to external battery negative post
are to be avoided when maintaining or test Step 4: Make a momentary contact
ing vehic le .
If engine does not crank (or cranks slowly), check

the following:
A WARNING
- Booster cable connections
Always wear safety glasses when working
- Vehicle battery ground cable connections to en-
with or around batteries. Be sure to leave
gine
the booster battery out of the watercraft.
- Starter power cable/connections from solenoid
to starter
1. Connect booster cables in this strict order:
- Carry out a SOLENOID DYNAMIC TEST.
2. RED booster cable:
If the above items all test good, replace the
3. Connect one clip to the starter post on the starter.
starter solenoid.
4. Connect the other clip to the positive (+) termi Starter Removal
nal on the external battery. 1 . Open or remove seat.
5. BLACK booster cable:
iS and aS Models
6. Connect one clip to the negative (-) battery ter
2. Remove rear ventilation cover. Refer to BODY.
minal in the vehicle.
7. Momentarily apply the second clip to the nega
tive (-) terminal of the external battery. 4. Lower moving deck.
All Models
smr2011-030 391
6. Disconnect battery. Refer to CHARGING SYS

TEM subsection.
Always disconnect the BLACK (-) battery ca

ble first and reconnect last.
NOTE: For better access to the starter, work from

starboard (RH side} and lay across the watercraft.
7. Disconnect starter power cable.
8. Remove starter retaining screws.
F 18HONA 1 2
1. Retaining circlip
2. Starter gear
Starter Gear Installation

Installation is the reverse of removal procedure.
However, pay particular attention to the following.
TYPICAL - REAR OF WATERCRAFT IN ON RH SIDE OF Use a new circlip.
ILLUSTRATION
7. Exhaust manifold
2. Staner Starter Installation
3. Starter retaining screws
4. Starter power cable retaining nut 1. Installation is the reverse of the removal proce
dure. However, pay particular attention to the
Starter Gear Removal following.
1. Remove starter. 2. Ensure starter and engine mating surfaces are
2. Remove gear retaining circlip and pull out free of debris. Serious problems may arise if
starter gear. starter is not properly aligned.
3. Apply ISOFLEX GREASE TOPAS NB 52 (P/N 293
550 021) on starter 0-ring s .
392 srnr2011·030
smr2007 ·025-00 8_b
1. Torque power cable retaining nut to 7 N•m (62 lbt-in) and apply
dielectric grease
2. Install rubber protector
A. 10N•m (891bt-ln)
8. Reinstall all remaining removed parts.

tmr1007-025-00 9•
_
1. Apply lsoflex grease Topas NB 52
Install starter.
NOTE: If starter does not mesh properly with
the intermediate gear: Pull starter out, slightly
rotate the starter gear then reinstall the starter.
Temporarily removing both 0-rings makes it eas
ier to align both gears. Once gears are aligned,
remove starter to install 0-rings being careful not
to rotate starter gear out of position, then reinstall
the starter.
4. Apply LOCTITE 243 (BLUE) (P/N 293 800 060)
on retaining screws and torque to 10 N•m
(89 lbf•in).
5. Connect the RED positive cable to the starter
and torque retaining nut to 7 N•m (62 lbf•in).
A WARNING
To prevent electric shock whenever connect
ing the RED power cable to the starter motor,
ensure the BLACK(-) battery cable is d i sco n
nected.
6. Apply DIELECTRIC GREASE (P/N 293 550 004) on

terminal and nut.
7. Install rubber protector over starter power cable
retaining nut.
smr2011-030 393
394
Subsection 05 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.))
DIGITALLY ENCODED SECURITY

SYSTEM (D.E.S.S.)
SERVICE TOOLS
DIAGNOSTIC HARNESS ............................................................. . . 529 036 188 ................................. 399-400
ECM ADAPTER TOOL . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529 036 166 ......................................... 400
FLUKE 115 MULTIMETER . .. ...... . . . . . . . . . . . . . . . . . . . . . . . ............ . ... ... ... ... .
. . 529 035 868 ................................. 399-400
GENERAL D.E.S.S. Key Types
SYSTEM DESCRIPTION
The D.E.S.S. system allows the engine to start
only if a tether cord cap is installed on the engine
cut-off switch and the D.E.S.S. key is recognized
as valid by the ECM.
NOTE: If desired. the tether cord can be used on
other watercraft. It only needs to be programmed
for the other watercraft.
The following components are specially designed
for this system: ECM, D.E.S.S. key and engine
cut-off switch. � m r 2009-035-00 6
The tether cord cap contains a magnet and a ROM In addition to the normal D.E.S.S. key, other spe
chip. cial keys can be programmed so that the vehicle
- The magnet closes the reed switche inside the can only be operated at a limited speed. Such a
engine cut-off switch, which is the equivalent feature is ideal for first time riders or renters.
of a mechanical ON/OFF switch.
The tether cord floats are color-coded to differen
- The chip has a unique digital code, which is tiate the type of D.E.S.S. keys.
the equivalent of the tooth-pattern on a conven
tional key. D.E.S.S.
FLOAT COLOR
KEY TYPE
The D.E.S.S. system is quite flexible. It allows
several different keys to be programmed into the Normal key YELLOW or BLACK
memory of the ECM. They can also be erased Learning key GREEN
individually.
Rental key ORANGE
The memory of the ECM is programmed to recog
nize the digital code of each D.E.S.S. key.
The Learning and Rental keys can be set through
5 settings to control the maximum watercraft
speed. Refer to LEARNING KEY AND RENTAL
KEY MODES in INTELLIGENT THROTTLE CON
TROL (ITC) subsection.
iS Models
NOTE: When a Learning or a Rental key is used,
the DOCK MODE is always active. Refer to SUS
PENSION (!SJ subsection for more information
about DOCK MODE.
smr2011·031 395
D.E.S.S. Key Beeper Codes

When a D.E.S.S. key is present on the vehicle en
gine cut-off switch once the START/STOP button
was pressed, the key is identified by the ECM and
coded beeper signals are emitted according to the
key recognition. See table:
BEEPER SIGNIFICATION
2 !lhort
Indicates the D.E.S.S. recognizes the key.
beeps
1 lo ng Indicates the D.E.S.S. does n ot recognize

beep the key.
' m r 2009-03 s.-00 5 _e

Other beeps can be heard. The ECM features a
1. Tether cord on engine cut-off switch
self-diagnostic mode. Refer to DIAGNOSTIC AND
FAULT CODES for more information. IMPORTANT
215 and 260 models: Approximately 3 minutes after

PROCEDURES pressing the START/STOP button. the ECM will stop
communicating with B.U.D.S. Therefore, operations
D.E.S.S. KEY with B.U.D.S. will be interrupted.
D.E.S.S. Key Recognition To reinstate communication, briefly press the

START/STOP button. Do not hold START/STOP
To allow key recognition, carry out the following button to avoid engine cranking.
steps:
1. Briefly press the START/STOP button to wake 5. Read ECM using Read Data button.
up the ECM.
2. Securely install the tether cord on watercraft file �iew M.EI® Module Iools .!:!elp
3. Press and hold the START/STOP button to start
engine.
D.E.S.S. Key Programming

1. Connect the watercraft to latest applicable
B.U.D.S. Refer to COMMUNICATION TOOLS
1'9� Read Data
� ..
Write Data
vnr2006-0 1 2·1 00_eo
2. IMPORTANT: Ensure all connections have
been made before starting B.U.D.S. to allow 6. Click on Keys tab.
proper operation.
3. Briefly press START/STOP button to power the
ECM.
4. Install a tether cord on the engine cut-off switch
to program a D.E.S.S. key.
-Key Usage,------.
state
396 sm-2011·031
Adding a Key
1 . Click on the Add Key button at the bottom of
the screen according to the key type you want
to program.
A WARNING
If programming a Learning or Rental key,
be sure to use the proper key type (color) to
avoid possible confusion.
r�J
...�Srt�
N smr1 0G 9 -03>005 _•
�"'"' &.<• t,..
,,,. 1=r.t.wt=--�3
I .....
7. Key to be erased
'-
,�
1: u..;i
11!<
1 �3 ....... 2. Click on Erase Key button at bottom of

�· B.U.D.S. screen.
1�.
ia.ti>
...,,
, 1 'l<oY Ung
"" ' f ...
Sb!• Typ<r
I
l<eyj Uocd -1-:01m�- 9
K�2 U1td "101
ma.I
�mr1�S-00 3_c
Key3 Und fNorrml
--- -
1. Add Key buttons F1u
Kay4
KtyS F190
2. After approximately 1 0 seconds, the following
window will pop up confirming the new key has I l<oy6
; Key7
frn�1
I't
ee
il
been saved in t h e PC computer. ;1
8
. Kay "'. -
i
l11:m111.1llon @ Er•.., Kay
" I
Etll••�ll<ey• ..\dd Loaming 1<e,e
The DESS®key was successftllly added to the I - I
document srnr1009-036·0C4_a
1. Click on this button
II QK II After approximately 10 seconds the following

message will appear.
•mr2008-020-00 8
3. If programming is complete, write the changes ��

- --- ------ -- - �
�
to the ECM. Refer to WRITING CHANGES TO
ECMin this subsection. The DESS® key was successfully erased from the
document.
Adding Another Key
1. Remove the tether cord from the engine cut-off
switch.
sm< 2000-03;;-007
2. Install the next tether cord on the engine cut-off
switch. The key is now erased in the PC computer.
3. Click on the Add Key button. 3. If programming is complete, write the changes
to the ECM. Refer to WRITING CHANGES TO
4. If programming is complete, write the changes
to the ECM. Refer to WRITING CHANGES TO ECMin this subsection.
ECMin this subsection. Erasing Another Key
Erasing a Key 1. Remove the tether cord from the engine cut-off
1. Install the tether cord on the engine cut-off switch.
switch. 2. Install the next tether cord to be erased on the
smr2011-031 397
3. Click on Erase Key button. NOTE: On 215 and 260 models, Briefly press the
4. If programming is complete, write the changes START/STOP button to prevent ECM communica
to the ECM. Refer to WRITING CHANGES TO tion interruption. Do not hold START/STOP but
ECM in this subsection. ton to avoid engine cranking.
1. Click the Write Data button.
Erasing All Keys
1. Click on Erase All Keys button at bottom of
screen.
Slate Typo
[§]
'
l<ey 1 UHd Nonn.t
· --·
l(ay2 Used No1mal

j
·-
I<�, 3 Und �Normal

Klir• Free
1<e1s F111
Read Data Write Data
�6 Fiw�------ 1
11<e 7
[Ko�-8 ::: � j
-
NOTE: If for some reason the writing operation
fails, exit B.U.D.S. Restart B.U.D.S. and reenter all
the previously lost information.
2. After the write operation,
. remove key from
1. Click on rhis button
D.E.S.S. post.
3. Try the key(s) on the watercraft.
NOTE: The following message will be displayed
in 8.U.D.S.
BEEPER
- - -
� - - - -� - - - ---�-
Confirm IX Beeper Troubleshooting

Doyou realy wenl to eraseal DES� keys from the doCl.melt? If no beep is heard when installing the tether
W cord on the engine cut-off switch, but the engine
can be started, refer to INFORMATION CENTER
)'.es Il Ho (GAUGE) subsection to check beeper operation.
smr2010.03&-001 If no beep is heard when installing the tether cord
on the engine cut-off switch, and the engine CAN
2. Click Yes to proceed with erasing all keys. NOT be started, refer to ELECTRONIC FUEL IN
3. When done, program at least one new key to JECTION (EFIJ subsection.
the vehicle. Refer to ADDING A KEYin this sub
section. ENGINE CUT-OFF SWITCH
4. When programming is complete, write the
Continuity Test of Engine Cut-Off
changes to the ECM. Refer to WRITING
Switch
CHANGES TO ECM in this subsection.
1. Disconnect the 24-pin steering connector from
NOTE: If there isn't at least one key programmed
the vehicle harness. Refer to START/STOP
to the watercraft, B.U.D.S. will not allow you to
SWITCH in the STARTING SYSTEM subsection
write the changes to the ECM and will prompt you
for details.
to add a key.
Writing Changes to ECM

Save the changes made in B.U.D.S. into the ECM
as follows.
398 smr2Ql1-031
s!>i 20 10-034-01 S _b
smr 20l 0-038-003_&
24-PIN STEERING CONNECTOR DISCONNECT

Step 1: Pull out safety lock
READING
Step 2: Press in on release tab ENGINE
Step 3: Pull locking collar down D.E.S.S. 24-PIN TEST @
CUT-OFF
KEY CONNECTOR 20°c
SWITCH
2. IMPORTANT: Connect the DIAGNOSTIC HAR (68°F)
NESS (P IN 529 036 188) to the 24-pin steering
- Open
connector only, NOT to the vehicle harness Pin 13 Pin 11
circuit
connector.
- Center
REQUIRED TOOLS Removed Pin 14
contact
DIAGNOSTIC HARNESS (PIN 529 036 188) Close to
- Ring
Pin 13 on
contact
FLUKE 115 MULTIMETER (PIN 529 035 868)
Install ed Pin 13 Pin 11 -
< 1
5 290361 68 smr201 0 ·1l39-00 2...•
ENGINE CUT-OFF SWITCH

1. Center contact
2. Ring contact
If any continuity test fails, replace engine cut-off

switch.
If all readings were as specified, carry out the
CONTINUITY TEST OF VEHICLE HARNESS TO
ENGINE CUT-OFF SWITCH
Continuity Test of Vehicle Harness to

Engine Cut-Off Switch
529005668
1. Disconnect the 24-pin steering connector. Re
l+f[1)i{ljj
Do not attempt to probe the 24-pin fer to START/STOP SWITCH i n the STARTING
connector on the watercraft. Use the test con SYSTEM subsection for details.
nector on the diagnostic harness.
3. Set multimeter to n.
4. Probe test connector on diagnostic harness to
check continuity as follows.
smr2011·031 399
REQUIRED TOOLS 24-PIN TEST ECM ADAPTER

READING
CONNECTOR TOOL
DIAGNOSTIC HARNESS (PIN 529 036 188)
11 B-E4
FLUKE 115 MULTIMETER (PIN 529 035 868)
14 B-92 Close too n
ECM ADAPTER TOOL (P/N 529 036 166)
13 B-F2
If any continuity test failed, check wiring harness

between 24-pin steering connector and ECM con
nector.
If problem persists and all tests have been per
formed, try a new ECM. Refer to ELECTRONIC
529036188
6. Reconnect 24-pin steering harness connector.
7. Reinstall removed components.
52 9035866
629038 1 66
2. Connect the DIAGNOSTIC HARNESS (P/N 529 036

188) to the 24-pin vehicle harness connector
only, NOT to the steering harness connector.
3. Disconnect connector "B" from ECM. Refer to
WIRING HARNESS AND CONNECTOR subsec
tion.
4. Install the ECM ADAPTER TOOL (P/N 529 036 166)
on ECM connector "B".
5. Probe test connector as follows.
400 smr2011-031
Subsection 06 (INFORMATION CENTER (GAUGE))
INFORMATION CENTER (GAUGE)

SERVICE TOOLS
DIAGNOSTIC HARNESS............................................................... 529 036 188 ......................... 433, 436-437
FLUKE 115 MULTIMETER . . .. ... . . . .. .. ........ . . . .. ...... .. ... .
. .. . . . . . . .. . . . .. . . . . . 529 035 868 ......... 432, 434, 436, 438, 443
SERVICE PRODUCTS
DIELECTRIC GREASE . .. ...... .. . . .. . ... ..... ....
. . . .. . . . . . ... ..... . .... ........ 293 550 004 ......................... 427, 440, 445
... . .. . .
smr201 l-002 401

GENERAL
INFORMATION CENTER (GTS MODELS)
Do not adjust the display while riding, you could lose control.
sml0
2 11-032-1 00.•
TYPICAL - INFORMATION CENTER

1. Multifunction gauge
Multifunction Gauge Description 2) Numerical Display

The numerical display provides an indication of
estimated watercraft speed. Watercraft speed
is based on various engine parameters received
from the ECM.
3) Touring Mode Indicator

When the TOURING mode indicator is ON, the de
fault TOURING mode is active.
Refer to INTELLIGENT THROTTLE CONTROL
(ITC) subsection for details.
4) Sport Mode Indicator
When the SPORT mode indicator is ON, sport
mode has been selected and is active.
Sl"l'\02 011.()03.021 I NOTE: Sport mode is not the default riding mode.
To be active, it must be selected on after each en
1) Multifunction Display gine start.
The multifunction display is used to:
5) Fuel Level Indication
- Display the WELCOME message on power up
A bar gauge located in the bottom RH side of the
- Display the KEY recognition message
multifunction display continuously indicates the
- Display the engine RPM
amount of fuel in the fuel tank while riding.
- Display fault messages.
When the fuel tank is full, 8 segments (bars) of
NOTE: RPM is the default indication when the en- the indicator are turned on. The top segment is
gine is running. not used.
402 smr2011-032
Low Fuel Warning The signal to turn on the maintenance reminder

When there is only 2 segments of fuel indicated and scrolling maintenance message comes from
(approximately 25% fuel tank capacity or 14 L the ECM.
(3.7 U.S. gal.), the following indications will come 10) High Temperature Indicator
ON to advise you that a low fuel condition exists.
The high temperature indicator comes ON when a
LOW FUEL LEVEL INDICATIONS high engine temperature or a high exhaust system
temperature is detected.
Last 2 fuel gauge segments
Flashing The signal to turn on the high temperature indi
Fuel tank symbol
cator and scrolling HIGH TEMPERATURE or HIGH
Audible advisory EXHAUST TEMPERATURE message comes from
(one long beep) the ECM.
Periodically
Scrolling LOW FUEL advisory
message
6) Hour Meter Display

Continuously displays the accumulated engine
hours as transmitted by the ECM.
Engine hours are calculated and stored by the
ECM.
7) Water Depth Display

The water depth display provides an indication of
the lake water depth.
The system is capable of indicating water depth
under the hull in single increments up to 50 m
(164 ft).
NOTE: Under certain conditions, the display may
stop indicating. The display's ability to provide an
indication of the waters's depth depends on the
conditions of use.
NOTE: The water depth indication is only avail
able when a depth sounder is installed and
detected.
Never use the depth sounder as a warning

device to ride in shallow water.
8) Check Engine Light

The check engine light comes ON when a fault is
detected by the engine management system.
The check engine light may be accompanied by
the applicable scrolling fault message in the mul
tifunction display.
The signal to turn on the check engine light and
scrolling fault message comes from the ECM.
9) Maintenance Reminder Indicator

The maintenance reminder indicator comes ON
when required maintenance is due.
smr2011-032 403
INFORMATION CENTER (GTX 155, GTI SERIES AND WAKE MODELS)
Do not adjust the display while riding, you could lose control.
tmr2 0 J1-03
2 · 1 0 1_t
TYPICAL GT/ AND GT/ SE MODELS

·
2 1 3
TYPICAL - GTX 155, GT/ LIMITED AND WAKE MODELS
2. Analog speedometer
3. Analog tachometer
Analog Speedometer Description

The speedometer, located in the LH side of the information center, provides an analog indication of the
speed of the watercraft in miles per hour (MPH) and kilometers per hour (km/h).
The speed indication is based on a GPS (Global Positioning System) incorporated within the information
center.
If for some reason the GPS signal is lost. a default mode is used whereby, the speed is calculated using
information received from other systems to provide an estimated watercraft speed.
404 smr2011-032
Analog Tachometer Description

The tachometer provides an analog indication of the revolutions per minute (RPM) of the engine. Multiply
the indicated number by 1000 to obtain the actual engine RPM.
Multifunction Gauge Features

GTI GTI SE GTI LIMITED WAKE GTX 155
1) Multifunction display x x x x x
2) Numerical display x x x x x
3) Touring mode indicator x x x x x
4) Sport mode indicator x x x x x

5) Fuel level indication x x x x x
6) Hour meter display x x x x x
7) Water depth indication Opt Opt Opt Opt Opt
8) CHECK ENGINE light x x x x x
9) MAINTENANCE REQUIRED
x x x x x
indicator
11) iBR fault indicator x x x x x
12) ECO mode indicator Opt x x x x
13) CRUISE mode indicator Opt Opt x x x
14) iBR position indicator x x x x x
15) SKI mode indicator Opt Opt Opt x Opt
16) VTS position indication Opt x x x x
X = Indicates a standard feature

Opt = Indicates a feature available as an option
Multifunction Gauge Description - Provide various indications as selected by the

operator
- Activating or ch an ging various functions or
modes of operation
- Display scrolling messages of function activa
tion or system faults
- Display fault codes.
· �· 1 -0ou22_. MULTIFUNCTION DISPLAY
1) M ultifu nctio n Display NOTE: The default indication in the multifunction

The multifunction display is used to: display is the compass direction.
- Display the WELCOME message on power up
- Display the KEY recognition message
smr2011-032 405
2) Numerical Display
The numerical display is used to provide a variety
of indications as selected by the operator using
the DISPLAY function in the multifunction display.
NUMERICAL DISPLAY
1. Numerical display indication

2. Unit of measurement of indication
AVAILABLE INDICATIONS IN NUMERICAL DISPLAY

GTI GTI SE GTI LIMITED WAKE GTX 155
Watercraft speed Indication by default
Engine RPM x x x x x
Engine temperature Opt Opt Opt Opt Opt
Clock NA x x x x
Learning and rental key settings x x x x x

CRUISE SPEED setting (from idle RPM) Opt Opt x x x
SLOW SPEED MODE setting Opt Opt x x x
Full VTS (with LH VTS switch) Opt Opt x Opt Opt
VTS preset Opt Opt x Opt Opt
VTS settings (through gauge, no switch) Opt x NA x x
SKI MODE settings Opt Opt Opt x Opt
Fuel consumption
Opt x x x x
(instant and average)
Fuel autonomy (distance and time to empty) Opt Opt x Opt Opt
Lap timer Opt Opt Opt Opt Opt
Top speed/RPM. average speed/RPM Opt Opt Opt Opt Opt
Altitude NA NA x NA NA
X An X indicates a standard feature

=
Opt Feature available as an option

=
NA Not Available
=
When the information center is first powered up, the numerical display defaults to the last selected in
dication.
406 smr2011·032
3) Touri n g Mode Indicator LOW FUEL LEVEL WARNING

When the TOURING mode indicator is ON, the de Last 2 fuel gauge segments
fault TOURING mode of operation is active. Flashing
Fuel tank symbol
Audible warning
(one long beep)
Periodically
Scrolling LOW FUEL
WARNING message
6) Hour Meter Display (HR)

4) Sport Mode In dicator

HOUR METER DISPLAY
NOTE: Eng ine hours are calculated and stored in

the ECM.
7) Water Depth Display
NOTE: Sport mode is not the default riding mode. The water depth display provides an indication of
To be active, it must be selected ON after each the lake water depth.
engine start.
The system is capable of indicating water depth
5) Fuel Level I n dicatio n under the hull in single increments up to 50 m
(164 ft).
A bar gauge located in the bottom RH side of the
multifunction display continuously indicates the NOTE: Under certain conditions, the display may
amount of fuel in the fuel tank while riding. stop indicating. The display's ability to provide and
indication of the water's depth depends on the
conditions of use.
FUEL LEVEL INDICATION
When the fuel tank is full, 8 segments {bars) of WATER DEPTH DISPLAY
the indicator are turned on. The top segment is
not used. NOTE: The water depth indication is only avail
able when a depth sounder is installed and
Low Fuel Level Warning
detected.
When there is only 2 segments of fuel indicated
{ap p roximately 25% fuel tank capacity or 14 L
{3.7 U.S. g al ) the following warnings will be ON.
. ,
Never use the depth sounder as a warning
device to ride in shallow water.
smt2011·032 407
8) Check Engine Light 11) iBR Fault Indicator

The check engine light comes ON when a fault is The iBR fault indicator comes ON when a fault in
detected by the engine management system. the iBR system has been detected.
CHECK ENGINE LIGHT iBR FAULT INDICATOR
The signal to turn on the check engine light and The signal to turn on the iBR fault indicator and
scrolling fault message comes from the ECM. scrolling fault message comes from the ECM or
iBR.
9) Maintenance Reminder Indicator
The maintenance reminder indicator comes ON
12) ECO Indicator
when required maintenance is due. The ECO indicator and a smile in the fuel tank
symbol comes ON when FUEL ECONOMY
MODE is activated.
MAINTENANCE REMINDER INDICATOR
NOTE: The signal to turn on the maintenance re ECO MODE INDICATOR
minder and to display the MAINTENANCE DUE (Fuel Economy Mode)
message in the multifunction display comes from
the ECM. 13) CRUISE Mode Indicator
The cruise mode indicator comes ON when:
10) High Temperature Indicator
- CRUISE MODE has been activated.
The high temperature indicator comes ON when a
- SLOW SPEED MODE has been activated.
high engine temperature or a high exhaust system
temperature is detected.
HIGH TEMPERATURE INDICATOR

14) iBR Position Indicator
NOTE: The signal to turn on the high temperature Provides an indication of the iBR gate position.
indicator and the scrolling HIGH TEMPERATURE - N (neutral)
or HIGH EXHAUST TEMPERATURE message in - F (forward)
the multifunction display comes from the ECM.
- R (reverse).
408 smr2011-032
Selecting Functions
When operating at speed, the multifunction dis
play provides an indication of the compass direc
tion and azimuth of the watercraft is traveling by
default.
1. To select the various functions available
through the multifunction display, press the
MODE button repeatedly until the desired
iBR POSITION INDICATOR
function is visible:
15) SKI MODE Indicator
The ski mode indicator is ON when SKI MODE is

active.
FUNCTION SUBMENU DISPLAYED IN

SEQUENCE WHEN MODE BUTTON PRESSED
REPEATEDLY
SKI MODE INDICATOR 2. Then press the SET button to enter that func-
tion.
16) VTS Position Indication NOTE: The available functions and the order in
The VTS position indication provides an indication which they appear depends on the watercraft
of the of the pump nozzle position. model. The fault code function is only available
when there is an active fault. The settings func
A single segment of a bar gauge type indicator is
tion is only available when the engine is shut off.
turned on to indicate the relative position of the
watercraft bow. FUNCTIONS AVAILABLE THROUGH
COMPASS
DRIVING MODE
(default function)
LAP TIMER DISPLAY
SKI MODE FAULT CODES
FUEL ECONOMY MODE KEY MODE
VTS POSITION INDICATION FUEL CONSUMPTION SETIINGS
VTS MODE
-
Navigating the Multifunction Display

Description of Functions Available
Through Multifunction Display
Do not adjust display while riding, you could
lose control. Compass
A GPS incorporated in the information center pro
vides the indication in the multifunction display.
The cardinal points, intermediate cardinal points,
as well as the azimuth the watercraft is travelling
are displayed by default in the multifunction dis
play when the watercraft is moving.
For a compass indication to be displayed, the GPS
must have a good uplink with at least three navi
gation satellites.
smr2011·032 409
Key Mode
The KEY MODE function is used for changing
LEARNING or RENTAL key settings.
Setting s
The SETIINGS function is used for:
- Changing the clock setting
COMPASS DIRECTION DISPLAYED HERE - Activating the iBR override function.
NOTE: The compass indication is only available

Activating Functions Through the
above 5 km/h (3 MPH). Multifunction Display
To activate the following operating modes, refer
to INTELLIGENT THROTTLE CONTROL (ITC) sub
Use the compass as a guide only. Not t o be section:
used for precision navigation purposes. - SPORT mode
- TOURING mode
Lap Timer - SKI mode
The lap timer can be used to record up to 50 indi - FUEL ECONOMY mode
vidual lap times. - KEY mode.
Ski Mode For VTS mode, refer to iBR AND VTSsubsection.
Ski mode is used for repeated controlled launches For DISPLAY modes, refer to CHANGING NU
when towing a skier or wakeboarder. MERICAL DISPLAY INDICATION in this subsec
tion.
Fuel Economy Mode
For FAULT CODES display function, refer to DIAG
Fuel economy mode is a function by which engine
fuel consumption is reduced.
For the SETIINGS function:
Fuel Consumption
- To change clock setting, refer to MULTIFUNC
The FUEL CONSUMPTION function is used to dis TION GAUGE SETUP in this subsection.
play the watercraft fuel consumption four differ - For the iBR override function, refer to iBR AND
ent ways: VTS subsection.
- Instant fuel flow per hour (gal/h or L/h)
Lap Timer
- Average fuel flow per hour (gal/h or Uhl
- Distance to empty (Mi or Km) 1. Press the MODE button repeatedly until LAP
TIME is visible in the multifunction display.
- Time to empty (h or min).
VTS Mode
The VTS MODE function is used to manually set
the VTS or change VTS PRESET settings.
Driving Mode
The DRIVING MODE function can be used for ac
tivating or deactivating SPORT mode.
Display
The DISPLAY function is used to change the indi
cation in the numerical display.
Fault Codes
The FAULT CODES function can only be used to
11
display active fault codes.
smo2011)
-02-l
0
FUNCTION SELECTED - LAP TIME
410 smr2011-032
2. Press the SET button to enter the function, the To view each l a p time, use the UP/DOWN arrow
lap timer will be activated and visible in the dis button. The lap counter will indicate which lap is
play. indicated.
To view the cumulative lap time of all laps
recorded, use the UP/DOWN arrow button until
ALL is visible in the lap counter.
LAP TIMER FUNCTION
1. 00'00'00 lap time displayed here

2. Lap number 'O' displayed here
LAP TIMER FUNCTION EXAMPLE
3. To start the timer. press the SET button.
1. Total lap times 02'23'37 displayed
NOTE: The timer starts immediately when press here
ing the SET button. 2. Lap count "ALL' displayed here
4. To record each lap time, press the SET button
To reset the lap timer and lap counter, press and
at the start of each lap.
hold the SET button until the timer and counter are
NOTE: The lap time will be recorded, the lap reset to 0 (zero).
counter in the numerical display will count the
number of laps recorded, and the timer will con Fuel Consumption Display
tinue to run. NOTE: The fuel consumption functions are not
continuously active and therefore do not record
in the background. The desired fuel consumption
function becomes active only when selected as
the indication in the numerical display.
When the LOW FUEL indications come on in the
multifunction gauge, the 'TIME TO EMPTY" and
"DISTANCE TO EMPTY" functions will indicate "O"
(zero) if they are the selected indication.
To display the watercraft fuel consumption, carry
1. 01 '02'34 lap time displayed here out the following:
2. Lap number ·1 • displayed here 1. Press the MODE button repeatedly until FUEL
CONSUMPTION is visible in the multifunction
5. To save the last lap and stop the timer, press display.
the MODE button.
1. 01 '21 '03 lap time displayed here

2. Lap number "2" displayed here
snv201HX32 411
Changing Numerical Display Indication

To change the indication in the numerical display,
carry out the following:
1. Press the MODE button on the RH handlebar
repeatedly until DISPLAY is visible in the multi
function display.
FUNCTION SELECTED - FUEL CONSUMPTION
2. Press the UP/DOWN arrow button to toggle to

the desired fuel consumption display mode.
omo2009-002-1 14�
1n FUNCTION SELECTED - DISPLAY
IU Vh 2. Press the SET button to enter the DISPLAY

function.
IfJ�i TflfJT 3. Press the UP/DOWN arrow button until the pre
ferred indication is visible in the multifunction
display.
- RPM
- SPEED
- CLOCK
emo20 1 0-002 - 1 10
- ENGINE TEMP
FUEL CONSUMPTION DISPLAY MODE - INSTANT FUEL FLOW
- ALTITUDE.
3. Press the SET button to save the setting and - TOP SPEED (RXT-X)
return to the main display. - AVG SPEED (RXT-X)
NOTE: The fuel consumption value selected will - TOP RPM (RXT-X)
be displayed in the numerical display. Double click - AVG RPM (RXT-X).
the SET button to reset the average fuel consump
tion indication. The display will momentarily indi
cate zero (0).
Multifunction Display Messages

For a list of usual messages that may be displayed
in the multifunction display, refer to MULTIFUNC lbba..
F�F1f1
TION DISPLAY MESSAGES in INFORMATION
CENTER (RXT,GTX (EXCEPT 7 55) AND WAKE
PRO SERIES).
smo<?00!!-002· 1 "-�
EXAMPLE - NUMERICAL DISPLAY SELEC TION - RPM
412 smr2011-032
4. Press the SET button to select and save the pre

ferred indication. or wait for the display function
to time out. The last indication visible will be au
tomatically saved.
Resetting Numerical Display Indication

The following numerical display indications can be
reset when selected:
- Average fuel consumption
- Top speed
- Average speed
- Top RPM
- Average RPM.
To reset the indication. double click the SET but
ton. The numerical display will momentarily indi
cate zero (0).
NOTE: Each of these functions become active
ONLY when selected as the numerical display
indication. they do not record in the background.
smr2011-032 413
Subsection 06 (INFORMATION CENTER (GAUGE})
INFORMATION CENTER
(RXT,GTX (EXCEPT 155) AND WAKE PRO SERIES)
Information Center Description
8 2
4 15 6 10 13 14 5 16
amo2 01(
>
-002 ·200_b
TYPICAL - RXT. GTX AND WAKE PRO SERIES EXCEPT GTX 155
1) Speedometer
The speedometer, located in the LH side of the If for some reason the GPS signal is lost. a de
information center, provides an analog indication fault mode is used whereby, the speed is calcu
of the speed of the watercraft in miles per hour lated using information received from other sys
(MPH} and kilometers per hour (km/h). tems to provide an estimated watercraft speed.
The speed indication is based on a GPS (Global Po 2) Tachometer
sitioning System) incorporated within the informa
The tachometer provides an analog indication of
tion center.
the revolutions per minute (RPM) of the engine.
An indicator light seen in the tachometer lights Multiply the indicated number by 1000 to obtain
up when the GPS has a good uplink with at least the actual engine RPM.
three satellites.
GPS INDICATOR LIGHT
414 srrr'201 1 -032

Subsection 06 {INFORMATION CENTER (GAUGE))
3} Multifunction Gauge
The multifunction gauge, located in the center
of the information center, is capable of providing
many indications simultaneously.
The numerical and multifunction displays in the
multifunction gauge can be used to display vari
ous indications, or for selecting modes of opera
tion and changing settings as explained in their re
spective subsections.
smo20094l2·1 1 4j
TYPICAL - MULTIFUNCTION GAUGE
MULTIFUNCTION GAUGE GTX GTX iS, RXT-X aS, WAKE GTX

RXT
FEATURES LTDiS RXTiS RXT-X PRO 215
Multifunction display x x x x x x
Numerical display x x x x x x
TOURING mode indicator x x x x x x
SPORT mode indicator x x x x x x
Fuel level indication x x x x x x
Hour meter display x x x x x x
Water depth indication x Opt Opt Opt Opt Opt
CHECK ENGINE indicator x x x x x x
MAINTENANCE REQUIRED indicator x x x x x x
iBR fault indicator x x x x x x
CRUISE mode indicator x x Opt x x x
iBR position indicator x x x x x x
SKI mode indicator Opt Opt Opt x Opt Opt
VTS position indication x x x x x x
X = An X indicates a standard feature

Opt = Feature available as an option
smr2011-032 415
4) Indicator Lights 5) Fuel Level Indication

Indicator lights (pilot lamps), located in the A bar gauge located in the bottom RH side of the
speedometer and tachometer indicator, inform multifunction display continuously indicates the
you of a selected function, or a system anomaly. amount of fuel in the fuel tank while riding.
An indicator light may be accompanied by a
scrolling message in the multifunction display.
See the following table for information on the
usual pilot lamps. Refer to DIAGNOSTIC AND
FAULT CODES subsection for details on malfunc
tion pilot lamps.
PILOT
MESSAGE
LAMPS DESCRIPTION
DI S PLAY
(ON)
@
MAIN TENANCE
Maintenance required
REMINDER
LOW or HIGH
cg
Low/high battery
BATIE RY
voltage amo2009-00 2·1 1 4_k
VOLTAGE FUEL LEVEL INDICATION
Low fuel level, approx.

25% tank capacity, When the fuel tank is full, 8 segments (bars) of
@ LOW-FUEL 14 L (3.7 U.S. gal.)

or fuel level sensor
the indicator are turned on. The top segment is
not used.
disconnected Low Fuel Warning
@
HIGH Engine or exhaust When there is only 2 segments of fuel indicated
TEMPERATURE system overheating (approximately 25% fuel tank capacity or 14 L
(3.7 U.S. gal.), the following warnings will be ON.
Check engine (minor
CHECK ENGINE LOW FUEL LEVEL WARNING
@
fault req. maint.) or
or LIMP HOME
LIMP HOME MODE Last 2 fuel gauge segments
MODE
(major eng. fault) ON
Fuel tank symbol (LED)
@
LOW OIL
Low oil pressure Audible warning (one long beep)
PRESSURE
Scrolling LOW FUEL WARNING Periodically
Scrolling SLOW CRUISE mode or message
8 SPEED MODE
message
SLOW SPEED mode
engaged The audible warning (one long beep) will be heard
periodically as long as the low fuel condition ex
8 - iBR system fault ists.

NOTE: The watercraft fuel consumption may be
displayed in the numerical display. Refer to NU
8 - 0.T.A.S. system fault MERICAL DISPLAYin this subsection.
6) VTS Position Indication
®
�
- Good GPS uplink The VTS position indication located in th e bottom
LH side of the multifunction display indicates the
Scrolli ng riding attitude of the watercraft.
@) SKI MODE
messages
SKI mode activated
A single segment of a bar gauge type indicator is
turned on to indicate the relative position of the
watercraft bow.
416 smr2011-032
smo2C0!;002· 114 _1 smo 20-0 9-002 · 114_n
VTS POSITION INDICATION EXAMPLE - NUMERICAL DISPLAY

1. Water depth indicatio n (GTX LTD iSJ
2. Numerical display
7) iS Position Indication
The iS position display (intelligent Suspension)
provides a visual indication of the relative height
of the suspension.
It also indicates if the suspension is in AUTO
mode of operation.
m
s m o 2 009-002 · 114_
1. iS position indicator
2. iS AUTO mode indicator
When the suspension system is operating in

AUTO mode, the AUTO indicator and all bar seg
ments of the position indicator will be on.
When the suspension height is adjusted using the
iS button, the system switches to MANUAL mode
of operation. The AUTO indication disappears and
only one segment of the bar gauge is turned on to
indicate the position of the suspension.
Refer to SUSPENSION (1S) subsection for details.
8) Numerical Display
The numerical display is used to provide a variety
of indications as selected by the operator using
the DISPLAY function in the multifunction display.
smr2011 ·032 417

AVAILABLE INDICATIONS IN GTX GTX iS, RXT-X aS, WAKE GTX

AXT
NUMERICAL DISPLAY LTDiS RXTiS RXT-X PRO 215
1) Watercraft speed Indication by default
2) Engine RPM x x x x x x
3) Engine temperature Opt Opt x Opt Opt Opt
4) Lake water temperature x x x x x x

5) Clock x x x x x x
6) Learning and rental key settings x x x x x x
7) CRUISE button
x x Opt x x x
(on handlebar)
8) CRUISE SPEED se tting x x Opt x x x
9) SLOW SPEED MODE setting x x Opt x x x
10) Full VTS (with LH VTS switch) x x x x Opt x
11) VTS preset x x x x Opt x
12) VTS settings (through gauge) N.A. N.A. N.A. N.A. x N.A.
13) SKI MODE settings Opt Opt Opt x Opt Opt
14) Fuel consumption

x x x x x x
(instant and average)
15) Fuel autonomy

x Opt x Opt Opt Opt
(distance and time to empty)
16) Lap timer Opt Opt x Opt Opt Opt
17) Top speed/RPM.

Opt Opt x Opt Opt Opt
average speed/RPM
18) Altitude x N.A. N.A. N.A. N.A. N.A.
X An X indic ates a standard fea tur e

=
Opt Feature available as an option

=
N.A. - Not Available
When the information center is first powered up, 10) Water Depth Display
the numerical display defaults to the last selected
GTX Limited iS Model
indication.
The NUMERICAL DISPLAY can be selected to
9) Mult ifu ncti on Display provide an i n dication of the lake water depth.
The multifunction display is used to: The system is capable of indicating water depth
- Display the WELCOME message on power up. under the hull in single increments up to 50 m
- Display t he KEY recognition message. (164 ft).
- Provide various indications as selected by the NOTE: Under certain conditions, the digital
operator. screen may stop displaying. The digital screen's
- Activating and setting various functions and ability to display the depth depends on the condi
modes of operation. tions of use.
- Display scrolling messages of function activa- To activate the water depth indication, refer to
tion or system faults. CHANGING NUMERICAL DISPLAY IND/CAT/ON
- Display fault codes. i n this subsection.
NOTE: The default indication in the multifunction

display is the compass di rection.
418 smr201 Hl32

Subsection 06 (INFORMATION CENTER {GAUGE))
12) Hour Meter Display (HR)

s mo2009-002-1 H_ r
GTX LIMITED IS
1. Depth sounder indicator
2. Water depth indication
NOTE: The water depth indication is only avail

able when a depth sounder is installed and smo201l9·002·1 14_s
HOUR METER D/SPLAY

detected.
The engine hours are calculated and stored in the
ECM.
Never use the de pth gauge as a warning de
vice to ride in shallow wate r. 13) iBR Position
Provides an indication of the iBR gate position.
11) Water Tern peratu re Display - N {neutral)
All Models Except GTX 155 - F {forward)
Continuously displays surface water temperature - R (reverse).
in degrees Celsius (°C ) or Fahrenheit (°F).
. . � ,-
l . """"
,.
\ "''
....
•
smo2009-002- 1 14_u
/BR POSITION - FORWARD ILLUSTRATED (F)

smo2009-002-114_1
WATER TEMPERATURE DISPLAY

14) Compass
The signal used to display water temperature A GPS incorporated in the information center pro
comes from the iBR module. vides the indication in the multifunction display.
The numerical display may also be selected to dis The cardinal points, intermediate cardinal points,
play water temp. See CHANGING NUMERICAL as well as the azimuth the watercraft is travelling
DISPLAY INDICATION in this subsection. are displayed in the multifunction display by de
fault when the watercraft is moving.
To change the unit of measurement (°C or °F),
refer to MULTIFUNCTION GAUGE SETUP in this
subsection.
smr2011-032 419
For a compass indication to be displayed, the GPS 16) Sport Mode Indicator
must first have a good uplink with at least three
navigation satellites.
above 5 km/h (3 MPH}.
Use the compass as a guide only. Not to be

used for precision navigation purposes.
smo2010- 002-201.JI
1. SPORT mode indicator on

NOTE: Sport mode is not the default riding mode.
To be active, it must be selected ON after each
engine start.
Navigating the Multifunction Display
TYPICAL
7. Compass indication Do not adjust display while riding, you could
2. Compass active indicator lose control.
15) Tourin g Mode I n d ic ator
Selecting Functions
When the TOURING mode indicator is on, the de
When operating at speed, the multifunction dis
fault TOURING mode is active.
play normally provides an indication of the com
pass direction and azimuth the watercraft is trav
eling.
1. To select the various functions available
through the multifunction display, press the
MODE button repeatedly until the desired
function is visible:
2. Press the SET button to enter that function.
NOTE: The available functions and the order in
which they appear depends on the watercraft
model. The fault code function is only available
when there is an active fault. The settings func
tion is only available when the engine is shut off.
smo201 0-00 2 ·100
_•
1. TOURING mode indicator on FUNCTIONS AVAILABLE THROUGH

COMPASS
DRIVING
(default function)
LAP TIMER DISPLAY

SKI MODE FAULT CODES
420 smr2011-032
FUNCTIONS AVAILABLE THROUGH VTS Mode

MULTIFUNCTION DISPLAY The VTS mode function is used to change VTS
FUEL ECONOMY MODE KEY MODE PRESET settings.
FUEL CONSUMPTION SETTINGS DRIVING Mode
VTS MODE - The DRIVING mode function is used for activating

or deactivating SPORT mode of throttle control.
Description of Functions Available Display

Through Multifunction Display The DISPLAY function is used to change the indi
cation in the numerical display of the information
Compass
center.
A GPS incorporated in the information center pro
vides the indication in the multifunction display. Fault Codes
The cardinal points, intermediate cardinal points, The FAULT CODES function can only be used to
as well as the azimuth the watercraft is travelling display active fault codes.
are displayed in the multifunction display by de
KEY Mode
fault when the watercraft is moving.
The KEY mode function is used for changing
For a compass indication to be displayed, the GPS
LEARNING or RENTAL key settings.
must have a good uplink with at least three navi
gation satellites. Sett i ngs
The SETIINGS function is used for:
- Changing clock setting
- DOCK mode function setting
- Activating the iBR override function.
NOTE: The settings function is only available
when the engine is shut off.
Fuel Consumption
The approximate watercraft fuel consumption
may be displayed in the numerical display 4 dif
ferent ways:
- Instant fuel flow per hour (gal/h or l/h}
- Average fuel flow per hour (gal/h or l/h)
smo20 09-002· 1 1 4_o - Distance to empty (Mi or Km)
MULTIFUNCTION DISPLAY- COMPASS HEADING INDICATION - Time to empty (h or min).

Activating Functions Through the
above 5 km/h (3 MPH}.
Multifunction Display
To activate the following operating modes, refer
Use the compass as a guide only. Not to be to INTELLIGENT THROTTLE CONTROL (ITC) sub
used for precision navigation purposes. section:
- SPORT mode
Lap limer - TOURING mode
The lap timer can be used to record up to 50 indi - SKI mode

vidual lap times and total lap times. - FU EL ECONOMY mode
- KEY mode.
SKI Mode
For VTS mode, refer to iBR AND VTSsubsection.
SKI mode is used for repeated controlled launches
and accurately maintained maximum speed when For DISPLAY modes, refer to CHANGING NU
towing a skier or wakeboarder. MERICAL DISPLAY IND/CATION in this subsec
tion.
smr2011-032 421
For FAULT CODES display function, refer to DIAG NOTE: The timer starts immediately when press
NOSTIC AND FAULT CODES subsection. ing the SET button.
For the SETTINGS function: 4. To record each lap time, press the SET button
- To change clock setting, refer to MULTIFUNC at the start of each lap.
TION GAUGE SETUP in this subsection. NOTE: The lap time will be recorded, the lap
- To access the iBR override function, refer to iBR counter in the numerical display will count the
AND VTS subsection. number of laps recorded, and the timer will con
- To access the DOCK mode function setting , re- tinue to run.
fer to SUSPENSION (!SJ.
Lap Timer
To activate and use the lap timer, carry out the fol
lowing:
1. Press the MODE button repeatedly until LAP
TI ME is visible in the multifunction display.
• m o2 0 1C >002·1 13 _
a
1. Lap time, first lap

2. Lap count 1
5. To save the last lap and stop the timer, press

the MODE button.
s m o2010-002·111
FUNCTION SELECTED: LAP TIME
2. Press the SET button to enter the function, the

lap timer will be activated and visible in the dis
play.
smo2010 002·114. a
1. Lap time, second lap

2. Lap count 2
To view each l a p time, use the UP or DOWN ar

row button. The lap counter will indicate which lap
is indicated.
To view the cumulative l a p time of all laps
recorded, use the UP or DOWN arrow button
Gm02 010<>02·112
LAP TIMER ACTIVATED

until ALL is visible in the lap counter.
3. To start the timer, press the SET button.
422 smr2011-032
ID
IfJ�iTflfJT
sm2 l- 002 · 115_ o

o 0H sm2
o 010·002· 1l0
1. Total lap time for 2 laps FUEL CONSUMPTION DISPLAY MODE: INSTANT FUEL FLOW
2. Lap count. ALL laps
3. Press the SET button to save the setting and
To reset the lap ti m e r and lap counter, press and return to the main display.
hold the SET button until the timer and counter are
NOTE: The fuel consumption value will be dis
reset to 0 (zero).
played in the numerical display. Double click the
Fuel Consumption Display SET button to reset the average fuel consumption
NOTE: The fuel consumption functions are not indication. The display will momentarily indicate
continuously active. They do not record in the zero (0).
background. The desired fuel consumption func
tion becomes active only when selected as the
Multifunction Display Messages
indication in the numerical display. The following is a list of usual messages that
may be displayed in the multifunction display.
To view the watercraft fuel consumption, carry out
Displayed messages are subject to the functions
the following:
as applicable to watercraft model.
1. Press the MODE button repeatedly until the
FUEL CONSUMPTION is visible in the multi USUAL MESSAGES
function display. WELCOME ABOARD
Power u p display
SEA-DOO
NORMAL KEY Normal key detected
LEARNING KEY Learning key detected
RENTAL KEY Rental key detected
Display menu for

DISPLAY numerical display
indication
Water depth indication

DEPTH
selection
RPM RPM indication selection

Watercraft speed
SPEED
indication selection
s mo201 0-00 2·109
ENGINE TEMP Engine temp selection
FUNCTION SELECTED: FUEL CONSUMPTION
Lake temperature
2. Press the UP or DOWN arrow button to select LAKE TEMPERATURE
indication selection
the desired fuel consumption display mode.
Altitude selection
ALTITUDE
(from GPS)
TOP SPEED Top speed selection
srnr201 l-032 423

USUAL MESSAGES USUAL MESSAGES

AVG SPEED Average speed selection OVA OFF iBR-OVR function disable
Ma xim um RPM OVA ON iBR-OVR function enable

TOP RPM
s election
SLOW SPEED MODE Slow speed mode
AVG RPM Average RPM selection ACTIVE acknowledgement
Message when system AUTOMATIC Automatic suspension

FUNCTION CANNOT
cannot enter a specific SUSPENSION acknowledgement
BE ENGAGED
function
MANUAL Manual suspension
CLOCK Clock function SUSPENSION acknowledgement
CHANGE CLOCK Menu for selecting

Clock setting function
OFFSET DRIVING MODE between TOURING
mode and SPORT mode
Menu for selecting fuel
FUEL CONSUMPTION
consumption display ENTERING SPORT
MODE - INCREASED
Used to display
ACCELERATION -
INSTANT FUEL FLOW instantaneous fuel Message when SPORT
INSTRUCT
consumption mode is selected
PASSENGERS TO
Used to display average HOLD ON - PRESS SET
AVERAGE FUEL FLOW fuel consumption since BUTTON
last reset
SPORT MODE Message when SPORT
Display distance ACTIVATED mode is activated
available based on fuel
DISTANCE TO EMPTY Message when SPORT
remaining in tank and SPORT MODE -
mode cannot be
instant fuel consumption RETURN TO IDLE
activated, engine not
TO ACTIVATE
Display time to empty at idle
based on fuel remaining
TIME TO EMPTY SPORT MODE ACTIVE - Message when driver
in tank and instant fuel
PRESS SET TO requests returning to
consumption
DISENGAGE TOURING mode
VTS MODE VTS preset menu
SPORT MODE ACTIVE -
Message when SPORT
PRESET 1 For changing PRESET 1 RETURN TO IDLE TO
mode is in use
CANCEL
PRESET 2 For changing PRESET 2
Message when user
Fault code menu for SPORT MODE
FAULT CODE first returns to TOURING
viewing codes DEACTIVATED
mode
KEY MODE KEY mo de menu
SKI MODE WAKE and SKI function
For changing learning
L-KEY Message when a rider
key setting
PLEASE EXIT SKI attempts to enter
For changing rental key MODE FIRST CRUISE mode when
A-KEY already in SKI mode
setting
For accessing DOCK Message when a rider

SETTINGS mode, iBR-OVR, and PLEASE EXIT SLOW attempts to enter SKI
CLOCK settings SPEED MODE FIRST mode when already in
SLOW SPEED mode
DOCK mode function
DOCK MODE Ramp curve or level of
menu RAMP
acceleration from 1 to 5
DOCK MODE OFF DOCK mode disable
Speed requested for SKI
DOCK MODE AUTO DOCK mode enable TARGET SPEED
mode
Suspension moving to SKI MODE - PRESS SE T SKI mode is unarmed
DOCK MODE ON
DOCK position TO START OR MODE but ready, the PWC is at
TO EXIT idle
iBR-OVR iBR mode function menu
424 sm12-01 1-032

USUAL MESSAGES USUAL MESSAGES

SKI MODE ARMED - Message scrolling when
SKI mode is ready but CRUISE - SPEED
RETURN TO IDLE adjusting cruise TARGET
the PWC is not at idle, ADJUSTING
OR PRESS MODE TO speed setting
the system is at standby
CANCEL
Message scrolling if
SKI MODE ACTIVE - PLEASE EXIT CRUISE CRUISE mode still active
PRESS MODE AND Message scrolling when MODE FIRST when trying to engage
RETURN TO IDLE TO SKI mode is active SLOW SPEED mode
CANCEL
Message when
Message scrolling when LOW FUEL approximately 25%
SKI MODE - SPEED
adjusting SKI mode fuel remaining
ADJUSTING
speed setting
The following is a list of messages related to a
Message scrolling when
SKI MODE ACTIVE - malfunction that may be displayed in the multi
the user pressed MODE
RETURN TO IDLE TO function gauge. Displayed messages are subject
to disengage but didn't
CANCEL to functions as applicable to watercraft model.
return to idle
LAP TIME Lap timer function FAULT MESSAGES
Menu option for MODE/SET, UP/DOWN

FUEL ECONOMY
selecting FUEL RIGHT KEYPAD ERROR arrow button
MODE
ECONOMY MODE malfunction
FUEL ECONOMY Engine low oil pressure

FUEL ECONOMY MODE LOW OIL PRESSURE
MODE - HOLD SET TO detected
is selected, scrolling
ACTIVATE OR MODE
instruction for activation HIGH EXHAUST High exhaust
TO EXIT
TEMPERATURE temperature detected
FUEL ECONOMY FUEL ECONOMY
High engine temperature
MODE - HOLD SET MODE is active, HIGH TEMPERATURE
detected
TO DEA CTIVATE OR scrolling instruction
MODE TO EXIT for deactivation Engine system
CHECK ENGINE malfunction or
Message when SLOW
SLOW SPEED MODE maintenance required
SPEED mode is in
ACTIVE
operation HIGH BATTERY High battery voltage
VOLTAGE detected
SLOW SPEED MODE Message when SLOW
ACTIVATED SPEED mode is selected LOW BATTERY Low battery voltage
VOLTAGE detected
Message scrolling when
SLOW SPEED MODE -
adjusting slow speed Major fault detected,
SPEED ADJUSTING LIMP HOME MODE
TARGET speed setting engine power limited
Message scrolling if FUEL SENSOR

Fuel level sensor fault
PLEASE EXIT SLOW SLOW SPEED mode is DEFECTIVE
SPEED MODE FIRST still active when trying to
Problem in iBR,
engage CRUISE mode WATER TEMP SENSOR
not sending water
DEFECTIVE
Message when CRUISE temperature info.
CRUISE MODE ACTIVE
mode is in operation
Cluster programming
CALIBRATION
CRUISE MODE Message when CRUISE corrupted, need to be
CHECKSUM ERROR
ACTIVATED mode is selected re-flashed using B.U.D.S.
MAINTENANCE Watercraft maintenance

REQUIRED required
SUPERCHARGER
Maintenance on
MAINTENANCE
supercharger required
REQUIRED
smf2011-0J2 425
Subsection 06 {INFORMATION CENTER (GAUGE))
FAULT MESSAGES - TOP RPM (RXT-X)

- AVG RPM (RXT-X)
DEPTH SOUNDER
Error message if depth - CLOCK.
MODULE
sounder is disconnected
COMMUNICATION NOTE: The DEPTH selection is only available if a
while riding
PROBLEM depth sounder is installed.
Error message if
iS MODULE
communication with
COMMUNICATION
the suspension module
PROBLEM
is lost while riding
lbbD...
Error message if
communication with
iBR MODULE ERROR
the iBR module is lost
F�F1f1
while riding
Message when a
FUNCTION CANNOT
function is not or cannot
BE ACTIVATED
be properly activated
Changing Numerical Display Indication

To change the indication in t he numerical display,
smo200S<OZ · l 14_q
carry out the following:
TYPICAL - NUMERICAL DISPLAY SELECTED - R PM
1. Press the MODE button on the RH handlebar
repeatedly until DISPLAY is visible in the multi 4. Press the SET button to select and save the pre
function display. ferred indication, or wait for the display function
to time out. The last indication visible will be au
tomatically saved.
The following abbreviations are used in the nu
merical display:
- FT or M
- RPM
- MPH or Km/h
- °F or °C
- AM or PM
- Gal/h or l/h.
Resetting Numerical Display Indication

The following numerical display indications can be
1mo2009-020 · 1 14_p reset :
FUNCTION SELECTED - DISPLAY - Average fuel consumption
- Top speed
2. Press the SET button to enter the DISPLAY
function. - Average speed
- Top RPM
3. Press the UP or DOWN arrow button until the
preferred indication appears. - Average RPM.
- RPM To reset indications, double click the SET button.

- SPEED The numerical display will momentarily indicate
zero (0).
- LAKE TEMPERATURE
- DEPTH NOTE: Each of these functions become active
ONLY when selected as the numerical display
- ENGINE TEMP (RXT-X)
indication. They do not record i n the background.
- ALTITUDE (GTX LTD iS)
- TOP SPEED (RXT-X)
- AVG SPEED (RXT-X)
426 smr2011-032
TROUBLESHOOTING Check for signs of moisture, corrosion or dullness.

Clean pins properly and coat them with DIELEC
DIAGNOSTIC TIPS TRIC GREASE (PIN 293 550 004) or other appropriate
lubricant when reassembling them. except if oth
NOTE: It is a good practice to check for fault erwise specified such as for the ECM connectors.
codes using B.U.D.S. software as a first trou
Pay attention to ground wires.
bleshooting step. Refer to COMMUNICATO I N
TOOLS AND B.U.D.S subsection.
TROUBLESHOOTING
IMPORTANT: When troubleshooting rin P.IP.c:trical
system fault, check battery condition, cables and
GUIDELINES
connections first. Press the START/STOP button and install the
tether cord on the engine cut-off switch.
Electrical System Activation
NOTE: Information center should come on, cycle
1. Press the START/STOP button. through its self test function, and stay on for
NOTE: Pressing the START/STOP button without approximately 3 minutes after which all electrical
the tether cord (D.E.S.S. key) installed on the en power will turn off.
gine cut-off switch will turn on electrical power Briefly press the START/STOP button every 3
without starting the engine; the information cen minutes to reenergize the electrical system. Do
ter will cycle through a self-test function and shut not hold the START/STOP button to avoid engine
off its display after a few seconds. However, the starting.
electrical system will stay powered up for approxi
NOTE: When troubleshooting using the following
mately three minutes after the START button was
guidelines, it is important to remember that some
pressed.
indications, functions and features described may
2. Install the tether cord on the engine cut-off not apply to every PWC model, or may be avail
switch to activate ECM and Information Center able as an option.
when testing procedures require a component
or system to be supplied with electrical power. Information Center "Does Not Turn
IMPORTANT: When B.U.D.S. is being used, the ON"
ECM will stop communicating with B.U.D.S. ap If the information center does not turn ON when
proximately 3 minutes after the START button is the START/STOP button is pressed. the power cir
pressed. T herefore, operations with B.U.D.S. will cuit or ground circuit to the information center is
be interrupted. To reestablish communication, probably open.
briefly press the START button. Do not hold the
START button to avoid engine starting. iS Models
Double click the iS button to move the suspen
Circuit Testing sion to the up position. If the suspension does not
Check the related-circuit fuse condition with a move to the up position, the problem is related
fuse tester or ohmmeter (a visual inspection to the electrical power system. Refer to POWER
could lead to a wrong conclusion). DISTRIBUTION AND GROUNDS subsection.
If the suspension moves to the up position, the
Electrical Connection Inspection electrical power system is functioning normally.
When replacing an electric or electronic compo
All Models
nent, always check electrical connections. Make
sure they are tight. make good contact, and are Test the 3 A GAUGE/OTAS/CAPS fuse (fuse 12) in
corrosion-free. Dirty, loose or corroded contacts fuse box 1 (FB1 }.
are poor conductors and are often the source of a If the fuse tests good, carry out an INFORMATION
system or component malfunction. CENTER INPUT VOLTAGE TEST
Pay particular attention to ensure that pins are not If the information center input voltage test is
bent or pushed out of their connectors. good. test for continuity of the gauge ground
Ensure all wire terminals are properly crimped on circuit (gauge connector pin 11 (BLACK wire} to
wires, and connector housings are properly fas the ground bus-bar (pin H7} in FB1.
tened. Refer to WIRING DIAGRAM for circuit details.
smr2011-032 427
Information Center Turns ON with - VTS indication

Some Indications Missing - iBR position indication
1. Connect to the latest applicable B.U.D.S. ver - CHECK ENGINE light is on.
sion, refer to COMMUNICATION TOOLS AND NOTE: The lake water temperature indication is
B.UD.S. subsection. not available for the GTI Series and WAKE models.
2. Read the fault codes, refer to DIAGNOSTIC The iBR CAN bus circuit is open or the iBR module
AND FA ULT CODES subsection. is at fault.
If a fault code is related to a communication NOTE: The ECM will generate several fault codes
problem, carry out a continuity test of the CAN and engage LIMP HOME mode.
bus wires between the applicable module and
Carry out a continuity check of the CAN bus wires
the CAN bus-bars in FB1. Refer to WIRING DI
from the CAN bus-bars in FB1 to the iBR module
AGRAM and CONTROLLER AREA NETWORK
(pins 2 and 3). Refer to the WIRING DIAGRAM
(CANJ subsections.
and CONTROLLER AREA NETWORK (CANJ sub
NOTE: The information center, ECM, iS module, sections for details.
iBR module, and the diagnostic connector are
linked together through CAN bus-bars in fuse NO RPM Indication and NO Engine
box 1. If one wire of the two wire CAN bus sys Hour Display
tem is open, communication will be slower than
If there is NO R P M indication and NO engine
normal. Multiple fault codes may be generated
hour display, and the watercraft is in LIMP HOME
and the ECM will put the watercraft in LIMP
mode, the CAN bus to the ECM is open.
HOME mode.
If one module cannot be seen in B.U.D.S., the
from the CAN bus-bars in FB 1 to the ECM module,
fault may be the wires that link the module to the
connector "B" pins C1 and C2 {8-C1 and B-C2). Re
CAN bus bars, or a problem internal to that mod
fer to the WIRING DIAGRAM and CONTROLLER
ule. Test the CAN bus wires from the faulty mod
AREA NETWORK (CAN} subsections for details.
ule to the CAN bus-bars in FB1 for continuity be
fore assuming the problem is the module.
NO iS Position Display
Information Center Goes Blank except If there is no iS position display (suspension posi
for: tion). the iS module is at fault, or its CAN bus cir
- GPS indicator ON cuit is open.
- Compass ON (if watercraft moving) Carry out a continuity check of the CAN bus wires
- Fuel level ON from the CAN bus-bars in FB1 to the iS module
(pins 2 and 3). Refer to the WIRING DIAGRAMfor
- iBR fault indicator light ON
details.
- Indicated speed
NOTE: If communication with the iS module can
- No other indications visible.
not be established when electrical power is first
NOTE: GPS, compass and iBR indications are not applied, the monitoring system assumes this is a
applicable to GTS models. normal situation (PWC not equipped with iS) and
There is no communication between the informa will not display an error message.
tion center and all other modules (ECM, iS, iBR).
NO Fuel Level Indication
from the CAN bus-bars in FB1 to the informa If there is no fuel level indication, test the fuel
tion center (pins 2 and 3). Refer to the WIRING level sensor and its wiring circuit to the infor
DIAGRAM and CONTROLLER AREA NETWORK mation center. Refer to FUEL TANK AND FUEL
(CANJ subsections for details. PUMP subsection.
If an open circuit is detected, carry out same test

NO Depth Gauge Indication
from the pin steering connector (pins 8 and 20).
If there is no depth gauge indication available and
All Indications ON Except for: the depth sounder active indicator is not on, refer
to DEPTH GAUGE in this subsection.
- LAKE WATER TEMP indication
428 smr2011-032
NOTE: If communication with the depth sounder NOTE: This circuit provides 12 Vdc to the GPS in
cannot be established when electrical power is the information center so that it memorizes the
first applied, the monitoring system assumes this satellites it was linked to for a period of two hours.
is a normal situation (PWC not equipped with This allows the indications to be available within
depth finder) and will not display an error mes a few seconds of restarting the watercraft (hot
sage. start). After a two hour period, the GPS will have
to reestablish new satellite links.
NO Speed or Compass Indication
Beeper Does Not Function
All Models ExceJpt GTS
The beeper is incorporated within the information
To obtain a speed or compass reading and to turn
center.
on the GPS indicator, the GPS requires a good up
link to at least three navigation satellites. If no beep code is heard when installing the
tether cord, first ensure ECM is powered. Refer
If there is no speed or compass indication, look for
to ELECTRONIC FUEL INJECTION (EFI) subsec
the GPS indicator icon. If the GPS indicator is off,
tion.
either the GPS cannot uplink with the satellites,
or the GPS system in the information center is at In B.U.D.S., carry out the following:
fault. - Cluster Buzzer Test on the cluster activation
page
If another watercraft nearby displays a good GPS
uplink (GPS indicator light on in cluster), the infor - Check for fault codes. Carry out service actions
mation center may need to be replaced. as applicable.
NOTE: If the GPS uplink is lost while navigating If the Cluster Buzzer Test failed, the ECM is
at speed, the speedometer will provide an esti powered, and the ECM and information center
mated speed indication based on other parame are communicating properly through the CAN
ters. The compass indication will not be available bus, replace the information center.
until a good satellite uplink is reestablished.
PROCEDURES
Speed and Compass Indication Slow
to Come ON INFORMATION CENTER
All Models Except GTS Information Center Self Test Function
When initially powering up the watercraft and driv When the START/STOP button is pressed mo
ing away, the speed and compass indications may mentarily and the vehicle powers up, all LCD
be slow to come on. This is normal as the GPS segments and indicator lights in the information
requires time to establish an uplink with the navi center will turn ON for 3 seconds (self test func
gation satellites (cold start). tion). This self test function allows the driver
If the watercraft was run long enough to display time to ensure that all indications are functioning
the compass and speed indications, shut down properly.
for a short period of time and then restarted (hot It also validates the information centers internal
start), the speed and compass indications should circuits, however, this does not validate proper op
not take more than 30 seconds to come on. eration of the individual external circuits and sen
If the speed and compass indications take more sors that provide inputs to the information center.
than 30 seconds to come on, test for the follow If a system fault is detected by the ECM, the ap
ing: plicable message and/or indicator light will be dis
- GPS fuse 4 in FB1 played, and a beep code may be heard.
- Battery voltage at pin 1 of the information cen- If the tether cord is not installed, the indications
ter in the information center will shut off a few sec
- Continuity of wire between information center onds after the self test function, but the electri
(pin 1) and contact A5 of FB1. cal system power stays on for approximately 3
minutes. Installing the tether cord on the engine
cut-off switch will turn the indications back on.
smr1011-032 429
NOTE: If the START/STOP button is pressed and

held without the tether cord installed. the informa
tion center will stay on as long as the START but
ton is held.
Multifunction Gauge Setup

/2: 3� AM
Clock Setting
r·t1c11t 1r·c:. r·
1.. r1r11 tfLJC� L..
1. Press the MODE button repeatedly until SET
TINGS is visible in the multifunction display.
s mo 201�2- 108
FUNCTION SELECTED: CHANGE CLOCK OFFSET
4. Press the UP or DOWN arrow button to adjust

the clock to the correct local time.
5. Press the SET button to save the setting and
return to the main display.
NOTE: The clock uses the GPS signal to main
tain the appropriate time referenced to Greenwich
Mean lime (GMT). When setting the clock, only
the hour digits may be changed. For the clock to
function, the GPS requires a good satellite uplink.
s m o 2CQS.()()2. 114_ -y
Units of Measurement and Language Setting
FUNCTION SELECTED: SETTINGS
1. Connect vehicle
to the latest applicable
2. Press the UP or DOWN arrow button repeat B.U.D.S. refer to the COMMUNI
version,
edly until CLOCK is visible. CATO
I N TOOLS AND B.UD.S. subsection.
2. Press the START/STOP button to energize the
electrical system.
NOTE: You will need to press the START button
every three minutes or the electrical system will
/2:3� shut off.

3. Select the Read Data button.
r·1 r1r·f ' 4. Choose the Setting tab at the top of the page.
L.. L.LJL. ' At the bottom LH side of the setting page, select
the Cluster tab.
smo2010-002 ·1 0 ?
FUNCTION SELECTED: CLOCK
3. Press the SET button to enter the function.

CHANGE CLOCK OFFSET message will be
displayed.
430 smr2011·032
......
MAINTENANCE REQUIRED message will scroll
�- �--
_ J�_·j� �J � � J fJ in the digital screen. These maintenance re
,1
- ...... 1-·-1-1,_1 ....,. 1 ,,..-1 minders must be cleared using B.U.D.S.
-
t2 I 1. Connect vehicle to the latest applicable

B.U.D.S. version, refer to the COMMUNI
CATION TOOLS AND 8.UD.S. subsection.
2. Press the START/STOP button to energize the
-·-
electrical system.
NOTE: You will need to press the START button
3
every three minutes or the electrical system will
!!i!i:tr· ��---'
smr20 11-032 -001_o
shut off.
TYPICAL 4. Choose the Vehicle tab at the top of the page.
1. Read Data
2. Setting tab 5. At the bottom RH side of the vehicle page
3. Cluster tab in the Last Service field, choose Reset Ser
vice/"Mai nt" or Reset Supercharger Mainte
In the Cluster Language field, choose the desired
nance button as applicable.
unit of language.
NOTE: If the supercharger maintenance was car
ried out before the reminder appeared in the in
1
formation center, the supercharger maintenance
�
Clui;te.r Language
2
Cluster Units
reminder must be reset in order to reset the su
percharger maintenance hour counter and prevent
tmpenat the reminder from appearing prematurely.
3
r.
Englsh r- Melnc
TYPICAL
1. Cluster Language field
2. Click on this arrow to expand list of available languages 2 ._ Pll'Pl"I' °"""''Qlll """'
In the Cluster Units field, choose the desired unit

.._
of measurement, Imperial or Metric.
....._
_.., -....
-- -
__.,. -
1 3 - -
ctster
� �·-� '�'
I
Clusler Lan� lJmts 4 )i --·
I
r. tmpenal "1lf2Q09.036.() , 1 _1
IEngish 3 r- Metric TYPICAL
1. Read Data
2. Vehicle tab
3. Reset Service/'Maint• button
4. Reset Supercharger Maintenance button
Information Center Pin-Out

TYPICAL
1. Cluster Units field
NOTE: Depending on watercraft model and in
stalled accessories, some multifunction gauge
Clearing the Maintenance Reminder connector pins may not be used.
Indicators
When the watercraft, engine or supercharger are
due for maintenance, the maintenance reminder
indicator will come on. and a scrolling MAIN
TENANCE REQUIRED or SUPERCHARGER
smr2011-032 431
INFORMATION CENTER PIN-OUT

PIN
FUNCTION
NO.
1 GPS back-up power
2 CAN HI
3 CAN LOW
4 Spare (buzzer external GNDJ
5 Spare (buzzer external GND)
6 Not used
Cruise switch signal Vdc •mr2009-042-002_•

7 TYPICAL
(SET switch for GTS models)
1. Gauge connector
2. Pull out lo unlock connector
8 Spare (digita l in pu t)
9 Not used 4. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to Vdc.
Cruise switch ground
10
(SET switch for GTS models) 5. Press the START button and install the tether
cord on the engine cut-off switch.
11 Gauge GND
6. Measure the information center input voltage
12 Gauge input Vdc power as per following table.
13 VTS switch si gna l (UP or DOWN)
INPUT VOLTAGE TEST AT GAUGE CONNECTOR
14 iS switch signal (UP or DOWN) PROBE VOLTAGE
15 VTS and iS switch common
Pin 12 (VIOLET) Pin 11 (BLACK)
Battery voltage
16 UP or DOWN arrow switch signal Pin 12 (VIOLET) Battery g round
17 MODE and SET switch signal
MODE/SET, UP/DOWN arrow switch

18
common
19 Fuel level sensor VDC signal
20 Fuel level sensor GND
Information Center Input Voltage Test

(at Gauge Connector)
GTS, GT! and WAKE Series
INPUT VOLTAGE TEST AT GAUGE CONNECTOR (PINS 12 TO
1. Remove the gauge bezel, refer to BODY sub 11)
section.
RXT, GTX and WAKE Pro Series

2. Remove the gauge support cover, refer to IN
FORMATION CENTER REMOVAL in this sub
section.
All Models
IN1)i(iJj Pull on connector with your hand as

you pull the connector lock out with the screw
driver. Do not twist t h e screwdriver.
432 smr2011·032
RXT and GTX Models Without iS or as

4. Reach into the front storage compartment and
remove the front air ventilation hoses.
smr200 9-03&003 c
INPUT VOLTAGE TEST AT GAUGE CONNECTOR (PIN 12 TO

BATTERY GROUND}
If battery voltage is measured as specified, re

place the information center. FRONT AIR VENTILATION HOSES
If battery voltage is measured to battery ground

All Models
but not to pin 11, carry out a CONTN I UITY TEST
OF GAUGE GROUND WIRE circuit from the 5. From under the steering support area, discon
gauge connector to the ground bus-bar contact in nect the 24-pin steering connector.
FB1 as described further in this subsection.
7. If battery voltage is not measured at the gauge
connector, carry out a INFORMATION CENTER
INPUT VOLTAGE TEST (AT STEERING CON
NECTOR).
Information Center Input Voltage Test

(at Steering Connector)
1. Open front storage compartment cover.
GTS, GT/ Series and Wake

2. Remove battery access panels.
S!>i2010.034-018.J>
TYPICAL - DISCONNECT 24-PIN STEERING CONNECTOR

Step 3: Pull locking collar down
6. Connect the DIAGNOSTIC HARNESS (P/N 529 036

188) to make an in-line connection between the
disconnected connectors.
smo201 1 -00.3-011_c
1. Battery access panels
RXT, GTX and WAKE Pro Series S 2903G1 8a
3. Remove front storage bin. 7. Press the START/STOP switch and install the
tether cord on the engine cut-off switch.
smao11-032 433
8. Carry out an input voltage test at the steering

connector (vehicle harness side) as per follow
ing table.
INFORMATION CENTER INPUT VOLTAGE

TEST (STEERING CONNECTOR)
TEST CONNECTOR ON
VOLTAGE
DIAGNOSTIC HARNESS
Pin 24 (VIOLET) Pin 1 (BLACK)

Battery voltage
Pin 24 (VIOLEn Battery ground
smo2011�1t_c
BATTERY AND FUSE A CCESS, FRONT STORAGE

COMPARTMENT
1. Buttery uccess panel
iS and aS Models
10. Open the boarding platform and remove the
RH storage bin.
RXT, GTX and Wake Pro Models

Without iS or aS
11. Remove the RH access panel on the boarding
platform.
sm'.lQt0--03&-003 b
TEST CONNECTOR OF DIAGNOSTIC HARNESS All Models
If battery voltage is read at steering connector (ve 12. Using the FLUKE 115 MULTIMETER (P/N 529 035
hicle harness side) as specified in previous table, 868) set to Vdc, measure battery voltage at the
but was not measured to pin 11 at the gauge con battery terminals.
nector (gauge ground wire), repair or replace the
BLACK ground wire between the gauge connec
tor and the steering connector.
If battery voltage is measured to battery ground
but not to pin 1, carry out a CONTINUITY TEST OF
GAUGE GROUND WIRE described further in this
subsection.
If no voltage is measured, carry out the following
steps.
GTS, GT/ and WAKE Models

9. Remove the battery access panel at the back of
the storage compartment.
smr20t 1.QJ2.00 3_a
TYPICAL • BATTERY VOLTAGE TEST
13. Remove fuse box cover.
434 smr2011-032
1 .. -
>12
1 -------11
snY20 11-027.002 _1
TYPICAL - CONTACT COORDINATES (FRONT VIEW FB1J

1. Fuse box cover
If battery voltage is measured at E8 but not at F8
14. Press the START/STOP button to energize {with fuse installed), replace the fuse.
electrical system and install the tether cord.
If battery voltage is measured at fuse contact E8,
15. Test for battery voltage between each of the refer to CONTINUITY TEST OF GAUGE POWER
terminals atop the GAUGE/OTAS/CAPS fuse WIRE in this subsection.
(12} and battery ground as per following table. If no voltage is measured at fuse contact E8,
VOLTAGE TEST AT FB1 slightly lift one corner of the long bus-bar (12
contacts long).
GAUGE FUSE TEST PROBES READING
16. Measure for battery Vdc between the bus-bar
Fuse pin ES Battery(-) Battery and battery ground.
numbers F8 post Vdc
VOLTAGE TEST AT LONG BUS-BAR

snv20i 1-027-00lJ>
VOLTAGE TEST AT FUSE CONTACTS

If battery voltage is measured at the long bus-bar,
repair or replace the wire jumper 08 to E8 (behind
fuse box).
Continuity Test of Gauge Power Wire

1. Remove tether cord from engine cut-off switch.
2. Disconnect gauge connector.
l�l•Jitij Pull connector lock out sideways.

smr2011-032 435
Subsection 06 {INFORMATION CENTER {GAUGE))
smr2009 ·042-002_o
TYPICAL •m12Q I 1-027-000_d

1. Gauge connector
FB1
2. Pull out lo unlock connector
1. Remove gauge fuse (F7J
3. Disconnect 24-pin steering connector. 6. Set FLUKE 115 MULTIMETER (P/N 529 035 868) to
n setting.
529035868
7. Test the information center power wire continu

TYPICAL - 24-PIN STEERING CONNECTOR DISCONNECT ity as per following table.
Step 2: Press in on release tab CONTINUITY TEST OF GAUGE POWER WIRE
TEST
4. Connect the DIAGNOSTIC HARNESS (P/N 529 036 CONNECTOR
GAUGE FUSE
188) to make an in-line connection between the ON READING
CONNECTOR BOX 1
disconnected connectors. DIAGNOSTIC
HARNESS
Pin 12 Pin 24 -
(VIOLET) !VIOLET)
Pin 12 Close to
-
F8
(VIOLET) on
Pin 24
-
F8
(VIOLED
5290361 86
5. Remove the gauge fuse in FB 1 .
436 smr201 l-032

Subsection 06 {INFORMATION CENTER {GAUGE))
10 1 9. Repair or replace wiring/connectors as re

quired.
Continuity Test of Gauge Ground Wire

1. Disconnect the 24-pin steering connector.
11 20
s m t2009-03&00
3 •
TYPICAL • 24-PIN STEERING CONNECTOR DISCONNECT

Step 1 · Pull our safety lock
Step 2: Press in on release cab
d 2. Connect the DIAGNOSTIC HARNESS (P/N 529 036

$11'1<2010-038·003 188) to make an in-line connection between the
TYPICAL • TEST CONNECTOR OF DIAGNOSTIC HARNESS disconnected connectors.
1 • )o 12
3. Remove the ground bus-bar in the fuse box.
smt2()11 -027-002.J
TYPICAL· CONTACT COORDINATES (FRONT VIEW FB1)
8. If an open circuit is measured, test the follow

ing:
CONTINUITY TEST OF GAUGE POWER WIRE

TEST CONNECTOR
FUSE BOX
ON DIAGNOSTIC READING
1
HARNESS
F8 to H9 -
.smr201 1 -027 003 .. o

H9toH11 -
Close to 0 n
TYPICAL
1. Ground bus bar
H11 Pin 24 (VIOLET)
5'11<201 HXl2 437

4. Set FLUKE 115 MULTIMETER (PIN 529 035 868) to

n selection and carry out a continuity test as
per following table. Refer to the WIRING DIA
GRAMfor circuit details.
TEST CONNECTOR OF DIAGNOSTIC HARNESS

S2903SS68
CONTINUITY TEST OF GAUGE GROUND WIRE

1 .. -
•12
MULTIMETER PROBES
TEST
CONNECTOR READING
GAUGE FUSE
ON
CONNECTOR BOX
DIAGNOSTIC
HARNESS
Pin 11 -
H7
(BLACK)
Close to
Pin 11
Pin 1 (BLACK) -
on
(BLACK)
-
Pin 1 (BLACK) H7
.s.mt201 l.Q27-002 ... a
TYPICAL - CONTACT COORDINATES (FRONT VIEW FB1J
5. Repair wiring and connectors as required.
Information Center Removal

GTS, GT! and WAKE Series
1 . Remove the bezel that covers the information
center and mirrors, refer to BODYsubsection.
11 20 2. Press in on the two retaining tabs at the top of

smr2009-036-003.e the information center.
438 smr2011-032
snv201 1 -032.()()4_s 1. LH side tab

RETAINING TABS AT TOP OF INFORMATION CENTER 2. Upper retaining tabs
3. Pull information center out of console. 5. Disconnect the gauge connector.
GTX, RTX and Wake Pro Series li![.Ji@j Pull connector lock out sideways.
2. Move the steering to its highest position, refer
to BODYsubsection.
3. Using a long flat screwdriver, insert the blade
between the lower loc king tabs {one each side)
of the gauge support cover, and carefully pry
the tabs outwards to release them from the
gauge support.
1. Gauge connector
2. Pull out to unlock
6. Insert a flat screwdriver between the upper

gauge locking tab and gauge support.
1. Long flat screwddver

2. Lockmg tab
3. Gauge support cover
4. Pull the bottom of the panel outwards to re

move it from the gauge support.
s mr200�6-0 1 0_a
GAUGE REMOVAL
1. Insert screwdriver here
7. Hold back of the gauge with one hand and care

fully compress the retaining tab to release the
information center from the gauge support.
smf.2011·032 439
Information Center Installation

Installation of the information center is the reverse
of the removal procedure. However, pay attention
to the following.
fltlAAIT--�
(PIN 293 550 004) to the gauge connector pins. 2 .......
-
2. Reconnect gauge connector and ensure proper

operation of gauge.
3. Insert and align the bottom of the gauge into - -
the support first, then push the top into the sup -
port and ensure it properly locks into the retain .......,..... ,� I

ing tab.
....
...,_ l:•Ntc r c;t l
GTX, RTX and Wake Pro Series
4. When reinstalling the gauge support cover, 1. Read Data button
2. Vehicle page tab
first insert the top of the cover into the sup 3. Tora/ Hours
4. Supercharger maimenance hours (approximate time left}
port. Then align the bottom of the cover with
the locking tabs on the outside of the gauge
4. Add the approximate time left to supercharger
support and push it in until it snaps back in
maintenance hours to the total hours to calcu
place.
late the hours at which the next supercharger
All Models maintenance is due.
NOTE: If you are installing a replacement informa Example: 104.08 + 95.52 = 200
tion center, refer to INFORMATION CENTER RE The next supercharger maintenance will be due at
PLACEMENTin this subsection. 200 hours (Total Hours in B.U.D.S. or hours indi
cated in the information center hour meter).
Information Center Replacement
5. Advise customer to bring the watercraft in for
Models With a Supercharger supercharger maintenance at the calculated
"Total Hours" even if the supercharger mainte
I01)itllj Before replacing the information nance advisory message did not come on in
center, it is very important to retrieve the the information center.
"approximate time left to Supercharger main
If the "approximate time left to Supercharger
tenance" in B.U.D.S. (on the Vehicle page), and
maintenance" hours cannot be retrieved in
to advise the customer when the watercraft
B.U.D.S. (because old cluster cannot be read
needs to be brought in for supercharger main
by B.U.D.S.), and the engine hours (Total Hours)
tenance.
at which the last supercharger maintenance was
The new information center will start counting the carried out are known, then add 100 to the last
"supercharger time to maintenance due hours• known Total Hours at which the last supercharger
from zero (0) as the hours are calculated and maintenance was carried out.
stored in the gauge cluster (old cluster), not in Once the supercharger maintenance has been
the ECM. The SUPERCHARGER MAINTENANCE carried out, the time left to supercharger main
REQUIRED indicators will then come on past the tenance must be reset using the Reset Super
real maintenance due hours. Indicated engine charger Maintenance function in B.U.D.S. This
hours in new gauge will be correct as they are ensures the following supercharger maintenance
calculated in the ECM. advisory message comes on as per normal in
1. Connect watercraft to the latest B.U.D.S. soft tervals. Refer to CLEARING MAINTENANCE
ware, refer to COMMUNICATION TOOLS AND REMINDER INDICATORS in this subsection.
B.UD.S. subsection.
3. In the Run Time field of the vehicle page, note
the accumulated Total Hours and the Super
charger maintenance (Approximate time left)
hours.
440 srnr2011·032
Subsection 06 (INFORMATION CENTER (GAUGE)�
....-
-
__,
-- -
�...... -
,...�.,,,...., 1 s mr2009 ·042-067_a
1 ----1•• ,._.....,.,,.____ J 1. LH side tab

2. Upper retaining latches
s m r2009-036-0 1L<
1. Reset Supercharger maintenance button 4. Disconnect the gauge connector.
All Models
NOTE: Replacement information centers are de
livered already programmed.
After the information center has been replaced,
connect the watercraft to the latest applicable
B.U.O.S. version and carry out any updates (if
required). Refer to COMMUNICATION TOOLS
Once the information center has been updated
(if required), select the applicable settings as de
scribed in SETTING LANGUAGE AND UNITS OF
MEASUREMENTin this subsection.
1. Gauge connector
GAUGE SUPPORT (RXT, GTX 2. Slide out gauge connector tab to unlock
AND WAKE PRO SERIES) 5. Using a small screwdriver, unlock back end of
Gauge Support Removal gauge support by pushing on tabs on each side
of the steering column.
1. Move steering to its upper most position.
2. Using a long flat screwdriver, unlatch both sides
of gauge support cover.
smr2009-042 .003_ a
1. Inner latches
6. Remove gauge support by pulling out its for

1. Long screwdriver ward tabs (one on each side), then pulling up
2. Locking tab
3. Gauge support cover
on the support.
3. Remove the cover.
smr2011-032 441
same is true for the UP/DOWN arrow switches,

iS switches and VTS switches on their respective
circuits.
If the command signal generated by the closure
of a switch concerns another module, a circuit
within the gauge will translate it to CAN protocol
and transmit it through the CAN bus. The applica
ble module will react to the command, carry out
the function, and transmit the result back through
the CAN bus.
s mr 200S'°'12.OO B_a The information center will use the signals from
1. Pull out locking tab the switches and the transmitted information
from the other modules, convert them to an in
Gauge Support Installation dication, and cancel the command signal it sent
out once the function has been carried out.
1. Reverse the removal procedure.
Command signals from the MODE and SET
2. Ensure proper operation of gauge once recon
switches are used by the information center only.
nected.
VTS and iS switch commands are translate and
MODE/SET AND UP/DOWN sent to the modules.
ARROW BUTIONS The UP/DOWN arrow switch commands are used

by the gauge for certain functions and settings.
Overview They will also be translated and sent out through
The MODE/SET and UP/DOWN arrow buttons the CAN bus to be used by the ECM for the
assembly contains a series of 4 diodes for the CRUISE, SKI mode and SLOW SPEED functions
MODE and SET switches, and another 4 diodes for increasing or decreasing speed when the
for the UP/DOWN arrow switches. Refer to functions are active, and by the iBR for iBR gate
WIRING DIAGRAM for simplified diagram of positioning in SLOW SPEED mode of operation.
switches. The UP/DOWN switches are also used for VTS
The center wire to the switches (pin C), is com trim on RXT 215, GTX 155, GTI SE 130 and 155,
mon to both sides of the switch assembly (some and WAKE models.
what like a ground wire). The other two wires NOTE: The voltages stated previously vary
(pins A and B), act as signal wires to the infor slightly depending on the actual voltage ap
mation center for each set of switches. They plied to the circuit and the current flow through
actually each form one branch of an electronic the diodes. When using a Fluke 115 multimeter
circuit within the information center. for testing in diode test mode, the voltage and
Each diode (in circuit) drops a nominal 0.6 Vdc current applied by the multimeter are lower than
when conducting electricity. If the circuit current in circuit. The quality of probe contact, the actual
passes through all four diodes (say MODE and probes and leads, and the precision of the meter
SET switches open), a drop of 2.4 Vdc would be calibration will all affect the results, which will
measured across the 4 the diodes (pin B to pin most likely be slightly lower than nominal values
C). This voltage drop of 2.4 Vdc measured at pin stated.
B tells the gauge the MODE and SET switches
are open. MODE/SET and UP/DOWN Arrow
Buttons Test Using 8.U.D.S.
If the MODE switch is pressed, 2 diodes are by
passed. The remaining two diodes in the circuit 1 . Connect the watercraft to the latest applicable
drop 1.2 Vdc (at pin Bl. B.U.D.S. version. Refer to COMMUNICATION
TOOLS AND 8. U. D.S.
If the SET switch is pressed, 1 diode is bypassed.
The remaining three diodes in the circuit drop 2. Press the START/STOP button to energize the
1.8 Vdc (at pin B). electrical system.
The gauge senses these voltages through pin 17 NOTE: You will need to press the START button
of the gauge connector, and interprets them as every three minutes or the electrical system will
signals that tell it which switch is activated. The shut off.
442 smr2011-032
3. Select the Read Data button. MODE/SET and UP/DOWN Switch Test
4. Choose the Monitoring tab at the top of the Using a Multimeter
page. GT! and WAKE Series
5. At the bottom LH side of the monitoring page, 1 . Remove the information center from the con
select the Cluster tab. sole, refer to INFORMATION CENTER RE
MOVAL (GT/ AND WAKE SERIES) in this sub
section.
RXT, GTX and WAKE PRO Sere

i s
2. Remove the gauge support cover, refer to IN
FORMATION CENTER REMOVAL (RXT, GTX
AND WAKE PRO SERIES) in this subsection.
All Models
3 ""''..�
-� M1Jill/j Pull connector lock out. Do not twist
--..
the screwdriver.
�
'JS!!:��-·
smr2009-036-00 1_•
1. Read Data button

2. Monitoring tab
3. Cluster tab
4. Switch inputs field
6. Press each of the MODE/SET and UP/DOWN

arrow buttons and look for the applicable indica
tor light to come on in the Switch inputs field
on lower RH side of the cluster page (Mode,
Set, Up or Down).
Switch inputs
1. Gauge connector
UP:@ Mode Button: €t
1
Down:• Set Button:@
868) to the diode test function.
Cruise: {f NOTE: It is important to set the multimeter
to the diode check function when testing the
MODE/SET and UP/DOWN arrow switches as it
contain diodes.
SWITCH INPUTS
1. MODE/SET and UP/DOWN arrow button indicator lg
i hts
If each of the gauge button indicator lights come

on when the applicable switch is pressed, the
problem may be related to the information center.
If one or all of the indicator lights does not come
on, refer to MODE/SET AND UP/DOWN ARROW
SWITCH TEST USING A MUL T/METER.
snv2011-032 443
UP/DOWN ARROW SWITCH TEST

SWITCH FLUKE GAUGE
VOLTAGE
POSITION 115 CONNECTOR
Red lead Pin 16 Approx.

UP Black lead Pin 18 1.1 Vdc
depressed Black lead Pin 16
OL
Red lead Pin 18

DOWN Black lead Pin 18 1.6 Vdc
depressed Black lead Pin 16
OL
Red lead Pin 18
NOTE: Remember that each diode should drop

approximately 0.6 Vdc when positively biassed,
and read as an OL (open circuit) when negatively
v mr? 000-0 2 0-005
biassed (leads reversed).
5. Test the MODE/SET and UP/DOWN arrow When measuring between pins 17 and 18, or 16
switches as per following tables. and 18, if an OL is obtained with both positive
MODE/SET SWITCH TEST and negative diode biassing, test the continuity of
each wire between the gauge and switch assem
SWITCH FLUKE GAUGE
VOLTAGE bly. If continuity is good, replace the switch as
sembly.
Red lead Pin 17 Approx. If any reading is significantly different than speci
Switch Black lead Pin 18 2 Vdc
fied, carry out the same test at the switch connec
released Black lead Pin 17 tor, refer to the wiring diagram. If you obtain the
OL
Red lead Pin 18 same results, replace the switch assembly.
Red lead Pin 17 Approx. If voltages measured on every switch are as spec
MODE Black lead Pin 18 1.1 Vdc ified (or very close to it), the switches and the
depressed wiring harness are good. The fault may be within
Black lead Pin 17
OL the gauge. Replace the gauge and carry out a
Red lead Pin 18
new MODE/SET AND UP/DOWN TEST USING
Black lead Pin 17 Approx. 8. UD.S. to ensure the problem is solved.
SET Red lead Pin 18 1.6 Vdc
depressed Black lead Pin 17 MODE/SET and UP/DOWN Switch
OL
Red lead Pin 18 Assembly Replacement (Except X
Package)
UP/DOWN ARROW SWITCH TEST
1 . Remove steering cover, refer to STEERING
SWITCH FLUKE GAUGE AND 0. T.A. S. subsection.
VOLTAGE
2. Disconnect connector from switch assembly.
Switch Black lead Pin 18 2 Vdc

released Black lead Pin 16
OL
Red lead Pin 18
444 smr2011-032
MODE/SET and UP/DOWN Switch

Assembly Replacement (X Package
only)
Switch Remova l
1 . Remove the 2 screws i n the front of the upper
handlebar housing.
smr'2009-036-013_a
TYPICAL GTX LIMITED iS ILLUSTRATED

-
1. MODE/SET and UP/DOWN switch connector
3. Remove switch assembly from support by lift

ing it off the support.
4. As applicable, ensure wiring from cruise switch
is properly inserted in slot provided before in
stalling MODE/SET and UP/DOWN arrow
switch assembly.
sm 12010-031-001_a
Step 1: Remove these two screws
2. Remove the screw at back of the handlebar.
smr2009-0'36-01 4_a
TYPICAL GTX LIMITED iS ILLUSTRATED

-
1. Cruise switch
2. Wiring in slot provided in support s mr2010--03 1· 002 .a
3. MODE/SET and UP/DOWN arrow switch connector
(P/N 293 550 004) on switch contact pins.
Ol'1il1Jj Do not try to pull the cover off the
housing at this time or damage to the cover will
6. Install connector on new switch assembly. occur.
7. Insert switch assembly in switch support.
3. Take hold of the housing cover to prevent it
8. Install steering cover, refer to STEERING AND from falling off the handlebar when unlocking
0. TA.S. the upper housing in the following step.
4. Using a small screwdriver, unlock the tab that
retains the upper housing and pull the upper
housing off.
Ol.Ji@Jj As you remove the upper housing,

hold on to the housing cover to prevent it from
falling off the handlebar.
smr2011·032 445
Switch Installation
dure however, pay attention to the f ollowing.
1. I nstall connector on switch assembly.
2. Insert switch assembly in handlebar housing.
3. Ensure proper wire routing.
4. Ensure proper position i n g of corrugated con
duit.
1mt'l01G-031.00 3 _ o
Step 3: Hold on to this housing cover

smao1 O-OIG-OCI 1 Jl
Step 1: Install connector

Step 2: Insert switch in handlebar housing
Step 3: Ensure proper wire routing
Step 4: Ensure proper positioning of corrugated conduit
5. Ens ure engagement of housing cover retaining

tabs.
6. Ensure engagement of upper housing locking
tabs.
omr201 0-031-004 _e
Step 5: Remove housing cover
6. Remove switch from handlebar housing.

7. Remove connector from switch.
srnr20 10-031-0 IO_c
Step 5: Ensure engagement of housing cover retaining tabs

S'll r20 10-0I0-001 _c Step 6: Ensure engagement of upper housing locking tabs
Srep 6: Remove switch

Step 7: Remove connector 7. Position the upper housing on the handlebar
housing.
8. E nsure proper engagement of the upper hous
ing and cover tabs.
446 smr2011-032
9. Install the three retaining screws for the upper DEPTH SOUNDER
housing and tighten them as specified.
Depth Sounder Troubleshooting
UPPER SWITCH HOUSING SCREW TORQUE
DEPTH SOUNDER TROUBLESHOOTING
POSSIBLE
SYMPTOM REMEDY
10. Connect watercraft to the latest applicable CAUSE
B.U.D.S. version, refer to COMMUNICATION Depth sounder Properly connect
TOOLS AND B.U.D.S. subsection. not connected. depth sounder.
11 . Ensure there are no fault codes, refer to DIAG Make sure
NOSTIC AND FAULT CODES subsection. depth sounder
is proper ly
12. Ensure proper operation of throttle lever and installed in
switch assembly. Depth sounder
battery holder
not proper ly
base. There
installed.
WATER TEMPERATURE SENSOR Nothing is
must be no air
gap between
The water temperature sensor is located within displayed in
hull and silicone
the information pad(s).
the iBR module that is part of the iBR actuator. It
center
cannot be tested or replaced separately. 12 Vdc wire or
Check fuse 3 in
ground wire to
Water from the jet pump passes through the iBR FB1 and wiring
depth sounder
actuator where the sensor measures its tempera harnesses.
open.
ture, generating a signal that is interpreted by the
Check
iBR module. The iBR module then sends the in
Problem with WHITE/BLACK
formation through the can-bus to the information
communication and WHITE/RED
center that translates it into a temperature indica link wires. wires to CAN
tion. bus-bars in FB 1 .
If the temperature sensor is defective, the tem Launch
perature indication will not be displayed and a Watercraft is not watercraft in
WATER TEMP SENSOR DEFECTIVE message in water. water and
will scroll in the multifunction display. recheck.
There is air
A lake water temperature sensor fault code
between
should be generated if the sensor is defective. silicone pad and Remove depth
- - - - (ft or m)
Refer to DIAGNOSTIC AND FAULT CODES is displayed depth sounder s ounde r.
If the lake water temp sensor is defective, replace or between Replace silicone
the iBR actuator. depth s ounde r pad.
and battery
holder base.
Depth sounder Try a new depth
is defective. sounder.
smr2011·032 447
smr'.2011-02 7-003_1
I. Depth sounder 3A fuse (F81)

sm2011-032-003..o
TYPICAL
Depth Sounder Removal 1. Diagnostic connector
4. Remove the electrical component support from
the battery holder. refer to CHARGING SYS
TEM
5. Remove the battery (with holder) from the wa
tercraft, refer to CHARGING SYSTEM.
A WARNING
Always disconnect the battery cables exactly
in the specified order, BLACK(-) battery cable
fir st then the RED (+) cable last.
6. Unlock the depth sounder clocking tabs from

the battery holder base and pull the depth
sounder out from the base.
1. Re·boardmg platform
2. Remove the starboard (RH) storage bin.
1. Locking tabs
2. Batiery holder base
1. Starboard storage bin 7. Disconnect the depth sounder connector from

the wiring harness.
3. Disconnect the diagnostic connector from its
holder.
Depth Sounder Inspection
Ensure the silicone pad is in good condition.
448 smr2011-032
NOTE: There must not be any air trapped be

tween the bottom of the depth sounder and the
bilge. Otherwise, the sounder will not function
correctly.
If the silicone pad is damaged, replace it.
Depth Sounder Silicone Pad

Replacement
1 . Place the flat side of the depth sounder on a
level surface.
2. Remove the old silicone pad from the bottom
of the depth sounder.
1. Depth sounder connector
3. Clean the concave surface of depth sound er. 2. Wiring harness
4. Remove both protectors from the silicone pad. 4. After installati on:
5. Apply silicone pad on depth sounder. 4.1 Try pulling the sounder out to ensure it
is prope rly locked in the ba ttery support
lill'tJlliJj
Make sure do not trap air between
base.
silicone pad and depth sounder. Otherwise,
the device wil l not work .
4.2 Try pushing on depth sounder. You must
feel a resistance (no air gap).
NOTE: An air gap can be eliminated by adding an
additional silicone pad.
5. Install the battery and electrical component
support in the reverse order of removal, refer
to CHARGING SYSTEM
6. Install the diagnostic connector in its holder.
7. Carry out the following procedure : TESTING
DEPTH SOUNDER OPERATION
Testing Depth Sounder Operation

1. Press START/STOP button.
ooi2009-002 0 1 3 o 2. Install the tether cord on the engine cut-off
1. Silicone pad switch.
2. Depth sounder
3. Check information center to confirm depth
Depth Sounder Installation sounder operation The depth sounder icon
.
is visible in the information center when the

1. Insert the depth sounder in the battery holder
depth sounder is detected.
base while paying attention to the position of
the wiring on the sounder with the groove in the
battery holder base.
2. Press firmly on the depth sounder until both
locking tabs are locked into the base.
3. Connect the sounder connector to the wiring
harness and route the wiring in the groove pro
vided in the battery ho ld er base.
osl2009 OOH11U
1. Deprh sounder icon
4. Reinstall all other removed parts.
smr201 l-032 449

5. Launch watercraft in water and check depth

sounder operation. Refer to INFORMATION
CENTER (RXT, GTX AND WAKE PRO SERIES}
for instructions on how to select the DEPTH
indication in numerical display
.
A WARNING
Never use the depth gauge as a warning de
vice to ride in shallow water. Use it as a nav
igation guide only. Not to be used to get pre
cise navigation data.
450 smr201 l-032

Section 06 STEERING AND PROPULSION
Subsection 01 (STEERING AND O.T.A.S.)
STEERING AND 0. T.A.S.

SERVICE TOOLS
D.E.S.S. POST REMOVER ........................................................... 529 . 035 943 ......................................... 461
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ......................................... 470
STEERING CABLE TOOL .............................................................. 295 000 145 ......................................... 465
SERVICE PRODUCTS
LOCTITE 243 (BLUE) ..................................................................... 293 800 060 ......................................... 459
LOCTITE 567 (PIPE SEALANT) ........................................ ............. 293 800 013 ......................................... 465
XPS SYNTHETIC GREASE............................................................. 293 550 010 ......................................... 463
smr2011-033 451
Subsection 01 (STEERING AND 0.T.A.S.)
STEERING COLUMN AND CABLE

GTS, GT/ and WAKE 155
XPS
synthetic
grease
&
Loctite 243&
.
--:>o
--"--
'"·
7 N•m
(62 lbfoin) /--..·,--.-..,
·
3.5 N•m � !
(31 lbfoinl I
I
I
I
·-. 1
·-- - �·'I
-
.
.... .. .. ...
..
-�-
"Q,
� .;
Loctite 5150
&(silicone sealant)
s m '201 l .O J3.-00l _a
452 smr2011-033
STEERING COLUMN
GTX, GTX iS RXT, RXT iS and Wake Pro
'
I
'
I
I
I
'
7 N•m !
(62 lbfoin) -......
6 N·m
(53 lbfoin) /'J
f)
, ,
I
/ 0.7 N•m
(6 lbf·in)
-�·�,
'
'
""'- '
�
'--.!
�
XPS
synthetic
grease
7N•m �/
(62 lbf·in)
0
�
Loctite
243
$mr2011-033-00 2 _a
smr2011-033 453
STEERING COLUMN
RXT-X, RXT-X as
0.7 N•m
(6 lbf•in)
XPS
synthetic I
:
�
gre
2 N•m
(18 lbf•in)
�/
/,·
!>
�
XPS
synthetic
<�W.i'::1
grease
�
&.._-___,,.
2 N•m
(18 lbf•in)
&
Loctite
243
smr2011.on<:I03 I
454 smr2011-033
Subsection 01 {STEERING AND O.T.A.S.)
STEERING COLUMN SUPPORT AND CABLE

GTX, RXT and Wake Pro Series
(62 !bf.in)
7N•m�\
(62 lbf.in)
-�9N•m
(80 lbfein)
'� "'"'
iS only
7 N•m
(62 !bf.in)
-� --------
I
��
<\),��,
�
----�
--- -
6 N•m
Loctite 5150
(silicone sealant)
7 N•m
(62 lbfoin) (53 lbfoin) �
2.5 N•m Loctite 567
(22 lbfoin) (pipe sealant)
smr2011-033 455
GENERAL ADJUSTMENT
and seNice products as in the exploded views. STEERING ALIGNMENT
Clean threads before applying a threadlocker. Re Install two bungee cords to maintain handlebar in
fer to SELF-LOCKING FASTENERS and LOCTITE position during the procedure.
Models with 1BR
complete procedure.
Raise the iBR gate by activating the iBR override
A WARNING function. Refer to 1BR AND VTSsubsection.
Torque wrench tightening specifications All Models Except RXT-X

Position steering so that the edge of the steering
Locking devices (e.g.: locking tabs, elastic
column cover and the edge of the gauge support
stop nuts, self-locking fasteners, cotter pins,
(or console) are flush.

dards.
SYSTEM DESCRIPTION (0.T.A.S.)

The O.T.A.S. (Off-Throttle Assisted Steering) pro
vides additional maneuverability in off-throttle sit
uations.
The system uses a pair of magnets attached to the
steering column and a Hall effect switch attached 1. Steering column cover
2. Console or gauge support
to the steering column support. 3 Flush edges
When activated by a magnet. the O.T.A.S. switch

RXT-X Models
sends a signal to the ECM.
Align the center of the rear extension block lower
The ECM activates a pre-programmed RPM set
tab with the center of the rib located in front of the
ting when the driver initiates a full turn after relea
steering tilt release handle.
sing throttle lever. The engine RPM is controlled
by the Intelligent Throttle Control (iTC).
The O.T.A.S. system is activated in the following
conditions:
- The engine speed must be above 4000 RPM for
at least 1.5 second (approximately).
- The throttle lever must be released completely.
;-- The steering must be fully turned within approx-
imately 4 seconds after throttle release.
The O.T.A.S. will stay activated for a random
period of time as long as the 0.T.A.S. switch is
closed.
O.T.A.S. will be deactivated if:
1. Lower tab of the rear extension block
- The throttle is reapplied, or 2. Rib
3. Steering tilt release handle
- The steering is turned sufficiently to open the
O.T.A.S. switch for more than one second.
All Models
Check jet pump nozzle alignment by placing a
straight edge on the nozzle outer end. Measure
the distance on each side of the straight edge.
456 smr2011·033
To adjust. carry out the following steps:

1 . Loosen the screws (2 each side) that secure the
handlebar extension tubes.
smrWll-003-0 1 0_
•
VIEW FROM UNDERNEATH THE HULL

1. Straight edge
2. Nozzle
A. Port measure
8. Starboard measure
When properly aligned, measures A and 8 are

equal.
smo2010-002 -006_
a
If necessary, adjust cable at steering column as EXTENSION TUBE RETAINING SCREWS (4)
follows:
2. Pull out on the handlebar grips to adjust handle-
Open storage compartment cover and remove
bar width.
basket or access cover as applicable.
NOTE: The handlebar width factory set position
Loosen steering cable clamp bolts.
is fully closed. The handlebar width may be in
Turn adjusting nut as required. creased by 2.5 cm (1 in) each side.
3. Rotate the handlebar grips to the desired posi-
tion of the controls.
NOTE: Rotating the handlebar grips rotates the
handlebar extension tubes and controls. The ex
tension tubes may be rotated plus or minus 18°
from the factory set position.
smr200!)-042.007_a
1. Steering column support

2. Steering cable clamp bolts
3. Steering cable clamp
4. Steering cable adjusting nut
lighten steering cable clamp bolts to 9 N•m

(80 lbf•in).
Wl1JilfJj Verify when the handlebar is turned
com pl etely to the left or right side, that there is
no interference with jet pump or reverse parts.
mo20
s 10-002 -006_1
ERGONOMIC ADJUSTMENTS
ERGONOMIC ADJUSTMENTS 1
Step 1: Adust handlebar width
Step 2: Adjusr
angular position of controls
RXT-X Models
The handlebar width and angular position of the 4. Using the index marks and scales on each side
of the handlebar, ensure identical width and
controls may be adjusted to driver preference by
extending and rotating the handlebar extension angular position of both handlebar extension
tubes. tubes.
smr2011-033 457
If 0.T.A.S. works when handlebar is turned on one

side only, check magnets condition, if magnets
and switch are securely installed.
To confirm is O.T.A.S. is functional, carry out
0. T.A.S. OPERATION in this subsection. If it is
not possible, carry out 0. T.A.S. SWITCH TEST
WITH 8. U. D.S.
PROCEDURES
HANDLEBAR GRIP
smo2010-002-00S_b
Handlebar Grip Removal
1. Width index
2. Width scale To remove handlebar grip, remove the cap, then
3. Angular position index
4. Angular position scale
the retaining screw.
5. Torque handlebar retaining screws to 9 N•m

(80 lbf•in).
INSPECTION
0.T.A.S. OPERATION
This test is to be performed with the watercraft in
the water (test tank or on a trailer).
INoi@j If the test is performed on a trailer,

ensure no debris or rocks can damage the jet smr2009-037·006_a
pump. TYPICAL- GTX LTD iS SHOWN

1. Handlebar grip
2. Handlebar grip screw
Start engine.
Raise engine speed higher than 4000 RPM for Pull out handlebar grip and remove grip insert
more than 1 second. from handlebar.
Release throttle while steering is in the straight
ahead position.
Within 1 to 3 seconds, turn handlebar all the way
to one side.
The O.T.A.S. should come on by keeping or
increasing engine speed to approximately
3000 RPM.
Then, engine speed will gradually decrease to idle
speed within approximately 5 seconds.
Repeat test for the other side. smr2009-037-007_a
If the engine does not behave as described, carry TYPICAL- GTX LTD iS SHOWN
1. Grip insert
out the 0. T.A.S. SWITCH TEST WITH B.U.D.S.
NOTE: Verify grip insert for damage.
TROUBLESHOOTING
Handlebar Grip Installation
DIAGNOSTIC TIPS When installing the grip insert in the handlebar,
ensure that it is properly inserted in the slot at the
Check fault codes as a first troubleshooting step.
end of the handlebar tubing.
458 smr2011-033
smr2009·037-0IO_o
&mr'2000·037-008_a
RH SIDE SHOWN
TYPICAL-GTX LTD iS SHOWN 1. Cover slots
1. Grip insert
2. Twist screwdriver to open cover.

Install handlebar grip on handlebar matching it to
the notch in the handlebar. 3. Remove the switch cover.
Apply LOCTITE 243 (BLUE) (P/N 293 800 060} on RXT-X Models
screw threads (or use new self-locking screws).
1 . Remove the 2 screws at front of the upper han
Install flat washer and handlebar grip screw. dlebar housing.
IA![•JmJj Ensure to install flat washer other

wise screw will damage the grip end.
Torque handlebar grip screw to 7 N•m (62 lbf•in).

Install cap.
cm12010.031-001_o
•mr'2009 037-009_0 Step 1: Remove these two screws

TYPICAL - GTX LTD iS SHOWN
1. Grip insert 2. Remove the screw at rear of the handlebar.
2. Gflp
3. Flat washer
4. Screw
5. Cap
HANDLEBAR SWITCH COVER

(LH OR RH)
Handlebar Switch Cover Removal (LH
or RH)
All Models Except RXT-X
1. Inse rt the end of a small screwdriver in one of
cover slots.
..,, . 2010.031-002
_•
smt2011·033 459
INoi@j Do not try to pull the cover off the 2. Insert the front tab and tilt the cover over the
housing at this time. switches (applicable models).
3. Hold the housing cover to prevent it from falling

off the handlebar when unlocking the upper
housing in the following step.
4. Using a small screwdriver, unlock the tab retain
ing the upper housing and pull the upper hous
ing off.
1,t{1)i@j As you remove the upper housing,

hold the housing cover to prevent it from
falling off the handlebar.
smr2009-037-012_ a
RH SIDE SHOWN
1. Front tab
3. Press on the cover to lock it.
RXT-X Models
1. Route wires to avoid pinching them.
2. Position the housing cover onto the handlebar
housing.
smr2010-031-003_a
3. Ensure positioning of corrugated conduit
Step 3: Hold on to this housing cover
$mt2010-031-009._b
Step 1: Ensure wiring is properly routed

Step 2: Install housing cover
smr20 10-ll3Hl04_a
Step 5: Remove housing cover 4. Position the upper housing on the handlebar
housing.
Handlebar Switch Cover Installation
5. Ensure proper engagement of the upper hous
(LH or RH)
ing and cover tabs.
1. Install the round rubber button in the cover.
460 smr2011-033
FRONT STEERING EXTENSION BLOCK
smr201 0-031-010_t1
Step 4: Ensure engagement of housing cover retaining tabs

Step 5: Ensure engagement of upper housing locking tabs
6. Install the three retaining screws for the upper

housing and torque them to 2 N•m (18 lbf•in).
7. Ensure proper operation of throttle lever.
EXTENSION BLOCKS
(RXT-X MODELS)
Extension Block Removal sbg20 I 0002-002.
a
REAR STEERING EXTENSION BLOCK

1. Remove all socket screws (Bx) that retain the
front and the rear extension blocks.
STEERING COVER
2. Separate both extension blocks.
3. Using the D.E.S.S. POST REMOVER (P/N 529
Steering Cover Removal
035 943), remove the engine cut-off switch All Models Except RXT-X
(D.E.S.S. post) retaining nut.
1. Using the D.E.S.S. POST REMOVER (P/N 529
035 943), remove the engine cut-off switch
(D.E.S.S. post) retaining nut.
529035943
Extension Block Installation

629035943
Tighten screws to 9 N•m (80 lbf•in) using the fol
lowing sequence.
smr2011-033 461
3.3 Release the five retaining tabs at the rear

of steering cover.
smr2009-037-01 5JI
2. Remove both handlebar switch covers. See s m r2009-037-01 6_6
procedure in this subsection. 1. Retaining tabs
3. Unlock steering cover from steering.

3.4 Remove the foam inside the steering
3.1 Insert a small tool, such as an Allen key, cover.
into a steering cover hole. Press the tool
3.5 Remove the engine cut-off switch from
against the retaining tab to unlock it. Re
the steering cover.
peat for the other side.
RXT-X Models
l!ll.JmJ#ll The toolmust be inserted per
fectly straight to avoid breaking the tab 1. Separate the extension blocks. See procedure
holder. in this subsection.
2. Remove screws securing the steering cover to
the front extension block.
Steering Cover Installation

1 . Install the engine cut-off switch.
1.1 Index the alignment pin of the engine cut
off switch with the notch of steering cover.
s mr2 009·037-01 3 _•
1. Allen key
3.2 In both cavities at the back of steering

cover, release both inner retaining tabs
using a long screwdriver.
1. Sreering cover norch
1.2 Press the engine cut-off switch until retain

ing tab is positioned correctly.
s m r2001H137-01 4 _o
1. Rear cavity
462 smr2011-003
5.4 Push both side of the cover to lock it with

the steering column.
5.5 Install switch covers.
RXT-X Models
cedure.
THROTTLE AND iBR LEVERS

NOTE: The following procedure demonstrates
1 Retaining tab the replacement of the throttle lever but the same
procedure will be used for the iBR lever.
2. Install the engine cut-off switch nut and tighten
it to 2N•m (181bf•in). Lever Replacement
3. Install the foam. 1. Remove HANDLEBAR SWITCH COVER, see
4. Place the engine cut-off switch harness in foam procedure in this subsection.
slot. 2. Remove the screw and washer securing throt
5. Install the steering cover. tle lever.
5.1 Check if all harnesses are route properly. 3. Remove throttle lever and its bushings.
All harness must be inserted in its slot.
smr2009-037-031_a
$0'l r 2009-037 - 019_a
7. Retaining screw
1. Harness slots
2. Washer
3. Bushings
5.2 Clip the top of the cover. 4. Throttle lever
5.3 Stretch the bottom of the steering cover 4. Clean throttle lever area from dust or any de
until the cover edge passes over the inner posits.
ribs.
5. Apply XPS SYNTHETIC GREASE (P/N 293 550 010)
on bushings and on the outer surface of the re
turn tab.
2009·037·020_ <"l
.Sl'IV
STEERING REMOVED FOR CLARITY PURPOSE

7. Inner ribs
smr2011-033 463
All Models
1. Detach steering cable from steering column.
1.1 Remove the bolt securing the ball joint to
the steering column arm.
omr2009-0J7-03�
1. Apply grease here
6. Install the lever.

6.1 Install both bushings in lever hole.
6.2 Insert sensor lever end into throttle lever
fork.
6.3 Position the return tab against the handle
bar. 1. Steering cable ball joint
2. Steering column arm
6.4 Secure the lever with washer and screw.
1.2 Remove the steering cable clamp bolts.
6.5 lighten the lever screw to 0.7 N•m
(6 lbf•in). 1.3 Unhook steering cable clamp.
7. Reinstall all removed parts using appropriate

procedures.
STEERING CABLE
Steering Cable Replacement
GTS, GT/ and Wake 155
Remove seat.
Open the front storage compartment cover.
sm 12009-0<!2-007_o
Remove access cover. TYPICAL

1. Steerni g column
Remove the gauge trim. Refer to BODYsubsec 2. Steenng column clamp bolts
3. Steering column clamp
tion.
4. Steering cable ad1ustmg nur
RXT GTX and Wake Pro

1.4 Place steering in its lower position (models
Open the seat and the front storage compartment with tilt steering).
cover.
1.5 Free steering cable from the clamp.
Remove the storage basket.
1. At rear of the watercraft, disconnect ball joint
Remove the gauge support. Refer to GAUGEsub from jet pump nozzle arm.
section.
RXT aS, RXT iS and GTX iS

Remove the moving deck. Refer to BODY sub
section.
Remove the adjusting nut from steering cable
end.
464 smr2011-033
4. Remove steering cable nut, half rings and

0-ring.
1. Steering cable bolr s mr20 09-037 ·023_a

2. Nozzle arm
TYPICAL - PUMP AND iBR SYSTEM REMOVED FOR CLARITY
PURPOSE ONLY
2. Remove ball joint and jam nut from cable. 1. Steering cable
2. Steering cable nut
3. Half rings
4. 0-ring
5. Remove the adjusting nut from the new steer

ing cable.
6. From inside the hull, pull the aft end of the cable
through the hull fitting.
7. Using a piece of hose, attach one end of the
new cable to the opposite end old cable to
gether.
8. Route the new cable in the hull by slowly pulling
s m r2009.00 7-02 1 _ a
the old one, then separate cable ends.
1. Steering cable 9. From inside of the hull, pass the aft end of the
2. Jam nut
3. Ball joint cable through the hull fitting.
10. Secure the steering cable to the hull fitting.
3. Using the STEERING CABLE TOOL (P/N 295 000
145), loosen steering cable nut. 10.1 Install 0-ring and half rings.
10.2 Apply LOCTITE 567 (PIPE SEALANT)
H-lj (P/N 293 800 013) on nut threads.

10.3 Secure steering cable with the steering
cable nut.
10.4 lighten nut to 6 N•m (53 lbf•in).
11. Install the ball joint on the end of the steering
cable.
11 .1 The threaded portion of steering cable in
serts into ball joint should have between
9 mm ± 1 mm (.354 in ± .039 in}.
smr2011-033·
011_ a
7. Steering cable nut

2. Steering cable s mr2006-03 t-006_&
A. 9mm ± 1 mm (354 in± .039in)
smr2011 ·0::0 465

11.2 Tighten jam nut to 2.5 N•m (22 lbf•in).

11.3 Position the steering cable ball joint to the
nozzle as per following illustration.
s m r'2 00 S-042-00 l_a
1. Steering column
2. Steerni g column clamp bolts
3. Attach steering cable to steering column arm.
1mr2009-03
7-025 _a
1. Ball joim bolt

2. Ball joint under nozzle arm
3. Washer
4. Nut
11.4 Tighten ball joint nut to 7 N•m (62 lbf•in).
RXT iS and GTX iS

1 . Check if the cable bellows is properly posi
tioned all around steering cable.
smr2 009-00 2·
001
0
1. Steering cable ball joint

4. Tighten retaining bolt to 5 N•m (44 lbf•in).

5. Carry out STEERING ALIGNMENT See proce
6. Install other removed parts.
1 Check fit
STEERING COLUMN
2. Reinstall the moving deck. Refer to BODYsub Steering Column Removal

section for complete procedure. GTS, GT/ and Wake 155
All Models Open the front storage cover.
1. Insert the steering cable through the bottom Remove the access cover.
end of the steering column.
Remove gauge trim, refer to BODY subsection.
2. Install steering cable clamp and its bolts. Do
not tighten bolts yet.
GTX, RXT and Wake Pro
Open the front storage cover and remove the stor
age basket.
Remove the gauge support. Refer to GAUGE sub
section.
1. Disconnect both connectors under the steering
column.
466 smr2011·033
• rn r 20 1 0-046-015_& 5ml2011-03J--0 05_a
1. Steering connector MODELS WITH TILT STEERING

2. 0. TA.S. connector 1. Stee rn
i g column support
2. Upper bu shin g
3. Lower bushing
2. Remove both screws securing the steering col
umn.
1. Steering column screws

•mi2011-0 33-006_8
MODELS WITHOUT TILT STEERING

3. Pull steering column out of its support. Ensure 1. Steering column support
to not damage wiring harness connectors and 2. Upper bushing
3. Lower bushing
O.T.A.S. magnets.
Check wear sleeve behind the steering column
Steering Column Inspection arm.
Check steering column for:
- Cracks
- Stress marks
- Sings of wear.
Check steering column support bushings.
smr20C9-037-029_ a
7. Wear sleeve
3. Steering column support
Replace any damaged or worn parts.
smr201 l-033 467

(STEERING AND O.T.A.S.)
Subsection 01
Steering Column Installation

The installation is essentially the reverse of the re
moval procedure. However, pay attention to the
following.
Carefully, drive steering column through steering
column support. Ensure not to hit the O.T.A.S.
magnet during steering column installation.
lighten steering column screws to 6 N•m
(53 lbf•in).
Reinstall all removed parts using appropriate pro
cedure.
STEERING COLUMN SUPPORT sm1

W1G-0<6-0 1 II.>
1. Steering connector
Steering Column Support Removal 2. 0. T.A.S. connector
(GTS, GTI and Wake 155)
4. Remove the gauge support. Refer to GAUGE
1. Remove steering column, see procedure in this
subsection.
subsection.
5. On both sides, remove both pivot bushings
2. Remove console, refer to BODY subsection.
(steering column support and steering adjust
3. Remove steering column support retaining ment handle).
screws.
1. Pivot bushmg of steering column support

2. Pivot bushing of steering adjustment handle
smr.20 11-033-007 _• NOTE: If pivot bushings retaining steering column

1. Steering column support are hard to remove, remove the retaining screw
2. Retaining screws
from the center hole and tighten it into the offset
hole. lighten screw until the pivot bushing comes
Steering Column Support Removal
out of steering column support.
(RXT, GTX and Wake Pro)
1. Refer to BODYand remove the following parts:
- Storage compartment cover
- Front grille (iS models)
- Body covers.
2. Remove storage basket.
3. Disconnect both connectors under the steering
column.
smt2009.o37-0d0_a
7. Center hole
2. Offset hole
468 sm12011-033
6. Remove steering column support and steering 0.T.A.S. Switch Input Voltage Test
adjustment handle from vehicle. Access the O.T.A.S. connector as follows:
7. Remove STEERING COLUMNfrom its support.
GT!, GTS and Wake 155
See the procedure in this subsection.
Steering Column Support Installation cess panel.
dure.
STEERING TILT RELEASE

HANDLE
Steering Tilt Release Handle
Replacement
Use the same procedure as for STEERING COL
UMN SUPPORT.
0.T.A.S. SWITCH
O.T.A.S. Switch Test with B.U.D.S.
Connect watercraft to B.U.D.S. Referto COMMU smo201 1 ·003·01 1_c
NICATION TOOLS AND B.UD.S. subsection. 1. Access panel
Select the Monitoring and iBR tabs. RXT, GTX and Wake Pro
Briefly press the START/STOP button to wake up Open front storage compartment cover.
the ECM.
Remove front storage bin.
Install the tether cord on the engine cut-off
Disconnect the top air ventilation hoses.
switch.
While monitoring the O.T.A.S. indicator in
B.U.D.S.. completely turn steering in one di
rection and keep it in this position.
The O.T.A.S. indicator should turn on when han
dlebar reaches the stopper.
' ·-! "" 1-1-1
RXT iS, RXT as and GTX iS

1 Open front storage compartment cover.
�-.. (J�-----
.1'.f ....
-
Remove front storage bin .

.:::: = =
� -----------
' =- - · -·-
- - - ------ -
For easier access. rise the moving deck using the
smr2009·037·004_a
iS "up" button.
MONITORING AND iBR TABS
1. 0. T.A.S. indicator
All Models
Repeat test for the other side. Disconnect the O.T.A.S. connector (keep the
If O.T.A.S. indicator does not turn on, carry out the 24-pin steering harness connected.
0. TA.S. SWITCH INPUT VOLTAGE TEST
smr2011·033 469
Subsection 01 {STEERING AND O.T.A.S.)
529036188
Press the START/STOP button to activate the

electrical system.
Using the FLUKE 115 MULTIMETER (P/N 529 035
868), check ground circuit as follows.
1mr2 01().()46.() 1 5J VO LTAGE

TEST PROBES
1. Steering connector (VDC)
2. 0. T.A.S. connector
PIN A PIN B
Connect the DIAGNOSTIC HARNESS (P/N 529 036 (3-pin (3-pin Battery voltage
188) in-line between the disconnected O.T.A.S. connector) connector)
connectors.
If voltage is not as specified, check wiring and
connectors.
If voltage is as specified, carry out the 0. T.A.S.
SWITCH SIGNAL TEST.
0.T.A.S. Switch Signal Test

Install the DIAGNOSTIC HARNESS (P/N 529 036 188)
as described in the 0. T.A.S. SWITCH INPUT VOLT
520036188 AGE TEST.

electrical system.
868), measure voltage as follows.
VOLTAGE
TEST PROBES
(VDC)
PIN A
Battery 529036188
(3-pin Battery voltage
negative post
connector) Press the START/STOP button to activate the
electrical system.
If voltage is not as specified, check wiring and
connectors. Using the FLUKE 115 MULTIMETER (PIN 529 035
868), check switch signal as follows.
If voltage is as specified, carry out the 0. T.A.S.
SWITCH GROUND TEST. HANDLEBAR
TEST PROBES VOLTAGE
POSITION
O.T.A.S. Switch Ground Test Straight 0.6 to 0.8
Install the DIAGNOSTIC HARNESS (P/N 529 036 188) ahead Vdc
as described in the 0. TA.S. SWITCH INPUT VOLT
Tur ned
AGE TEST. PINC PIN B
completely
(3-pin (3-pin
to the right 2.0 to 2.5
connector) connector)
Turn ed Vd c
completely
to the left
470 smr2011-033
Subsect i o n 01 (STEERING AND 0.T.A.S.)
If voltage is not as specified, replace the switch. O.T.A.S. MAGNETS

NOTE: To avoid useless switch replacement,
Magnets Replacement
make sure magnets are in good condition. Also.
make sure magnets and switch are securely 1. Remove STEERING COLUMN, see procedure
clipped. in this subsection.
2. Pull magnets off the steering column.
0.T.A.S. Switch Replacement
Models Without 77/t Steering
Remove steering column. see procedure in this
subsection.
Models with 77/t Steering

Remove STEERING COLUMN SUPPORT, see
Remove steering column from its support by re
moving both retaining screws.
.smr2011-033-008_ 0
1. Magnets
2. Steering column
Reverse removal procedure to reinstall the mag

nets.
1. Steering column screws
All Models
1. Using a small screwdriver. unhook the switch
from steering support.
s m t2�7-038 _1
1. Switch retaining tabs
Reverse removal procedure to reinstall the

O.T.A.S. switch.
smr2011.Q33 471
472
Subsection 02 OBR AND VTS)
iBRANDVTS
SERVICE TOOLS
DIAGNOSTIC HARNESS............... ..
. . . . . ........... . . . . . . . ..... . .
.... ..
. . . . . . . . . 529 036 188 ................................. 489-491
FLUKE 115 MULTIMETER ........ .. . .
. ... ... . .. . . . .
. . .. . . . . ..... . ..... . .
.. ......... . . 529 035 868 ................. 489, 494-495, 513
SERVICE PRODUCTS
DIELECTRIC GREASE .. .. . .. . . . .. . . .. . . .. 293 550 004 ................................. 500 514
,
. . .. ........ ... . . . . . ..... .... . . ......... . . .....
LOCTITE 243 (BLUE) . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .......... . . . . . . . . . . . . 293 800 060 ................................. 499-500
smt2011-034 473
Subsection 02 {iBR AND VTS)
iBR GATE COMPONENTS

GT/ and Wake Models
12 N•m
(106 lbf•in) ��
�Loctite 243
I'
24 N•m
(18 lbfoft)
24 N•m
(18 lbfoft)
5 N•m
�-(44 lbf•in)
S.1.
1 1cone · �
sealant 5150
12 N•m
�
(106 lbf.in)
Loctite
24 3 mm mm
� 24 N•m
4N•m
bf•ftl
(35 lbf•in)
\ .
�'��
mm
4N•m
(35 lbf.in)
!Em = Component must be replaced when removed. (18 lbfoft)

emr201 I 034 001_4
474 smr2011·034
Subsection 02 (iBR AND VTS)
iBR GATE COMPONENTS

GTX, RXT and Wake Pro Models
(18 lbfoft)
12 N•m
(106 lbf•in)
Loctite
/
4 N•m
(35 lbfoin)
Loctite
243 &
�/-
mm
6 N•m
(53 lbfoin)
m:m
4 N•m
(35 lbfoin)
Imm · Component must be replaced when removed.

""'2011.0J&-OOZ..•
smr201 l-034 475

iBR ACTUATOR
All Models
GT/ series
WAKE 755
RXT/GTX series
WAKE PR0275
Imm
12 N•m
( 106 lbfein)
l?Im = Component must be replaced when removed.
476 smr2011-034
GENERAL
and service products as indicated in the exploded
view.
complete procedure.
A wARNING
must be strictly adhered to. S<ld l009-001-039J>
1. /BR gate
2. iBR module and motor
stop nuts, self-locking fasteners, cotter pins, 3. Jet pump
When the iBR lever is pulled in, it operates the
brake and reverse lever sensor (BRLS). It is a dou
ble output hall effect sensor. The redundancy is
used for security purposes.
dards.
SYSTEM DESCRIPTION (iBR)

The iBR (intelligent Brake and Reverse) is an elec
tronically controlled braking and reverse system.
The iBR module controls the position of the iBR
gate to provide forward thrust, reverse thrust,
braking thrust. and neutral.
The operator commands the position of the iBR
gate using either the throttle lever for forward
thrust, or the iBR lever for neutral, reverse, and
for the braking function.
The iBR lever is located on the LH side of the han
dlebar. s d 02C()9-001.02 9_ a
1. iBR lever
2. BRLS sensor
The BRLS sends the signals to the iBR module.

The iBR module controls an electric motor that in
turn raises or lowers the iBR gate through a me
chanical drive unit.
NOTE: The iBR gate will move when commanded
by the iBR lever only if the engine is running. For
maintenance purposes, the iBR OVERRIDE func
tion available through the gauge can be used to
electrically move the gate to the desired position.
1. iBR lever (intelligent Brake and Reverse)
The iBR module is programmed with various pa
rameters that it compares to the input signals and
information it obtains through the CAN bus from
the other electronic modules.
Depending on vehicle speed and how far the iBR
lever is pulled in, the iBR module will automatically
adjust the iBR gate movement speed and stroke.
smr2011·034 477
NOTE: The iBR lever must be pulled in at least Braking Mode

25% of its travel (approximately) before the iBR
If the watercraft speed is 8 km/h (5 MPH) per hour
gate starts to move. The first 25% of iBR lever
and above when the iBR lever is pulled in, braking
travel has no effect on the iBR gate.
mode is engaged.
Every time the iBR gate moves when commanded
When the iBR lever is pulled in to engage braking,
by the iBR lever, engine RPM is momentarily re the following occurs:
duced to idle speed as the gate moves.
- Engine RPM is reduced to idle.
A WARNING - The iBR gate moves to the maximum down po
sition.
If it is necessary to remove any foreign ob
- Engine RPM ramps up to the engine power
ject caught in the iBR gate, nozzle or linkages,
commanded by the iBR lever.
strictly observe the following before proceed
ing: When operating in braking mode, the iBR gate al
- Remove tether cord from engine cut-off ways moves to the maximum down position. The
switch. throttle lever signal is overridden and engine RPM
is now dependent on watercraft speed and how
- Wait at least 5 minutes or remove iBR
far the iBR lever is pulled in.
fuses.
- Do not press on START/STOP button. If If watercraft speed is high when braking is ap
START/STOP button is pressed, wait an plied, engine power will be initially low and
other 5 minutes. then ramp up to the power commanded by the
iBR lever position. The engine RPM may be in
Forward Mode creased, as necessary, to apply a stronger braking
effect with the jet pump thrust when the condi
To engage forward:
tions dictate.
- Start engine
As the watercraft slows to less than 8 km/h
- Pull in the throttle lever.
{5 MPH). the following occurs:
The iBR gate will automatically move to the for - Braking mode ceases.
ward position (full up).
- Reverse mode takes over if the iBR lever is not
NOTE: The full up position of the iBR gate is de released.
pendent on the selected VTS trim position. - Throttle control reverts back to the throttle
lever.
Reverse Mode
If the watercraft speed is below 8 km/h (5 MPH) Neutral Mode
when the iBR lever is pulled in, reverse mode is Every time the iBR lever is pulled in and released,
engaged. the iBR gate will default to the neutral position,
When the iBR lever is pulled in to engage reverse. except if the throttle lever is still pulled in when
the following occurs: the iBR lever is released. If the throttle lever is
- Engine RPM is reduced to idle. still pulled, the iBR gate will move to the forward
position when the iBR lever is released and the
- The iBR gate moves to the reverse position.
watercraft will accelerate forward.
- Engine RPM ramps up to the engine power
commanded by the throttle lever. iBR Override Function
When operating in reverse mode, the iBR lever To permit easy access to the jet pump, nozzle, iBR
controls the iBR gate position and the engine RPM gate, and various linkages for inspection, mainte
is controlled by the throttle lever. nance, cleaning or removal of debris, the iBR sys
The iBR gate position can be modulated anywhere tem provides for an iBR override function that is
between the neutral and full reverse positions de accessible through the information center.
pending on the position of the iBR lever. If the When iBR override is activated, it allows the
iBR lever position is varied during reverse opera user to electrically move the iBR gate and nozzle
tion, engine RPM is reduced to idle every time the through its full range of motion.
iBR gate moves. It is therefore recommended to
maintain the iBR lever completely pulled in.
Maximum engine RPM in reverse is 5000 RPM.
478 5mr2011-034
fi!l1Ji@lj An object or tool caught in the iBR

gate, nozzle o r linkages when using the iBR
override function may cause damage to these
components. Remove any foreign object that
may obstruct the iBR gate travel.
Activating iBR Override Function
A WARNING
When using the iBR override function, ensure
nobody stands near the rear of the watercraft.
Movement of the iBR gate may squeeze fin
gers.
smo2009-00 2- 114_y
To use the iBR override function, carry out the fol SETTINGS
lowing step.
4. Press the SET button (RH handlebar) to enter
1. Press the START/STOP button.
the Settings function.
2. Install the tether cord.
5. If iBR OVR is not the following function dis
played, press the UP/DOWN arrow button until
iBR OVR is displayed.
Step 7: Press START/STOP button

Step 2: Install tether cord
NOTE: Do not start the engine. The tether cord

must be installed to ensure the information center
smo2009-002·1 1 4_1f
will not shut off all indications after its self test
iBR OVERRIDE
function. Briefly press the START/STOP button to
reactivate the electrical system when required. 6. Press the SET button to enter iBR OVR function
3. Press the Mode button on the RH handlebar re and display OVR OFF.
peatedly until SETTINGS is visible in the digital
display of the information center.
smr2011·034 479
NOTE: When the engine is started, the iBR OVR

function is deactivated and the iBR gate wi ll move
to the neutral posi tion
.
A WARNING
When moving the iBR gate using the iBR
override function, ensure nobody stands
near the rear of the watercraft. Movement of
the gate may squeeze fingers .
SYSTEM DESCRIPTION (VTS)

The VTS system is actually part of the iBR system.
"'1o2009-00 2 -114_1\h
It provides watercraft pitch trim adjustments by
OVERRIDE OFF
adjusting the horizontal position of the jet nozzle.
7. Press t h e UP/DOWN arrow button {RH handle The VTS can be electrically trimmed to the desired
bar) to display OVR ON. attitude within the VTS range, or to one of 2 preset
t rim positions.
The VTS switch (or Up/Down switch) sends com
mand signals to the gauge. The gauge converts
them to CAN protocol and sends them through
the CAN bus to the iBR module on the iBR actua
tor. The actuator then moves the iBR gate which
moves the nozzle to the desired trim position.
flit I NOTE: The nozzle and iBR gate move together
LJI tf in the VTS trim range up to the maximum noz
zle down position If NEUTRAL, BRAKING or RE
.
VERSE is engaged, the iBR gate moves past the

VTS full down position. When FORWARD thrust
is reengaged, the nozzle and iBR gate move up to
the last selected VTS trim position.
s0102ooe-002-114_gg
The nozzle trim position can be seen on the VTS
OVERRIDE ON
p ositi on indicator in the informatio n center.
8. Press the SET button to select the OVR ON NOTE: Changing the VTS trim position without
func tion The gauge will return to its normal dis
. the engine running in forward thrust mode only
play. changes the indication. The nozzle will move
to the select e d VTS trim position when forward
Models with a VTS Switch thrust is engaged.
9. Press the VTS UP or DOWN button (LH handle
bar) to move the iBR gate.
Models Withouts VTS Switch

10. Press the UP/DOWN arrow button (RH han-
dlebar) to move the iBR gate.
Deactivating iBR Override Function

To deactivate the iBR override function, carry out
one of the following:
1. Repeat previous steps and p res s the SET but
ton when OVR OFF is visible.
2. Remove tether co rd and wait for the electrical
power to shut off (approximately 3 minu tes ) .
3. Start the engine.
480 smr2011-034
Subsection 02 (iBR AND VTS}
Using the Up/Down Button

(RH side of Handlebar}
1. Press the MODE button to display the VTS
function in the gauge.
2. Press the UP or DOWN arrow button to change
the VTS setting.
INFORMATION CENTER - VTS POSITION INDICATOR

1. Bow up
2. Bowdown
NOTE: Only the segment indicating the relative

position of the VTS will be on. The illustration
shows all segments on as can be seen during the sdd2009-00 1-024J
self test function. 1. Bow up

2. Bowdown
The VTS system provides the following features
according to models
- Nozzle trimming
- Selection of 2 preset trim positions
- Recording of 2 preset trim positions.
Nozzle Trimming
Watercraft must be operating in forward position.
Depending on the model, 5 or 9 trim positions are
available.
Using the VTS B u tton

(LH side of Handlebar}
Press the UP or DOWN arrow button to change
the VTS setting. smo20 1C-002-106_ a
FUNCTION SELECTED - VTS

1. VTS setting
3. Press the SET button to save the desired set-

ting.
Using Preset Trim Positions

Two preset trim positions can be selected.
To select the highest trim position recorded, dou
ble-click on the VTS UP arrow button (bow up}.
To select the lowest trim position recorded, dou
ble-click on the VTS DOWN arrow button (bow
down).
TYPICAL VTS CONTROL BUTTON
-
1. Bow up
2. Bowdown
smr2011-034 481
odd 2 DOMlO
i l-019_c
DOUBLE-CLICK UP OR DOWN TO USE PRESET POSITIONS

7. Highest preset position on UP arrow
2. Lowest preset position on DOWN arrow s mo2
009-00 2-11•-�
FUNCTION SELECTED - VTS MODE
Recording Preset Trim Positions

4. Press the SET button to display PRESET 1.
Two different VTS trim positions may be recorded
5. Press the VTS UP/DOWN button to change the
for quickly selecting the preferred watercraft trim
PRESET 1 VTS position.
attitude.
When the VTS PRESE T trim positions are
changed, the new settings will remain recorded
in memory.
To record VTS preset trim positions:
switch.
3. Press the MODE button repeatedly until VTS
M O DE is displayed.
smo2009-00
2-114_e
FUNCTION SELECTED - PRESET 1

1. Preset 1 function
2. vrs setting selected to 1
3. vrs position indicator ar settin g 1 (bow down)
6. Press the SET button to save PRESET 1 and

display PRESET 2.
7. Set PRESET 2
8. Press the SET button to save the settings.
NOTE: The VTS system will compare the preset
I. MODE button
2. SET button trim settings recorded, the highest position will be
3. UP/DOWN arrow button assigned to the UP arrow (bow up), the lowest to
the DOWN arrow.
482 smr2011-034
ADJUSTMENT
IBR NEUTRAL ADJUSTMENT

GT/ 130/155, GTX 155 AND WAKE 155
When in NEUTRAL, if the watercraft creeps
forward or backward, the iBR system may be
trimmed.
If the watercraft is moving forwards, momentarily
press the DOWN arrow button on RH side of han
dlebar.
If the watercraft is moving backwards, momentar
ily press the UP arrow button on RH side of han
1. iBR gate moved to up position
dlebar.
2. Take hold of the lower edge of the iBR gate and
pull down on it slightly, then release it.
sod2 009-00 1 -024_i
TRIMMING THE iBR NEUTRAL POSITION

1. UP arrow button (to stop rearward movement)
2. DOWN arrow button (to stop forward movement)
PULL DOWN SLIGHTLY ON iBR GATE
NOTE: Press the UP/DOWN arrow button repeat
edly until proper adjustment of the neutral position Distance "A" Measurement
is attained and the watercraft stops moving.
Using a machinists ruler, measure the distance be
tween the bottom of the guard and the trailing
MAINTENANCE edge of the iBR gate. Note as measurement "A".
iBR GATE BACKLASH CHECK

1. Using the iBR override function, move the iBR
gate to the up position. Refer to SYSTEM DE
SCRIPTION (1BR) in this subsection.
s m r2 0-09· 008-0J 8_a
1. iBR guard
2. Measurement 'A•
smr2011-034 483
Distance "B" Measurement FRICTION SLEEVE

Without using excessive force, push up on the REPLACEMENT
trailing edge of the iBR gate to pick up the back
The 4 friction sleeves on the VTS trim ring should
lash in the gate mechanism. As you hold the gate
be replaced if they show signs of advanced wear
up, measure the distance between the trailing
(flat spots), or every 100 hours as per the mainte
edge of the guard and the trailing edge of the iBR
nance schedule.
gate again. Note as measurement ·s·.
� ' -•
1. Worn friction sleeve (flat spot)
1. To replace the friction sleeves, remove the iBR

gate and VTS ring as an assembly, refer to 1BR
•m '2009-0 �0-01 9_a GATE AND VTS RING REMOVAL in this subsec
1. iBR guard tion.
2. Lift up on iBR q,ate
3. Measurement B'
iBR Gate Backlash Calculation

Subtract measurement ·s· from 'A' to obtain the
iBR gate backlash.
iBR GATE BACKLASH (A - B)

MAXIMUM I 25mm {.98in)
Backlash Measurement Result

If backlash is excessive, inspect and replace iBR
gate parts as required in the following order:
1. Tightening of screws retaining the U-arm to the
actuator shaft
2. Splines on actuator shaft end and in U-arm
7. Friction sleeves (2 each side)
3. Friction sleeves
4. Bushings 2. Remove the worn friction sleeves from the VTS
ring and install new ones.
5. Contact points (VTS trim ring, U-arm, iBR gate)
6. iBR actuator. 3. Apply service products, torques, and install
new screws with threadlocker as specified in
Check iBR gate backlash and gate operation after
the exploded view.
parts replacement and reassembly.
484 smr2011·034
INSPECTION NOTE: If iBR gate is not in the neutral position be

fore the engine start, it will move to the neutral
position on engine start up.
IBR SYSTEM FUNCTIONAL TEST
2. Depress the throttle lever slightly, then release
Test on Dry Land it. Forward movement of the watercraft con
NOTE: This test requires two persons. One per firms the iBR gate has moved to the forward
son to start engine and operate controls, and one position.
person to observe iBR gate movement. 3. Depress the iBR lever fully. Rearward move
1. Provide adequate ventilation ot exhaust gases ment of the watercraft confirms the iBR gate
or move watercraft outside. has moved to the reverse position.
4. Release the iBR lever completely. Reverse
ll![oitlJjDo not install an exhaust ventilation
thrust should cease and the watercraft should
hose in the iBR gate area or damage may oc
continue to drift rearward on momentum.
cur when the iBR gate moves downward dur
ing operation. 5. Apply a small amount of forward thrust to stop
rearward velocity, then tap the iBR lever to re
2. Connect a water hose to the watercraft to pro turn the iBR gate to neutral.
vide exhaust system cooling when operating
6. Shut engine off.
engine. Refer to EXHAUST SYSTEM subsec
tion for procedure.
VTS FUNCTIONAL TEST
l+![1V{ij
NOTE: This test requires two persons. One pe r
- Ensure there are no tools or other object that
son to start engine and operate controls, and one
may interfere with the iBR gate movement.
person to observe nozzle and iBR gate movement.
- Do not run engine for more than 2 minutes
out of water or damage may occur to drive 1 . Provide adequate ventil ation of exhaust gases
shaft seal carrier. or move watercraft outside.
A WARNING l+!loi@j Do not install an exhaust ventilation

hose in the iBR gate area or damage may oc
The person observing the iBR gate move
cur when the iBR gate moves downward dur
ment must stand to the side of the stern well
ing operation.
clear of the iBR gate and pump nozzle in full
view of the operator. 2. Connect a water hose to the watercraft to pro
vide exhaust system cooling when operating
3. Start engine and let idle. engine. Refer to EXHAUST SYSTEM su b sec
tion for procedure.
NOTE: If iBR gate was not in the neutral position,
it will move to the neutral position on engine start W.Ji[ljj
up.
- Ensure there are no tools or other object that
4. Depress the throttle lever slightly and visually may interfere with the iBR gate movement.
confirm the iBR gate moves to the forward po - Do not run watercraft for more than 2 min
sition (up to the VTS trim position). then release utes out of water or damage may occur.
throttle. The iBR gate must remain in the for
ward position. A WARNING
5. Depress the iBR lever fully and confirm the iBR The person observing the iBR gate move
gate moves to the full down position. ment must stand to the side of the stern well
6. Release the iBR lever completely and confirm clear of the iBR gate and pump nozzle in full
the iBR gate moves to the neutral posi tion .
view of the operator.
7. Disconnect water hose then shut engine off.
Test with Watercraft on a Waterway

1. Start engine and let idle.
smr2011-034 485
NOTE: The VTS system cannot be tested without 7. Double click the VTS UP and DOWN button al-
the engine operating in forward thrust. If the en ternately to test the VTS preset trim positions.
gine is not running in forward thrust, only the VTS If double clicking the VTS UP or DOWN button
indication will change when the VTS control but does not cause the nozzle position or indication to
ton is pressed; the nozzle will not change position change, navigate to the VTS MODE function in the
until forward thrust is engaged by pulling the throt gauge and check for recorded PRESET 1 and PRE
tle lever. SET 2 settings . If no presets are recorded, record
3. Start engine. PRESET 1 bow up and PRESET 2 bow down, exit
4. 1-'ull in and release t h e throttle lever to engage the funcliu11 e:md t:arry out a new test.
forward thrust. allow engine to run at idle RPM. If both PRESET 1 and PRESET 2 ha v e the same
setting, note the operator's setting and change
Models with a VTS Switch
one PRESET, exit th e function and carry out a new
5. Push the VTS UP and DOWN button alternately test. Return the PRESET to the operator's prefer
to check VTS operation. ence after testing is complete.
Models Without a VTS Switch

8. Press the MODE button to display VTS.
sdd2009 ·00 1-019_c
1. vrs up button
2. vrs down button
6. Confirm nozzle movement and VTS position in

dication change in the information center. I. MODE button
:smo2010-00 2 - 10G_a
1. Bow up vrs FUNCTION

2. Bowdown 1. vrs setting
NOTE: Only the segment indicating the relative 9. Press the UP/DOWN arrow button {RH handle
position of the VTS will be on. The illustration bar) to change the VTS angle.
shows all seg ment s on as visible duri ng the
gauge self test function.
486 smr2011-034
- Try moving the iBR using the iBR UP and iBR

DOWN buttons on the iBR activation page in
B.U.D.S.
- Carry out an 1BR SYSTEM FUNCTIONAL TEST
to check for proper gate and actuator move
ment.
- Visually inspect system connectors for mois
ture ingress, corrosion, and proper contact.
- Check for excessive backlash in the gate mech
anism.
- Remove the screws retaining the U-arm to the
sdd20 0 9-00 1-02•_;
actuator shaft. Move the gate up and down by
1. UP arrow button hand to check for freedom of movement.
10. Ensure the VTS setting in the gauge moves PROCEDURES

with the VTS.
iBR LEVER SENSOR (BRLS)

TROUBLESHOOTING
BRLS Test Using B.U.D.S.
The iBR system is self monitoring. If a fault oc
NOTE: The BRLS is composed of a twin hall ef
curs in the iBR system, it will raise a fault code and
fect sensor. A resistance test of the sensor can
communicate it to the information center through
not be carried out.
the CAN bus. The information center will turn on
the iBR indicator light to advise the operator of 1. Connect watercraft to the latest B.U.D.S. soft
the iBR system fault. If the fault remains active. ware, refer to COMMUNICATION TOOLS AND
it may be displayed in the gauge. If it is no longer B.U.D.S.
active, B.U.D.S. must be used to read the fault. 2. Check for an applicable fault code, refer to DI
AGNOSTIC AND FAULT CODES.
TESTING SEQUENCE 3. If a fault is indicated, follow service actions as
To troubleshoot the iBR system. carry out the fol indicated in B.U.D.S.
lowing in this order:
BRLS Voltage Test
- Ensure the iBR gate movement is not ob
structed in any way. Test for BRLS input voltage as well as BRLS signal
voltages as per following steps.
- Ensure the iBR gate mechanisms (gate, VTS
ring, U-arm and linkages) are all in good condi iS Models
tion and do not show signs of excessive wear
or friction.
- Cycle the iBR gate up and down using the 1BR 2. Install the tether cord on the engine cut-off
OVERRIDE function as described in this sub switch to energize the electrical system.
section. NOTE: DO NOT start the engine.
- Check the iBR power fuse (F5) and the iBR con
trol fuse (F17) in fuse box if the gate did not
move using the iBR OVERRIDE function.
- Connect the watercraft to B.U.D.S. to check
for iBR system or CAN bus related fault
codes. Carry out service actions as indicated
in B.U.D.S.
- If a CAN bus communication fault with the iBR
module is indicated, or the iBR module is not
visible in 8.U.D.S., carry out a continuity test
of the CAN bus wires between the iBR mod
ule and the CAN bus-bars in fuse box. Refer
to CONTROLLER AREA NETWORK (CAN) sub
section.
smr2011-034 487
sdd 200!Kl0 1 -01 9_Q

Step 2: Install tether cord
NOTE: Briefly press the START/STOP button to

Step 1: Push storage bin latches backwards (one each side)
reactivate the electrical system when required.
Step 2: Lift and tilt forward to remove storage bin
3. Set the suspension to its maximum height by
double clicking the iS UP button. This will pro Models Without iS
vide better access to the steering connectors. 6. Disconnect the top of the two front air ventila
tion hoses, refer to BODYsubsection.
009-00 1-01 9_f

Sdd2
Step 1: Suspension to maximum height by pressing and holding

the iS UP
NOTE: If more height is required or if the iS sys

All Models
tem cannot be used, manually lift the suspension
using a hoist and the anchor points close to han 7. Reach in through the storage bin opening un
dlebars. Then safety lock it in the up position. der the steering area and disconnect the 24-pin
steering connector.
QZ,JitiJIDo not lift the watercraft using the
anchor points.
4. Remove the tether cord and wait approximately

3 minutes for the electrical system power to
shut off.
All Models
5. Open the front storage compartment cover and
remove the storage bin.
488 sm12011-034
11. Using a FLUKE 115 MULTIMETER (P/N 529 035

868) set to Vdc, measure the BRLS voltages
from the test connector of the diagnostic har
ness as per following tables.
TYPICAL 24-PIN STEERING CONNECTOR DISCONNECT

-

8. Connect the DIAGNOSTIC HARNESS (PIN 529 036

188) in series between the disconnected steer s mt201 0 · 038-003 _0
ing connectors. TEST CONNECTOR OF DIAGNOSTIC HARNESS
TEST CONNECTOR
iBR LEVER iBR LEVER
OF DIAGNOSTIC
RELEASED PULLED IN
HARNESS
PINS VOLTAGE (Vdc}
21 15
4.9 - 5.1
22 16
15 18 0.15 0.35
- 1.4 - 1.6
5 290361 8$
DIAGNOSTIC HARNESS (PIN 529 036 188) 19 16 0.4 - 0.6 2.9 - 3.1
9. Press the START/STOP button to wake up the 12. If voltage measured is as specified, the BRLS
electrical system. sensor is functioning properly.
10. Install the tether cord on the engine cut-off NOTE: When moving iBR lever, BRLS voltage
switch. change should increase or decrease in a steady
linear fashion.
13. If voltage is out of specification, carry out a
continuity test of the wiring between the iBR
module and the BRLS sensor, refer to CONTI
NUITY TEST OF BRLS WIRING HARNESS
Continuity Test of BRLS Wiring

Harness
1. Ensure the 24-pin steering connector pins are
clean, make good contact, and properly con
nected.
s dd20 09-001· 019_g
Models Without the X Package
Step 2: Install tether cord 2. Remove the steering cover, refer to STEERING
AND 0 TA.S subsection.
smr2011·034 489
Models with the X Package All Models

3. Remove the upper housing and housing cover 7. Disconnect the 12-pin connector from the iBR
from the LH handlebar housing, refer to STEER actuator.
ING AND 0. TA. S. subsection.
All Models
4. Disconnect the BRLS connector.
$mr 2009-03S-003_b
TYPICAL
Step 1: Disconnect the 12-pin connector
20094B00 1 _a
Jrt r
8. Measure for continuity from the BRLS connec
TYPICAL
1. BRLS
tor to the 12-pin iBR actuator connector as per
2 BRLS connector following table.
iS Models CONTINUITY TEST OF BRLS WIRING HARNESS

5. Open the boarding platform and remove the LH
BRLS 12 PIN iBR
storage bin. RESISTANCE
CONNECTOR CONNECTOR
Pin A (VI/YU Pin 4 (VI/YU

Pin B (BK) Pin 6 (BK)
Pin C (Yl/BK) Pin 8 (YL/BKl Close to 0 n
Pin D (VI/YU Pin 7 (VI/YU (continuity)
Pin E (BK) Pin 9 (BK)
Pin F (YL/WH) Pin 5 (YL/WH)
If continuity is good, replace BRLS.

If an open circuit or a higher than normal resis
tance is measured, carry out the continuity tests
in the following tables to find the problem wire or
connection:
- From the BRLS to the 24-pin steering connector
- From the steering connectors to the iBR actua-
tor 12 pin connector.
Step 1: Open the boarding platform
Step 2: Remove the LH storage bin 9. Connect the DIAGNOSTIC HARNESS (P/N 529 036
188) to the steering connector (steering side
Models Without iS only).
6. Remove the LH access panel on the boarding NOTE: Resistance readings may be slightly
platform or remove seat. higher than normal (maximum .5 f.l) when mea
suring from the test connector on the diagnostic
harness.
490 smr2011-034
CONTINUITY TEST BRLS TO 24-PIN 5. Gently pull the sensor from its support and the
STEERING CONNECTOR iBR lever. Depress the lever as required to ease
sensor removal.
TEST
BRLS RESISTANCE
CONNECTOR
Pin A
Pin 21 (Vl/YL)
(VI/YU
Pin B (BK) Pin 15 (BK)
Pin C
Pin 18 (YL/BK)
(YUBK) Close to On
Pin D (continuity)
Pin 22 (VI/YU
{Vl/YL)
Pin E (BK) Pin 16 (BK)
Pin F
Pin 19 (YL/WH)
(YL/WH)
10. Connect the DIAGNOSTIC HARNESS (P/N 529

036 188) to the steering connector (vehicle s m r2009-00 S.00 l _ c
TYPICAL
side only). 1. BRLS
2. BRLS connector
CONTINUITY TEST STEERING CONNECTORS 3. Sensor retaining tabs
TO iBR CONNECTOR
6. Remove connector from the BRLS.
TEST
12 PIN iBR RESISTANCE
CONNECTOR
BRLS Installation
Pin 7
Pin 22 (VI/YU Models Without the X Package
(Vl/YL)
1. Install BRLS sensor in the reverse order of re
Pin 16 (BK) Pin 9 (BK)
moval.
Pin 5
Pin 19 (YL/WH) 2. Ensure wiring harness is properly routed
(YL/WH) Close to 0 n through slot provided in sensor support be
Pin 4 (continuity)
fore installing steering cover.
Pin 21 (VI/YU
(Vl/YL)
Pin 15 (BK) Pin 6 (BK)
Pin 8
Pin 18 (YL/BK)
(YUBK)
11 Repair or replace wiring/connector as re

.
quired.
BRLS Removal
Models Without the X Package
1. Remove steering cover, refer to STEERING
AND 0. T.A.S. subsection.
Models with the X Package

2. Remove the upper housing and housing cover
sm 1 2 009-038· D O I ..b
from the LH handlebar housing, refer to STEER 1. Wire harness routed in slot
ING AND 0. T.A.S. subsection.
All Models
tercraft to the latest B.U.D.S. software, refer to
3. Open the sensor retaining tabs. DIAGNOSTIC AND FAULT CODES.
4. Pull up on the connector end of the BRLS.
smr2011-034 491
4. Carry out an iBR SYSTEM FUNCTIONAL TEST

using the iBR lever (engine must be running).
Models with the X Package

Install BRLS sensor in the reverse order of re
moval. However, pay attention to the following:
1. I nstall connector on BRLS and ensure wiring is
properly position ed in handlebar housing.
Step 7: Ensure engagemenr of housing cover retaining tabs

Step 8: Ensure engagement of upper housing locking tabs
9. I nstall the three retaining screws for the upper

housing and torque them to 2 N•m (18 lbf•in).
tercraft to the latest B.U.D.S. software refer ,
to DIAGNOSTIC AND FAULT CODES.

Srep 1: Ensure proper wire routing 11 . Carry out an 1BR SYSTEM FUNCTIONAL TEST
using the iBR lever (engine must be running).
2. Inse rt the BRLS in the iBR lever.
3. Align the BRLS in the housing, then press it into iBR ACTUATOR
the housing until both locking tabs engage. En
sure it is properly locked in place.
RZ.JmJI The iBR actuator motor must never
4. Ensure wiring is not pinched. be tested by applying 12 Vdc directly to it's
5. Position the housing cover onto the handlebar connector. Doing so may cause a lock-up and
housing .
damage internal actuator components, ne
cessitating replacement of the iBR actuator
6. Ensure positioning of corrugated conduit
assembly.
iBR Actuator Operation Test Using

B.U.D.S.
1. Connect watercraft to the latest B.U.D.S. soft
ware, refer to COMMUN/CATION TOOLS AND
B.U.D.S.
2. Click the Read Data button.
3. Check for applicable fault codes on the Faults
page.
4. Click the Activati on tab.
5. In the lower LH corner click the iBR tab.
,
smr2010-042--0
05 _a
Step 2: Insert BRLS in iBR lever

Step 3: Ensure locking tab engagement
Step 4: Ensure wiring 1s not pinched
Step 5: lnsra// housing cover
7. Position the upper housing onto the handlebar.

8. Ensure proper engagement of the housing and
cover tabs.
492 ;mr2011-034
iBR Actuator Motor Current Test Using

B.U.D.S.
1. On the iBR activation page in B.U.D.S., note the
iBR Position (Deg) indication.
lBR MotorQment
3 1
I il!R "°"'""" <Pv!I;
j
al.,...
W•lci-�... ...-,,-.---
I-
smf.!00 9-03&-028_ • ""°""' I IBR�ltlon (Deg-)
TYPICAL
1. Read Data
2. Activation tab smr 2 000-03 8- 029.P
3. iBR tab 1. iBR position indication
6. In B.U.0.S., click iBR UP and iBR DOWN but 2. Activate the iBR override function, refer to 1BR
tons alternately and look for a change in iBR Po OVERRIDE FUNCTION in the beginning of this
sition (Deg). subsection.
3. Press and hold the VTS UP button on the LH
handlebar to position the iBR to the full up po
sition and look for the iBR Motor Current indi
cation in B.U.D.S. Also look for a change of iBR
Position (Deg) indication.
NOTE: Current draw indication will not be stable.
High and low peaks will be observed. Look for the
maximum average current draw.
®�.!!ULJ
smr2009-03S.028.J>
TYPICAL
1. iBR UP/DOWN buttons
2. iBR position indication
If the iBR moves using these buttons but does not

move using the iBR lever, refer to BRLS VOLTAGE
TESTin this subsection.
IBRO- J iBR Position(�)
If the iBR does not move, check the iBR fuses (F5
s m •2009-038-032.. b
and F17) in fuse box. If fuse are good, refer to 1BR
Step 1: Note iBR current draw
ACTUATOR INPUT VOLTAGE TESTin this subsec Step 2: Note iBR position indication change
tion.
smr2011 ·034 493

4. Press and hold the VTS DOWN button and look

for the iBR Motor Current draw indication.
Also look for a change of iBR Position (Deg)
indication.
IBR Motor Current

0
30
-�O so
l 1. iBR motor harness connector

2. iBR motor module connector

IBR.,...., I 1aR Position {Deg; 868} to Vdc selection.
3. Install insulated clips on the multimeter leads
and clip leads to pins in the motor connector on
Step 1: Note iBR current draw the iBR module.
Step 2: Note iBR position indication change
iBR ACTUATOR CURRENT DRAW
DOWN SELECTION -5 to -15 A
UP SELECTION +10 to +20 A
If current draw is abnormally high (between 20

and 30 A), check the following:
- Ensure iBR gate is free of debris.
- Remove the screws retaining the U-arm to the
actuator shaft. Check for excessive friction in
gate movement.
- Check iBR gate friction sleeves and bushings. �,.
- Check for proper voltage to the iBR motor, see TEST OF iBR MODULE OUTPUT voe TO iBR MOTOR
tBR MOTOR VOLTAGE TESTin this subsection.
NOTE: On GTI models, temporary install test
- Check for fault codes using B.U.D.S.
wires with a connector to the motor connector on
Remove debris, replace iBR gate components, or the iBR module. Measure voltage on test wires.
replace the iBR actuator as applicable.
4. Using the iBR override function (see SYSTEM
iBR Motor Voltage Test DESCRIPTION (!BR in this subsection), press
the VTS UP button and read the iBR module
1. Disconnect the 2-pin connector on iBR module.
motor output voltage.
NOTE: The iBR UP button on the iBR Activation
page in B.U.D.S. may be used instead of the iBR
override function.
494 smr2011-034
NOTE: The 12 Vdc and ground will alternate be

tween pins with a change of iBR direction.
iBR Actuator Input Voltage Test

1. Disconnect the 3-pin and 12-pin connectors
from the iBR module.
sdd2009-0J 1 -019_o
1. VTS UP
2. VTS DOWN

5. Press the VTS DOWN button and read the iBR
module motor output voltage.
NOTE: The iBR DOWN button on the iBR Activa
tion page in B.U.D.S. may be used instead of the
iBR override function.
iBR MOTOR VOLTAGE TEST srnr2C09-038-00 3_a
TYPICAL
Battery voltage (ove r 12 Vdc} 1. 3-pin connecror
2. 12-pin connector
�
NO E: Voltage measured should be battery volt
NOTE: The 3-pin connector provides battery
ag� 1n both UP or DOWN directions. Voltage po
power directly to the iBR module for the actuator
larity should reverse as UP or DOWN button is
motor through the fuse F5. The 12 pin connector
pressed alternately.
provides BRLS signals, CAN bus, and a switched
- If battery voltage i s not measured, refer to iBR 12 Vdc power to the iBR module through the fuse
ACTUATOR INPUT VOLTAGE TESTin this sub
F17. Refer to WIRING DIAGRAM.
section.
2. Set the FLUKE 1 1 5 MULTIMETER (P/N 529 035
- If battery voltage is measured in both direc
868) to Vdc selection.
tions, refer to iBR POWER TEST USING A TEST
LIGHTin this subsection. 3. Measure for the battery input voltage (through
.
- If battery voltage is measured and the test light fuse F5) to the 1BR actuator as per following
is bright for both iBR UP or DOWN selections table.
the iBR motor is at fault and the iBR actuato � iBR ACTUATOR INPUT VOLTAGE TEST
must be replaced. (30 AMP BATTERY POWER)
- If battery voltage is low or test light is dim in
3 PIN CONNECTOR BATTERY READING
both directions, refer to 1BR ACTUATOR INPUT
VOLTAGE TESTin this subsection. Pin 2 Pin 1 -
Battery
- If battery voltage is measured and test light is Pin 2 - Neg. (-) post vo ltage
dim in one direction, replace the iBR actuator.
If battery voltage is not measured, check the fol
iBR Power Test Usi ng a Test Light
lowing:
1 . Connect the clip of a 12 Vdc test light to the - iBR fuse F5 in fuse box
battery ground (or engine ground).
- Battery voltage at fuse contact 84 of fuse box
2. Touch the test light probe to each pin of the - Wire continuity from pin 2 of iBR 3-pin connec-
motor output connector on the iBR module as tor to A4 of fuse box
you select the iBR UP and DOWN alternately. - Jumper continuity fuse contact 84 to C3 of 12
The test light should come on bright for one pin Vdc bus-bar in fuse box.
only in each direction.
smr2011 ·004 495

If voltage is good to the negative battery post but - Wire continuity from pin 1 of iBR 12-pin connec
not to pin 1 of the connector (ground wire to en tor to F3 of fuse box
gine), check for an open or bad ground wire (loose. - Jumper continuity fuse contact E3 to D3 of 12
corroded. or pitted terminals, wire continuity, etc.) Vdc accessory bus-bar in fuse box.
If battery voltage measured is as spec if ied, carry If voltage is good to the negative battery post
out same test using a 12 Vdc test light. Test light but not to pin 1 of the connector (ground wire to
should be bright. engine), check for an open or bad ground wire
If test light is not bright to pin 1 only, look for a (loose, corroded, or pitted terminals. wire conti
bad contact on the ground circuit {loose, t.:u1 r uded, nuity, etc.).
pitted, etc.). If battery voltage measured is as specified, carry
If test light is not bright to the negative battery out same test using a 12 Vdc test light. Test light
post. first check voltage at battery terminals to en should be bright.
sure battery is not discharged. If battery voltage If test light is not bright to pin 1 of the 3 pin con
is good, look for a bad contact in the 30 amp 12 V nector, look for a bad contact on the ground circuit
iBR power circuit (loose, corroded, pitted, etc.). (loose, corroded, pitted, etc.).
If the 30 amp 12 Vdc power to the iBR actuator is If test light is not bright to battery negative ter
good, test for the switched 5 amp 12 Vdc as per minal, first check voltage at battery terminals to
following steps. ensure battery is not discharged . If battery volt
4. Briefly press the START/STOP button to wake age is good, look for a bad contact in the 12 V
the electrical system. iBR switched power circuit (loose, corroded, pit
ted, etc . ) .
If the iBR actuator input voltages and ground cir
cuit are good, and there is no CAN bus or BRLS
fault, replace the iBR actuator.
iBR Actuator Removal

GT/ and Wake Models
A CAUTION Remove iBR fuse before work

ing in the iBR gate area. Refer to POWER DIS
TRIBUTION.
sdd 2009-001-01 9_g 14'tt1i@j Do not try to move the iBR gate
Step 1: Press START/STOP button when all components a re installed .
Step 2: Install D.E.S.5. key
1. Remove iBR Gate ass'y. Refer to !BR GA TEi n
5. Measure for the switched input voltage to the this subsection.
iBR actuator as per following table.
2. Remove iBR actuator retaining screws.
iBR ACTUATOR INPUT VOLTAGE TEST
(5 AMP SWITCHED)
iBR CONNECTORS
BATTE RY READING
12 PIN 3 PIN
Pin 1 Pin 1 -
Battery
Pin 1 - Neg. (-) post voltage
NOTE: The 5 A switched power to the iBR actua

tor is for the iBR electronic module and BRLS.
If battery voltage is not measured at all, check the
following:
- i BR control (CRTU fuse f 17 in fuse box
- Battery voltage at fuse contact E3 of fuse box
496 smr2011-03A
smr2011-0J4.003_
a
PRYING iBR ACTUATOR
IBR acwaror
1. Remove screws
3. Remove seat.
From Inside Bilge
4. Cut locking tie.
5. Discon n ect hose from muffler.
6. Move hose end away.
•mr20 1 1-0J4.00 B_a
1. Pull out
8. Cut locking tie.

9. Disconnect the indicated connectors .
1. Cut locking tie

2. Disconnect hose
7. Pull out i BR actuator.

NOTE: It may be necessary to pry out iBR actua
tor.
"""'20 1 1 .()34-007 _•
7. Unplug connscrors
smr2011-034 497

1. Move the iBR gate to the forward position (full
up) using the iBR OVERRIDE function. Refer
to SYSTEM DESCRIPTION (iBR) in this subsec
tion.
li!ltli@j Do not try to move the iBR gate

when all components are installed.
A CAUTION Wait at least 5 minutes for wa

tercraft electrical power system to shut down
or remove iBR fuses before working in the iBR
gate area.
iS Models
2. Open the boarding platform and remove the LH
storage bin.
TYPICAL
1. Pressure hose from jet pump
Models Without iS u
2. Press re hose to intercooler (260 hp models)
3. Pressure hose to exhaust manifold
3. Remove the LH access panel on the boarding
platform. 6. From jet pump area, remove and discard the
All Models two hexagonal screws securing the U-arm to
the iBR actuator shaft.
4. Disconnect the two aft electrical connectors
from the iBR actuator The forward electrical
.
connector (iBR motor power) does not need to

be removed.
•mr2 0 11-034-00EI _
•
1. U-arm
2. Hexagonal screws
7. From bilge, remove the five hexagonal screws

securing the iBR actuator to the LH support
plate.
TYPICAL
1. iBR actuator 3 pin connector
2. iBR actuator 72 pm connector
5. Disconnect the three water pressure hoses in

dicated in the following illustration from the iBR
actuator.
498 smr2011-034
TYPICAL
7. Hexagonal screws to remove (1 screw not visible)
1. U-arm splines
8. Pull the iBR actuator from the support plate.
Replace parts as necessary.
iBR Actuator Inspection
iBR Actuator Installation
Check condition of iBR actuator gasket.
GT/ and Wake Models
Check condition of splines on actuator shaft end
and in U-arm. Installation is the reverse of the removal proce
Clean actuator mounting screw threads and apply
LOCTITE 243 (BLUE) (P/N 293 800 060) on threads {or
install new screws with threadlocker).
lighten actuator mounting screw to specification
as per following sequence.
TIGHTENING TORQUE
1. Actuator shaft splines
1m1201 l -034-00 3_l>
iBR ACTUATOR SCREW TIGHTENING SEQUENCE
Clean iBR shaft screw threads and apply LOCTITE

243 (BLUE) (P/N 293 800 060) on threads (or install
new screws with threadlocker).
smt2011-034 499
Secure U-arm to iBR shaft.

Apply a small amount of DIELECTRIC GREASE
(P/N 293 550 004) to the connector pins before
plugging the connectors to the iBR actuator.
Reinstall iBR fuse.
Check watercraft in water for water tightness.

dure however, pay attention to the following:
- Clean all actuator mounting screw threads and
apply LOCTITE 243 (BLUE) (P/N 293 800 060) on
threads (or install new screws with thread
locker).
- Install the U-arm on iBR shaft using new hexag smr20 I 1·034-009.•
onal screw with threadlocker. GT/ AND WAKE MODELS

1. Nozzle arm
- Torque hexagonal screws securing iBR actuator 2. Remove screw
- Torque gear clamps securing water pressure

hoses to 2 N•m (18 lbf•in).
- Apply a small amount of DIELECTRIC GREASE
(PIN 293 550 004) to the connector pins before
installing the connectors on the iBR actuator.
- Check watercraft in water for water tightness.
iBR GATE
iBR Gate Removal (with VTS Trim Rin g
and Steering Nozzle)
A CAUTION Remove iBR fuse before work
ing in the iBR gate area. Refer to POWER DIS
smr2009·038-007.•
TRIBUTION.
GTX, RXT AND WAKE PRO MODELS
1. Remove screw
fiff1Jifl1j
Do not try to move the iBR gate 2. Nozzle lever
when all components are installed.
2. Remove screws retaining U-arm to iBR actuator
1. Disconnect the steering cable from the steering shaft.
nozzle arm.
smr'ZO l l-034-010_1
TYPICAL
7. Remove screws
500 smr2011.034
A CAUTION From now on, reta i n iBR gate to

prevent it to fall. Pay attention not to caught
your fingers.
3. Raise iBR gate to its upper position. Hold in po
sition.
4. Remove screw from iBR gate LH pivot point.
NOTE: Pull out bushing along with the screw.
sml'20 1 l -034-0 13 b
TYPICAL RH SIDE
-
1. Remove screws
Pull out iBR gate ass'y with U-arm.
TYPICAL - LH SIDE
1. Remove screw and bushing
smr2011 -034-0 ! b
TYPICAL
iBR Gate and VTS Trim Ring

Disassembly
VTS Trim Ring Removal
Remove the two hexagonal screws securing the
iBR gate to the VTS trim ring.
TYPICAL
1. Bushing
5. Remove screw from iBR gate RH pivot point.

NOTE: Pull out bushing along with the screw.
6. Remove screw from U-arm pivot point
smr2011-034 501
NOTE: Friction sleeves should be replaced as

specified in maintenance chart or if they show
sml'2009-03B-O11_ a
TYPICAL
signs of wear (flat surfaces). Plastic bushings
1. iBR gate retaining hexagonal screws to remove are press fit and should be replaced if they show
signs of wear, deformation, or if the iBR gate
Trim Ring Inspection
backlash is beyond service limit.
1. Inspect trim ring and metal spacers for cracks,
3. Inspect gate stoppers for signs of wear.
oblong holes, evidence of wear and deforma
tion.
2. Inspect plastic bushings and friction sleeves for
cracks, deformation and signs of wear.
"'"2011-0 34-016..a
TYPICAL
TYPICAL VTS TRIM RING (WITH NOZZLE AND STEERING ARM)
1. Stoppers
1. Friction sleeves (2 each side)
2. Plastic bushings (x8)
4. Replace parts as required.
Steering Nozzle Removal
GT/ and Wake Models

1. Remove screws securing nozzle to VTS ring.
smr2009-038-022_o
TYPICAL • WORN AND DEFORMED PLASTIC BUSHING
502 smr2011·034
Steering Nozzle Lever Removal

1. Remove the hexagonal screws se curing the
steering arms (links) to the steering nozzle
lever, top and bottom.
1. Remove screws

1. Remove the 2 hex agonal screws securing the
smr2009-038-01i_d
steering arms (links) to the steering nozzle (top
7. Hexagonal screws to remove (top and bottom)
and bottom).
2. Rem ov e the hexagonal screws securing the
steering nozzle lever to the VTS trim ring top,
and bottom.
1. Hexagonal screws to remove (top and bottom)
2. Remove the 2 socket head screws securing the

nozzle to the VTS trim ring (1 t op and 1 bottom). J. Hexagonal scrows to remove (top and bottom)
Steering Nozzle Inspection

1. Inspect steering nozzle for cracks, wear, defor-
mation, and other damages.
Inspect bushings for wear or other damage.
Steering Nozzle Lever Inspection

1. Inspect steering nozzle lever, steering arms,
and spacers for cracks, elongated holes, ev
idence of wear, deformation and other dam
1. Socket head screws to remove (top and bottom)
ages.
2. Replace a s r equi red .
smr201 l·034 503

iBR Gate Inspection

1. Inspect the iBR gate and its plastic liner for
cracks, out of round holes, evidence of wear,
deformation and other damages.
2. Inspect plastic bushings (x4) for cracks, wear.
and deformation.
3. Replace as required.
1. Small end of nozzle

2. Steering lever
3. Warning label
iBR Gate Installation (with VTS Trim

Ring and Steering Nozzle)
GT/ and Wake Models
smr'2Q09.008..0 1 d _a
1. Plastic liner Installation is the reverse of the removal proce

2. Plastic bushings dure however, pay attention to the following.
Position iBR gate down and components as
iBR Gate and VTS Ring Reassembly
shown to install into position.
Install all parts removed in the reverse order of re
moval, however pay attention to the following:
- Install new friction sleeves (as required).
- Install new plastic bushings (as required).
- Install new hexagonal screws with thread-
locker.
- Torque all retaining screws as per exploded
view.
When installing the iBR gate onto the VTS ring,
position the VTS ring so that the small end of the
steering nozzle is facing you with the steering
lever towards the RH side.
Position the iBR gate over the ring so that the
warning label is facing you (right side up) and
install the mounting hardware as seen in the �o 1 1.0 34-01 s_1
exploded view. The attachment points for the

linkage arms will be facing away from you (not Insert iBR gate ass'y between mounting plates.
visible in following illustration of iBR gate and VTS
ring assembly).
504 smr20 I I·034

- Install all new hexagonal screws with thread

locker.
- Lift the 2 linkage arms on the U-arm as you
insert the iBR gate and VTS ring between the
mounting plates.
- Secure the VTS ring to the mounting plates,
then secure the linkage arms to the iBR gate.
- Torque all retaining screws as specified in ex
ploded view.
l1i[1JiliJj Overtorquing wil l damage inserts.
U-ARM
U-Arm Removal
srr u2011·034-0 2 0 _
a
1. RH mounting plate GT/ and Wake

2. Rib here
Remove U-arm as an assembly with iBR gate. Re
NOTE: Ensure RH mounting plate is in place be fer to !BR GATE in this subsection.
fore inserting iBR gate ass'y. Also position its ribs
RXT, GTX and Wake Pro
as illustrated.
1. Carry out the !BR GATE REMOVAL (WITH VTS
Raise iBR gate to its upper position. Hold in posi
TRIM RING) procedure as detailed in this sub
tion.
section.
Use new screws with threadlocker for installation.
2. Remove the RH U-arm retaining hexagonal
Loosely install M8 x 70 mm screws on RH side. screw and washer.
3. Secure the U-arm with one hand and remove
the RH spacer sleeve.
4. Remove U-arm from actuator shaft.
smr20 1 1 -03<!-01 3_b
1. MB x 70 screws here
Install screw on LH side of VTS ring pivot point

then iBR shaft screws. 1. U-arm
2. Hexagonal screw and washer
Torque all retaining screws as specified in ex 3. Spacer sleeve
4. Actuator shaft
ploded view.
fMoi[IJj Over torquing will damage inserts. U-Arm Inspection

1. Inspect U-arm and linkage arms (x2} for cracks,
wear, and signs of twisting and bending.
Installation is the reverse of the removal proce ;
2. Ensure the VTS cams on the U-arm are not
worn, cracked or broken.
smr2011·034 505
3. Inspect the plastic bushings (x5) for cracks.

wear and deformation.
1. Linkage arms 1. RH supporr plate

2. Plastic bushings (x5)
3. VTS cams LH Support Plate Removal
1. Remove iBR actuator. Refer to procedure in
U-Arm Installation this subsection.
2. Remove support plate mounting screws.
1
- Install all new hexagonal screws with thread-
locker.
- Torque all retaining screws as per exploded
view.
iBR GATE SUPPORT PLATES

iBR Gate Support Plate Removal
GT! and Wake Models
RH Support Plate Removal
1. Remove iBR gate ass'y. Refer to procedure in
this subsection.
2. Remove support plate. 3'-023 _
•mf.I011-0 1
1. Mounting screws
3. Pull out support plate.

Preparation
NOTE: The following steps must be carried out
when removing the LH or RH support pl ates.
iS Models
1. Open the boarding platform. Refer to BODY
subsection.
506 smr2011-034
All Models
2. Remove the following items, see procedures in
this subsection:
- iBR gate, VTS trim ring and the steering noz
zle as an assembly
- iBR U-arm.
RH Support Plate Removal
iS Models
1. Remove the RH storage bin, refer to the BODY
subsection.
Models Without iS smr2 009-043· 002_a
1. Support plate retaining screws

2. Remove RH access panel from the boarding
platform. NOTE: Two locking tabs on the inner plate locks
it to the outer plate exhaust nozzle.
All Models
6. Using a small screwdriver or a scriber, lift the
3. Remove the battery, refer to CHARGING SYS
upper locking tab slightly to help release the
TEM subsection.
plates and avoid breaking the tabs.
4. Disconnect the exhaust hose from the RH inner
support plate.
smr2009·043-001 _a
1. Exhaust hose
2. Clamp to loosen 1. Locking tab x2 (top and bottom)
5. Remove and discard the 2 hexagonal screws 7. Carefully pull the RH inner support plate off the
securing the outer support plate to the inner outer plate.
support plate.
smr2009
·043-0
04_;
7. RH inner support plate
smr2011-034 507
8. Pull the outer plate off the hull.
LH Support Plate Removal

1. Remove the iBR actuator, refer to procedure in
this subsection.
2. Cut the locking ties and disconnect the 2 bailer
hoses from the jet pump venturi.
stnr20 l D-042-007_a
TYPICAL
1. Bailer hoses (x2)
2. lntercooler bleed hose (models with external intercoolerJ
3. Pump water pressure hose
5. Remove and discard the 5 hexagonal screws

securing the outer support plate to the inner
support plate.
1. Bailer hoses
3. Loosen the gear clamp and disconnect the wa

ter pressure hose from the jet pump.
TYPICAL
1. Hexagonal screws to remove
2. Outer support plate
6. From the iBR actuator side, carefully com

press the outer support plate tab retaining the
two support plates together using a common
screwdriver.
7. Water pressure hose
4. Disconnect the hoses connected to the fitting

plate mounted in the iBR support plate.
508 smt2011-034
5. Install the exhaust hose on the support plate

fitting and torque the gear clamp to 4 N•m
(35 lbf•in).
6. Install the battery, refer to CHARGING SYSTEM
subsection.
7. Install remaining parts in the reverse order of
removal. Refer to applicable procedures for de
tails, torque values and service products.
t;V1JittJj Overtorquing will damage inserts.
LH Support Plate Installation

1. Ensure formed seals are in good condition and
properly installed on each support plate.
2. Position the LH inner support plate in front of
TYPICAL
its mounting position in the hull.
1. Fitting plate tab
2. Inner plate tab
3. As you hold the inner support plate, insert the
3. Outer plate tab to compress
round extension on the outer support plate
7. Pull the inner support plate off the outer support through the hull. Push the outer plate in until it
plate. snaps onto the inner plate.
8. Pull the outer support plate from the hull. 4. Install 5 new hexagonal screws to secure iBR
support plates and torque as per exploded view.
iBR Support Plate Installation
5. Install the fitting plate, refer to FITTING PLATE
GT/ and Wake Models in this subsection.
RH Support Plate Installation

6. Install remaining parts in reverse order of re
moval. Refer to appropriate procedures for de
Installation is the reverse of the removal proce tails, seNice products and torque values.
dure.
LH Support Plate Installation FITIING PLATE

Installation is the reverse of the removal proce The fitting plate connects the bailer and pressure
dure however, pay attention to the following: hoses inside the hull to the hoses that are con
1. Install screws to secure support plate to iBR ac nected to the jet pump. It also provides the drain
tuator and torque as per exploded view. fitting for the intercooler drain hose (260 hp en
gine only).
2. Ensure formed seal is in good condition and
properly install on support plate.
Fitting Plate Removal
RH Support Plate Installation {215/260 Engines)
1. Ensure formed seals are in good condition and 1. Remove the iBR actuator for access to the fit
properly installed on each support plate. ting plate, refer to iBR ACTUATOR in this sec
tion.
2. Position the RH inner support plate in front of
its mounting position in the hull. 2. Disconnect the hoses connected to the fitting
plate (inside hull).
3. As you hold the inner support plate, insert ex
haust fitting on the outer support plate through
the hull. Push the outer plate in until it snaps
onto the inner plate.
4. Install 2 new hexagonal screws to secure
iBR support plates and torque to 1 2 N•m
(106 lbf•in}.
smr201 I·034 509

smr'2010-042-00 7 JI
TYPICAL
7. Bailer hoses {x2J
2. lntercooler bleed hose (models with an external intercooler
3. Water pressure hose from jet pump
3. Cut the locking ties and disconnect the 2 bailer

hoses from the jet pump venturi. 1. Water pressure hose
5. Compress the fitting plate retaining tab and

push the fitting plate out of the outer support
plate.
smr2 009439.Q0 2
._ •
1. Bailer hoses
4. Loosen the gear clamp and disconnect the wa 1. Fitting plate tabs
ter pressure hose from the jet pump.
6. Discard the fitting plate.
fi!l'1ffll)j
When the fitting plate retaining tabs
are compressed for removal, the tabs become
deformed and weakened. Do not reinstall a
used fitting plate. Always install a new fitting
plate. Failure to comply with this notice can
result in water seeping into the bilge.
510 smr2011-034
2. Inse rt the fitting plate through the outer iBR

support plate.
IM'1itiJI The fitting plate used on models

with an external intercooler is slightly different
than, and not interchangeable with, the fitting
plate used on all other models. Be sure to use
the correct fitting plate.
3. Push the fitting plate in until it bottoms out and

the retaining tabs (x2) snap securely into posi
tion.
1Nt1itiJI Ensure both tabs are properly locked

smr2009·0<>3·007_a
to secure fitting plate to the support plate. If
NEW FITTING PLATE fitting plate is not properly locked in position,
1. Good re ta1i1ing tabs water may seep into the bilge.
�mr2009-043-00 9_a
OLD FITTING PLATE (00 NOT REUSE)

1. BAD retaining labs (compressed and deformed)
1. Top firring plate retaining tab (bottom tab similar)
4. Install the hoses on the inner fitting plate.

5. Torque gear clamps to 1.7 N•m (15 lbf•in).
sm.12009-043-01 0_8:
OLD FITTING PLATE (BAD RETAINING TAB CONTACT)

1. Retaining tab
-sm r 20 1 0-04 2-007_a
Fitting Plate Installation TYPICAL

1. Bailer hoses (x2J
2. lntercooler bleed hose (models with an external intercoole1)
1. Ensu re the 0-ring seal is properly installed on
3. Water pressure hose from jet pump
the fitting plate and in good condition.
6. Install the three hoses on the jet pump.
smr2011-034 511
Subsection 02 (iBR AND V TS)
7. Torque the gear clamp securing pressure hose protocol and transmit it through the CAN bus. The
to the jet pump to 1.7 N•m (15 lbf•in}. VTS module will react to the command, carry out
8. Install remaining parts in the reverse order of the function, and transmit the result back through
removal, refer to appropriate procedure in this the CAN bus.
subsection. The gauge will use the signals from the switches
and the transmitted information from the other
VTS CONTROL BUTTON modules, convert them to an indication, and
cancel the command signal it sent out once the
function has been carried out.
NOTE: The voltages stated above vary slightly de
pending on the actual voltage applied to the circuit
and the current flow through the diodes. When
using a Fluke 115 multimeter for testing in diode
test mode, the voltage and current applied by the
multimeter are lower than in circuit. The quality
of probe contact, the actual probes and leads. and
the precision of the meter calibration will all affect
the results, which will most likely be slightly lower
than nominal values stated.
sd�2009o(l()1-019.e VTS Control Button Functional Test

1. VTS up button Using iBR Override Function
2. VTS down button
VTS Button Overview 2. Install tether cord to power up the electrical sys-
The VTS button contain a series of 4 diodes for the tem.
UP and DOWN arrow switches. Refer to WIRING NOTE: Briefly press the START/STOP button to
DIAGRAM reactivate the electrical system when required.
The center wire to the switches (pin "C"), is com 3. Activate the iBR override function, refer to SYS
mon for iS button and VTS button (somewhat like TEM DESCRIPTION (18RJ in this subsection.
a ground wire). The other two wires (pins "A" and
4. Press and hold the VTS DOWN arrow button.
"8"), act as signal wires to the gauge for each set
The iBR gate and steering nozzle will move
of switches. They actually each form one branch
downwards together until they reach the full
of an electronic circuit within the gauge.
VTS down position. The iBR gate will then
Each diode (in circuit) drops a nominal 0.6 Vdc continue moving to the full reverse/braking
when conducting electricity. If the circuit current position alone.
passes through all four diodes (say VTS switch
5. Depress and hold the VTS UP arrow button and
open). a drop of 2.4 Vdc would be measured
ensure the iBR gate moves up to the forward
across the 4 diodes (pin "A" to pin "C"). This drop
position.
of 2.4 Vdc measured at pin "A" tells the gauge the
VTS switch is open. NOTE: If the VTS button is released before full
travel of the iBR gate, movement of the iBR gate
If the VTS UP button is pressed, 2 diodes are by
will cease.
passed by the closed switch. The remaining two
diodes in the circuit drop 1.2 Vdc (at pin "A"}. If the iBR does not respond to VTS button com
mands (UP or DOWN), carry out the following VTS
If the VTS DOWN button is pressed, 1 diode is by
SWITCH TEST USING B.UD.S.
passed by the closed switch. The remaining three
diodes in the circuit drop 1.8 Vdc (at pin "A").
VTS Control Button Test Using
The gauge senses these voltages through pin 13 8.U.D.S.
of its connector. and interprets them as signals
1. Connect watercraft to the latest B.U.D.S. soft
that tell it which switch is activated (VTS UP or
ware, refer to COMMUNICATION TOOLS AND
VTS DOWN).
B.U.D.S.
Since the command signal generated by the clo
2. Click the Read Data button.
sure of a VTS switch concerns the VTS module,
a circuit within the gauge will translate it to CAN
512 smr2011-034
3. Check for an applicable fault code on the l&oifiij Pull connector lock out. Do not twist
FAULTS page. the screwdriver.
4. Click the Monitoring tab.
5. In the lower LH corner, click the Cluster tab.
6. On the LH handlebar, press the VTS UP and
DOWN button alternately and look for the VTS
UP and VTS Down indicator lights to come on
in the Cluster Lamp Active area in B.U.D.S.
1. Gauge connector
3. Use a FLUKE 115 MULTIMETER (P/N 529 035 868)

set to the diode test function. Test the VTS but
ton switches as per following tables.
NOTE: It is important to set the multimeter to the
diode check function when testing the VTS control
switches.
TYPICAL
1. Read Data button
2. Monitorn
i g tab
3. Cluster tab
4. Cluster Lamp Active area
Cluster Lamp Active
1 �VTSU'0 SlbµOllS\OOU'.()
-----..VTSOomQ SuspQrsonDawn:<;)
TYPICAL
1. VTS UP and VTS Down indicator lights
If each of the gauge button indicator lights come

on when the applicable switch is pressed, the VTS
control button switches and wiring are good. The
problem may be related to the information center NOTE: Pay attention to multimeter lead position
or iBR module. for diode biasing during test. Remember that
each diode should drop approximately 0.6 Vdc
If one or all of the indicator lights do not come on,
when positively biassed, and read as an OL (open
refer to VTS CONTROL BUTTON TEST USING A
circuit) when negatively biassed (leads reversed).
MULTIMETER.
VTS Control Button Test Using a

Multimeter
1. Remove the gauge support cover, refer to
GAUGE subsection.
smr2011-034 513
VTS CONTROL TEST

SWITCH MULTIMETER GAUGE
VOLTAGE
POSITION LEAD CONNECTOR
RED lead Pin 13 Approx.

Switch BLACK lead Pin 15 2 Vdc
released BLACK lead Pin 13
OL
RED lead Pin 15

UP BLACK lead Pin 15 1.1 Vdc
depressed BLACK lead Pin 13
OL
RED lead Pin 15

DOWN BLACK lead Pin 15 1.6 Vdc omr2009-038·034.•
TYPICAL
depressed BLACK lead Pin 13 1. VTS!iS switch connector
OL
RED lead Pin 15
4. Remove switch assembly from support by lift
When measuring between pins 13 and 15, if an ing it off the support.
OL is obtained with both positive and negative
diode biassing, test the continuity of each wire VTS Control Button Installation
between the gauge and switch assembly. If con 1. Apply a small amount of DIELECTRIC GREASE
tinuity is good, replace the switch assembly. (P/N 293 550 004) on switch contact pins.
If any reading is significantly different than speci 2. Install connector on new switch assembly.
fied, carry out the same test at the switch connec
3. Ensure wiring from START switch is properly
tor, refer to the wiring diagram. If you obtain the
inserted in slot provided before installing VTS
same results, replace the switch assembly.
and iS control button assembly.
If voltages measured on the VTS UP and DOWN
switch are as specified (or very close to it), the
switches and the wiring harness are good. The
fault may be within the gauge. Replace the gauge
and carry out a new VTS BUTTON TEST USING
B. U.D.S. to ensure the problem is solved.
VTS Control Button Removal

NOTE: On iS models, the VTS and iS control but
tons come as a switch assembly that must be re
placed as a unit.
Models with a VTS Switch

1 . Remove steering cover, refer to STEERING
AND 0. T.A.S.
Models Without a VTS Switch

I. START/STOP switch
2. Remove the upper housing and housing cover 2. Wiring routed in slot provided m support
from the LH handlebar housing. 3. VTS/1S switch connector
All Models 4. Insert switch assembly in switch support.

3. Remove connector from switch assembly. 5. Install
remaining removed parts, refer to
STEERING AND 0. T.A. S.
6. Carry out an operational test of the VTS and
iS systems to ensure proper operation of new
switch assembly.
514 smr2011·034
Subsection 03 (JET PUMP)
JET PUMP
SERVICE TOOLS
Descrp
i tion
IMPELLER REMOVER/INSTALLER .............................................. . 529 035 820 ................. 529-531, 533, 536
IMPELLER REMOVER/INSTALLER .............................................. . 529 035 956 ................. 529-531, 533, 536
IMPELLER SHAFT BEARING TOOL ............................................ . 529 036 168 ' ......................... '...... 533-534
IMPELLER SHAFT PUSHER......................................................... . 529 035 955 ................................. 533-534
PRESSURE CAP ...........................................................................
529 . 036 172 ......................................... 519
529
PUMP PLATE................................................................................ . 036 224 ................................. 521-522
SEAL/BEARING PUSHER .............................................................. 529 035 819 ......................................... 535
VACUUM/PRESSURE PUMP ...................................................... 529 . . 021 800 ......................................... 519
SERVICE PRODUCTS
JET PUMP BEARING GREASE ................................................... 293 550 032 .. ......................... 528, 535, 537
LOCTITE 243 (BLUE) ................................................................... 293 800 060.. ................................. 526, 537
LOCTITE 577 (THREAD SEALANTI ............................................... 293 800 050 .................. '...................... 530
LOCTITE 767 (ANTISEIZE LUBRICANTI ...................................... 293 800 070 . ........................................ ' 529
PULLEY FLANGE CLEANER ........................................................ 413 711 809 . ......................................... 524
TRIPLE-GUARD GREASE .............................................................. 296 000 329 ......................... 524-525, 530
XPS LUBE 293 600 016
................................ ...................................................... .............................. '.. 525, 529
smr2011-035 515
Models with Jet Pump Bolted to Pump Support
Triple-guard
grease
I
I
I
(
g =Component must be replaced when removed.

"""2011-035-001_.•
516 smr2()1 1 ·035

Models with Jet Pump Bolted to Ride Plate
See
DRIVE SHAFT
I Triple-guard See
�
J
/&grease BODY
�-:�· '-.... �
/
�'.,,l/'4:1'I
�>
&
Loctite 577
(thread sealant)
"
Loctite 767
(antiseize
lubricant)
Jet pump
bearing grease& ·-.....
...... 125 N•m
1.7 N·�"'-..... (92 lbMt)
(15 lbfoin) -..... • ......._
&
Loctite
243
4.5 N•m 21 N•m
(40 lbf•in) (15 lbfoft)
smr2011-035 517
GENERAL
fer to SELF-LOCKING FASTENER and LOCTITE
complete procedure. 1
A WARNING
Torque wrench tightening specifications s m r2C07-02S-0!> 1_a
must be strictly adhered to. TYPICAL - UNDERNEATH HULL

1. Impeller
Locking devices when removed (e.g.: locking 2. Impeller boot
tabs, elastic stop nuts, self locking fasteners,
- 3. Wear ring

IMPELLER/WEAR RING
JET PUMP MAIN COMPONENTS CLEARANCE
This clearance is critical for jet pump performance.
To check clearance, remove jet pump.
Using a feeler gauge, measure clearance between
impeller blade tip and wear ring. Measure each
blade at its center.
sm r 2000·027·0 11...P
TYPICAL
1. Nozzle
2. Venturi
smr2005- 0 27--00 8
3. Jet pump housing
4. Wear ring
5. Impeller MAXIMUM WEAR
6 Stator
MODEL
.CLEARANCE
All models 0.35 mm (.014 in)
INSPECTION
IMPELLER CONDITION IMPELLER SHAFT RADIAL PLAY

Condition of impeller, impeller boot and wear Radial play is critical for jet pump life span.
ring can be quickly checked from underneath the To check radial play, remove jet pump.
watercraft. With the vehicle on the trailer, use
Make sure impeller shaft turns freely and
a flashlight to visually inspect them through the
smoothly.
inlet grate.
1. Retain housing in a soft jaw vise making sure
not to damage housing lug.
2. Set a dial gauge and position its tip onto metal
end, close to the end of the impeller hub.
3. Move shaft end up and down. Difference be
tween highest and lowest dial gauge reading is
radial play.
518 smr2011-035
52ll021800
TYPICAL - MEASURING IMPELLER SHAFT RADIAL PLAY

1. Dial gauge
2. Measure close to impeller hub end
RADIAL PLAY
0 mm (0 in}
Excessive play can come either from worn bearing

or damaged jet pump housing bearing surface.
LEAK TEST
Whenever performing any type of repair on the jet
pump, a leak test should be carry out. TYPICAL
Proceed as follows:
4. Pressurize pump.
1. Remove impeller cover. Refer to IMPELLER
COVER in this subsection. LEAK TEST PRESSURE
2. Install the PRESSURE CAP (P/N 529 036 172) on Maximum 70 kPa (1 O PSI)
pump housing.
5. Pump must maintain this pressure for at least
5 minutes.
- If there is a pressure drop, spray soapy wa
ter around cover. If there are no bubbles, im
'.'._.
.
peller shaft, impeller shaft seal must be re
;.;q
.•• ' •.--
-
·
..· -
-
placed. Jet pump unit has to be disassem
� .
·- · .
-
. . .
·�� .: _:. bled.

529006 172 NOTE: If there is 2 or 3 bubbles coming out from
the seal on the impeller side is acceptable. Leaks
3. Connect the VACUUM/PRESSURE PUMP (P/N 529
from other areas must be repaired.
021 800) to the pressure cap fitting.
smt2011-035 519
TYPICAL sm1 2 011 .() 35-00 9 •

7. Small leak here is acceptable
JET PUMP BOLTED TO PUMP SUPPORT
ffl1Ji[iij Repair any leak. Failure to correct a

1. Sacrificial anode location
leak will lead to premature wear of pump com

ponents.
6. Disconnect pump and remove pressure ca p .

7. Reinstall impeller cover. Refer to IMPELLER
COVER in this subs ection.
PROCEDURES
NOTE: Whenever removing a part, visually check
for damage such as: corrosion, cracks, split,
break, porosity, cavitation deformation, distor
,
tion, heating discoloration, wear pattern, defec

tive plating, missing or broken balls in ball bearing ,
water damage di agnosed by black-colored spots

on metal parts, etc. Replace any damaged parts.
As a quick check, manually feel clearance and end JET PUMP BOLTED TO RIDE PLATE
play, where a pplicable to detect excessive wear.
,
7. Sacrfi icial anode locatt0n
Sacrificial Anode Removal

SACRIFICIAL ANODE
Unscrew sacrificial anode hexagonal screw and
Sacrificial Anode Inspection remove anode.
Check for wear. If worn more than half, replace
anode.
G m r Z006-027-000
520 smr2011-035
Sacrificial Anode Installation

dure.
Torque anode retaining screw as specified in ex
ploded view.
0
JET PUMP HOUSING
5290362 2 4
NOTE: The jet pump housing can be removed as
an assembly with the venturi. This is the preferred
Jet Pump Housing Removal (Jet Pump
procedure when either the drive shaft or engine
Bolted to Ride Plate)
removal is required.
Remove the following parts as applicable.
Jet Pump Housing Removal (Jet Pump 1. Remove iBR gate and VTS trim ring. Refer to
Bolted to Pump Support) !BR AND VTS subsection.
Do the following as applicable. 2. Cut locking ties and disconnect both bailer
1. Remove the iBR gate and VTS trim ring. Refer hoses from the venturi.
to iBR AND VTS subsection.
2. Detach steering cable from nozzle.
3. Remove the nuts that retain the jet pump to the
pump support.
s mr2009-039-002_ a
TYPICAL
1. Bailer /Joses
3. Loosen gear clamp and remove the hose from

1. Nuts to remove the water pressure outlet fitting on the jet pump
housing.
4. Pull back jet pump housing to remove it from
the pump support. It may be necessary to wig
gle it slightly as you pull back on the pump.
Temporarily fasten the PUMP PLATE (P/N 529 036
224) to pump support to support drive shaft and
avoid PTO oil seal damage.
smr201 l-035 521

Jet Pump Housing Inspection and

Cleaning
1. Visually inspect jet pump housing. Pay atten
tion to the stator. Ensure the assembly is clean
and free of any debris and defects.
Do t he following as applicable.
2. Blow low pressure compressed air through the
TYPICAL pressure outlet fitting and make sure it is clear.
7. Water pressure hose
4. Remove the socket screws that retain the jet

pump to the ride plate.
s mr20 I 1-03S.004 _a
TYPICAL
7. Pressure outlet
3. Ensure cap screw is tight.

4. Ensure the neoprene seal is in good condition.
7. Socket screws to remove (x4) Replace as required.
5. Pull back jet pump housing to remove it from

the pump support. It may be necessary to wig
gle it slightly as you pull back on the pump.
NOTE: The jet pump housing is held tightly in the
pump support due to the neoprene seal at the for
ward end of the pump. There are no fasteners se
curing the jet pump housing to the pump support.
Temporarily fasten the PUMP PLATE (P/N 529 036
224) to pump support to support drive shaft and
avoid PTO oil seal damage.
522 smr2011-035
5. Check the 4 pump adapters (jet pump bolted to

ride plate). Ensure they are free of any cracks.
NOTE: Do not remove the jet pump housing
adapters from the pump unless it is necessary to
do so.
•mr 2 0 1 t -035-00 9 _o

1. Cap screw
2. Neoprene seal
smr2009-0 3 9-0 06_.
1. Jet pump housing adapters (x4)
Jet Pump Housing Adapter

Replacement (Jet Pump Bolted to
Ride Plate)
Adapters incorporate a keyway at the pump hous
ing end of the adapter that provide for a small
amount of play for mounting the jet pump.
$CTir2009-0 9 · 00 5_a
3
JET PUMP BOLTED TO RIDE PLATE

1. Pressure hose fitting
2. Neoprene seal
NOTE: Ensure holes of pressure inlet remain

clear to ensure an adequate water supply for the
intercooler and exhaust system.
s m (.?009-09 9-007_•
1. Adapter key
smr 2009-03 9·0 I 0 -

•
TYPICAL
s mr2009-03 9-
00e_a
1. Fitting
2. Holes in pump housmg 1. Pump housing adapter keywav
smr2011-035 523
If adapters are removed or replaced, or a new

pump housing is installed, adapters may be 1
aligned to the pump housing using a spare ride
plate as a jig. Carry out the following steps.
1. Install the four adapters on the jet pump hous
ing leaving the hexagonal screws slightly loose.
2. Install the pump on a spare ride plate, the
mounting screws should be tight, but it is not
required to torque them.
3. Torque hexagonal screws retaining the
adapters to the jet pump housing as speci
fied in the exploded view.
4. Remove the jet pump housing from the spare
sm12011-03S.005_a
ride plate and install it on the watercraft ride
1 Slide adapter onto pump
plate. 2. New a-rings here
Jet Pump Housing Installation Install new 0-rings on pump support.
Brush and clean impeller splines and drive shaft The water flow is controlled by a calibrated re
splines with PULLEY FLANGE CLEANER (P/N 413 ducer. Ensure to install the YELLOW color-coded
711 809) or equivalent. Splines must be free of reducer.
any residue.
@c1)jl1Jj Improper reducer can cause over
Lubricate drive shaft splines, impeller splines and heating and damage to exhaust system.
the inside of the impeller boot with TRIPLE-GUARD
GREASE (P/N 296 000 329).
Ensure the neoprene seal is properly installed on
the jet pump.
s mr 2011 -03S.006_ a
1. Install new 0-rings

2. Calibrated reducer
Generously apply TRIPLE-GUARD GREASE (P/N 296

ooo 329) on drive shaft splines.
TYPICAL Install jet pump.
1. Neoprene seal
NOTE: If necessary, wiggle jet pump to engage
Jet Pump Bolted to Pump Support drive shaft splines in impeller.
Install new 0-rings then slide water outlet adapter Install new nuts and torque as per table and the
onto pump. illustrated sequence.
TORQUE
524 smr2011-035
smr20 11-035-009 .)l
NOTE: Slightly lubricate wear ring with XPS LUBE

(P/N 293 600 016) to minimize friction during initial smr 11-03 5-050_
a
impeller start. STRICTLY FOLLOW THESE INSTRUCTIONS

1. Use new screw
Jet Pump Bolted to Ride Plate Torque to 35 N•m (26 lbf•ft) twice
Allow one day to settle without using watercraft
Generously apply TRIPLE-GUARD GREASE (P/N 296
000 329) on drive shaft splines. NOTE: Slightly lubricate wear ring with XPS LUBE
(P/N 293 600 016) to minimize friction during initial
While holding the pump housing with the pump
impeller start.
adapters downwards, align the pump with the
drive shaft and carefully push the pump into the
pump support. VENTURI
Use NEW screws to retain pump adapters to ride Venturi Removal
plate.
Jet Pump Housing installed
Torque each screw to 35 N•m (26 lbf•ft) then
torque each screw a second time. As applicable, do the following.
1. Remove the iBR gate and VTS trim ring as an
fiil1)i(iJj Fa i l ure to properly follow the above
assembly. Refer to 1BR AND VTS subsection.
procedure might lead to screw loosenin g .
2. Remove nozzle.
Wait one day before using the watercraft to let
3. Cut locking ties and remove the 2 bailer hoses
time for the thread locker to settle.
from the venturi.
4. Refer to JET PUMP HOUSING REMOVED to
continue procedure.
Jet Pump Housing Removed

1. Remove the screws retaining the venturi to the
jet pump housing.
smr2011-035 525
IMPELLER COVER
Impeller Cover Removal
1. Remove the venturi.
2. With pump housing in vertical position, remove
and discard the 3 retaining screws.

1. Venturi retaining screws
F18JOLA
TYPICAL
3. Using a fiber hammer, gently tap impeller cover

to help release it from the jet pump housing.
4. Use a flat screwdriver in the slots provided as
pry points to remove it from the jet pump hous
ing.
smr200
9.C
l39 -0
02..b
JET PUMP BOLTED TO RIDE PLATE

1. Bailer hoses
2. Venturi retammg screws
Venturi Installation
cedure. Pay attention to the following .
As applicable align venturi bai ler holes with those

,
in pu m p support.
7. Slot
threads of venturi screws (or install new self-lock
ing screws).
Install venturi screws and flat washers.
Torque venturi screws to 21 N•m (15 lbf•ft).
As applicable, ensure bailer hoses and fittings are
in good condition.
526 smr2011·035
sm • 2 009 -0 0 6- 002_a
1. Seal on impeller side
f18JOMA
TYPICAL
5. Remove both 0-rings.
1. Cover 0-rings
Check impeller boot and 0-rings condition on im

peller. Replace as required.
TYPICAL
1. 0-rings
Impeller Cover Inspection

Check for presence of water in cover and bearing
area. If water is found, replace seals on impeller
side. Also replace 0-rings and/or impeller cover.
1. Impeller boot
2. Impeller 0-ring
3. Pump housing 0-ring
Perform a leak test. Refer to LEAK TEST in this

subsection.
Impeller Cover Installation

1. Install 0-rings in their respective groove.
srnr2011-035 527
NOTE: Push cover against pump housing while

alternately tightening screws. Make sure 0-rings
are positioned correctly and they are not damaged
when pushing the cover.
5. Torque cover screws to 7.5N•m (661bf•in).
IMPELLER
Impeller Removal
NOTE: If impeller shaft is to be disassembled,
loosen the impeller shaft nut prior to removing
the impeller.
1 Remove jet pump from the watercraft. Refer to
.
F18JONA
JET PUMP HOUSING in this subsection.
TYPICAL
2. Put 23 ml (.8 U.S. oz) of JET PUMP BEARING COVER in this subsection.
GREASE (P/N 293 550 032) in the cover. 3. Remove impeller boot by turning it clockwise
(LH threads).
Fl8J18't.
TYPICAL
3. Install impeller cover by aligning the cover index

mark with the pump top fin as shown.
F19J06A
TYPICAL
1. Unscrew clockwise
4. Mount the flat sides of impeller shaft in a vise.
1. Alg
i n mark with top fin
NOTE: Cover can only be installed in one position

as screw holes are not located symmetrically.
4. Secure cover with NEW self-locking screws.
528 sml'2011-035
6. To pull impeller out of the pump, apply a rotating

movement as you pull on the impeller.
Impeller Installation
1. Mount the flat sides of the impeller shaft in a
vise.
smr2009-006 -00 5_•
TYPICAL
1. Flar side
5. Unsc re w the impeller counterclockwise using

the required tool.
ENGINE REQUIRED TOOL
130, 155 smr'2009-006-0
_o 0S
(P/N 529 035 820) TYPICAL
1. Flat side
215, 260
(P/N 529 035 956) 2. Apply LOCTITE 767 (ANTISEIZE LUBRICANT)
(P/N 293 800 070) on threads of impeller shaft.
5290
3 59�
TYPICAL
NOTE: It may be necessary to heat the impeller

to ease removal.
fillui/ilNever use an impact wrench to

loosen impeller.
TYPICAL
1. Antiseize lubf/cant
3. Apply XPS LUBE (P/N 293 600 016) on the wear

ring surface.
smr2009-006 ·00G_b
TYPICAL
smr2011-035 529
11fl•D@j Never use an impact wrench to

tighten impeller shaft.
TYPICAL
7. XPS lube
4. Start screwing the impeller on its shaft.

smr\?009-0-06-00 G_a
TYPICAL
7. Apply LOCTITE 577 (THREAD SEALANT) (PIN 293

800 050) on impeller boot threads.
8. Apply TRIPLE-GUARD GREASE (P/N 296 000 329)

inside impeller boot.
9. Install impeller boot on impeller and tighten
counterclockwise.
WEAR RING
Wear Ring Inspection
Check wear ring for:
- Deep scratches
TYPICAL - Irregular surface
5. Mount the required tool in impeller splines. - Any apparent damage.

Check IMPELLER/WEAR RING CLEARANCE, see
ENGI NE REQUIRED TOOL
procedure at the beginning of this subsection.
130, 155
(P/N 529 035 820) Wear Ring Removal
IMPELLER REMOVER/INSTALLER 1. Remove the iBR gate, VTS trim ring and the
215, 260
(P/N 529 035 956) steering nozzle as an assembly. See procedure
in !BR AND VTS subsection.
2. Remove jet pump from watercraft. Refer to
JET PUMP HOUSING in this subsection.
3. Remove impeller from jet pump housing, refer
to IMPELLER in this subsection.
4. Place jet pump housing in a vise with soft jaws.
S2 9005!l56
TYPICAL
It is best to clamp housing using a lower ear.
5. Cut wear ring at two places.
6. Torque impeller as per table.
IM1Jifij When cutting ring, be careful not to
I
TORQUE
damage jet pump housing.
125N•m (921bf•ft)
NOTE: Wear ring can be cut using a jigsaw, a
Remove tool. small grinder or a low clearance hacksaw.
530 smr2011 ·036

6. After cutting ring, insert a screwdriver blade be

tween jet pump housing and ring outside diam
eter.
7. Push ring so that it can collapse internally.
8. Pull ring out.
Wear Ring Installation

To install wear ring in housing. use a square steel
plate of approximately 180 x 180 mm x 6 mm thick
(7 x 7 in x 1/4 in} and a press.
Manually engage ring in housing making sure it is
equally inserted all around. Press ring until it seats
into bottom of housing.
Rl1J1FA
1. Piece of wood
2. Rounded edge
3. Wearring
IMPELLER SHAFT AND BEARING

Impeller Shaft and Bearing Removal
COVER in this subsection.
2. Mount in a vise the proper impeller remover/in
staller as per table.
1. Rounded edge
2. Press wear ring
2903 5
5 956
If a press is not readily available, a piece of wood
TYPICAL
such as a 2 x 4 in x 12 in long, can be used.
Manually engage ring in housing making sure it ENGINE REQUIRED TOOL
is equally inserted all around. Place wood piece IMPELLER REMOVER/INSTALLER
over ring. Using a hammer, strike on wood to 130. 155
(P/N 529 035 820)
push ring. Strike one side then rotate wood piece
about 90° and strike again. Frequently rotate 215, 260
(P/N 529 035 956)
wood piece so that ring slides in evenly until it
seats into bottom of housing.
smr2011-035 531
F18JOP6 smr2009-00&00 9 ...a
TYPICAL
TYPICAL
1. Impeller remover/insraller tool
5. Remove impeller shaft nut.
3. Install jet pump housing over impeller re
mover/installer tool.
TYPICAL
1. Nur
F18JOOA 6. Remove impeller as described in this subsec

tion.
TYPICAL
7. From the impeller side, remove circlip, seals,
4. Using a 30 mm socket, unscrew the impeller spacer and 0-ring.
shaft nut counterclockwise.
NOTE: If impeller loosens instead of shaft nut,
refer to IMPELLER SHAFT NUT REMOVAL IF
IMPELLER HAS LOOSENED further in this pro
cedure.
TYPICAL
1. Circlip
2. Seal
532 smr2011·035
Subsection 03 {JET PUMP)
8. Use the IMPELLER SHAFT PUSHER (P/N 529 035

955) to press impeller shaft out of p u m p hous
ing.
NOTE: Bearing will come out with the impeller
shaft.
TYPICAL
1. Impeller shaft and bearing
529035955
2. Bearing tool on INNER race
Impeller Shaft Nut Removal if Impeller Has

Loosened
1. Turn pump upside down and mount the flat
sides of impeller shaft in a vise.
TYPICAL
s m.'2009-006-005_•
TYPICAL
1. Flat side
2. Mount in the impeller splines the proper im

peller remover/installer a s per table.
smr2009-006 .01 I
TYPICAL
529005956
9. Use the IMPELLER SHAFT BEARING TOOL TYPICAL

(P/N 529 036 168) to press bearing off impeller
shaft. ENGINE REQUIRED TOOL
130, 155
(P/N 529 035 820)
215, 260
(P/N 529 035 956)
smr'Z011-035 533
3. Torque impeller more than impeller shaft nut.
omr2009-0<J6-01 9_
1
TYPICAL
1. Threads
2. Seal lip contact surface
3. Threads
Inspect ball bearing for corrosion.
Impeller Shaft and Bearing Installation
TYPICAL
Bearin g Installation
4. Turn pump upside down and retry unscrewing moval procedure. However, pay attention to the
impeller shaft nut. following.
1. Using the IMPELLER SHAFT BEARING TOOL
(P/N 529 036 168) on the bearing inner race,
press the bearing on the impeller shaft.
2. Use the IMPELLER SHAFT PUSHER (PIN 529 035
955) to protect the impeller shaft threads.
NOTE: The bearing can be installed in either direc
tion.
TYPICAL
5. If impeller still loosens instead of nut. retighten

impeller more and retry. Repeat until nut
loosens.
6. Remove impeller as described in this subsec
ti on .
7. Return to step 5 in the IMPELLER SHAFT AND

BEARING REMOVAL main procedure. TYPICAL
1. Impeller shaft bearing tool on INNER race
Impeller Shaft and Bearing Inspection 2. Impeller shaft and bearing
3. Impeller shaft installer/pusher tool
With your finger nail, feel seal lip contact surface
on shaft. If any irregular surface is found, replace 3. Press bearing until it bottoms.
shaft and seals. Im pel le r Shaft Installation
Check condition of shaft threads. NOTE: Ensure there is no 0-ring in pump housing
on the cover side.
1. From the outlet side of pump, press impeller
shaft assembly into housing using the IM
PELLER SHAFT BEARING TOOL (P/N 529 036
168).
534 srr.r2011-035
F18J12A
TYPICAL
TYPICAL
1. Bearing tool
2. Impeller shaft and bearing
7. Press a NEW double lip seal using the
2. Press bearing until it bottoms. SEALJBEARING PUSHER (P/N 529 035 819) until
NOTE: Ensure impeller shaft turns freely and seal bottoms. Make sure seal lip are facing
smoothly. u pwards.
3. Turn pump upside down.

4. Coat shaft surface wit h JET PUMP BEARING
GREASE (P/N 293 550 032).
5. Install 0-ring at bottom.
n
s v 2 009.006-01 5.a
1. Sea/lip up
F19J07A 2 1
TYPICAL
1. 0-ring at bottom
2. Coat surface
6. Apply 4 ml (.1 U.S. oz) of JET PUMP BEARING

GREASE (P/N 293 550 032) on bearing.
f18J13A
1. Seal lip facing up
smr2011-035 535
TYPICAL
1. 0-rings
TYPICAL
1. Seal/bsaring pusher 12. Before installi ng any o t her parts, pressurize jet
pump to insure proper seal installation. Refer
8. Install spacer and then the other seal ( thin) . En to LEAK TESTin this subsection.
sure seal lip is facing up.
13. Ins ta ll impeller. Refer to IMPELLER in this
subsection.
14. Mount in a vise the proper impeller re
i staller as per table.
mover/n
TYPICAL
ENGINE TOOL P/N
1. IMPELLER REMOVER/INSTALLER
Seal lip facing up 130, 155
(P/N 529 035 820)
9. I nstall circlip.
215, 260
(P/N 529 035 956)
smr200&-027-00 7 .c
TYPICAL
1. C1rclip
F18JtlPB
10. Turn pump upside down. 1. lmp&lf&r rsmover/installer tool
11. In sta l l the two 0-rings in pump ho using.

15. Install jet pump housing over this tool.
536 smr2011-035
19. Install the impeller cover. Refer to IMPELLER

COVER in this subsection.
NOZZLE (GTS MODELS)

Nozzle Removal
Disconnect steering cable from nozzle arm. Refer
to STEERING AND 0. TA.S.
Remove screws retaining nozzle to venturi.
F18JOOA
TYPICAL
16. Using a 30 mm socket. screw the impeller

shaft nut on clockwise.
17. Torque nut as specified in exploded view.
8
smr2011-035-008_
1. Screws
Remove nozzle.
Steering Nozzle Inspection

Inspect steering nozzle for cracks. wear. deforma
tion, and other damages.
Inspect bushings for wear or other damage.
Replace parts as required.
smr 2009.00S-009_b
18. Apply 24 ml (.8 u .S. oz) of JET PUMP BEARING Nozzle Installation
GREASE (P/N 293 550 032) on the bearing (nut The installation is the reverse of the removal pro
side). cedure. However, pay attention to the following.
screw threads (or use new self-locking screws).
Torque screws as per table ..
T ORQUE
Secure steering cable to nozzle arm. Refer to Re

fer to STEERING AND 0. TA.S.
Perform the STEERING ALIGNMENT. Refer to
STEERING AND 0. TA.S.
sm r20-09--00 6 .0 1 8
smr2011-035 537
538
Subsection 04 (DRIVE SHAFT}
DRIVE SHAFT
SERVICE TOOLS
DRIVE SHAFT C-CLIP REMOVER................................................. 529 036 026 ......................................... 542
FLOATING RING TOOL (TYPE I)................................................... 529 035 841 ................................. 542, 547
PTO SUPPORT TOOL................................................................... 529 035 842 ........ .......... . . . ............ 543, 546
SERVICE PRODUCTS
Description P�rt Number Page
PULLEY FLANGE CLEANER ............................ ........ ......... ......... "413 711 809 ......................................... 544
. . .
XPS LUBE...................................................................................... 293 600 016 ......................................... 543

XPS SYNTHETIC GREASE............................................................. 293 550 010 ......................................... 546
smr2011-036 539
Subsection 04 (DRIVE SHAFT)
XPS
Engine synthetic
oil grease
Triple guard
grease
2 N•m
(18 lbfoin)

Jl'l'A10l l-036-00l _b
540 smt2011-036
GENERAL 2
Jet pump must be removed to replace any com

ponents of the drive system. Refer to JET PUMP
for removal procedure.
complete procedure.
A WARNING
Torque wrench tightening sp ecifications
F18LI GB
Locking devices must be replaced with new TYPICAL
1. Detach expansion reservoir
ones (e.g.: locking tabs, elastic stop nuts, 2. Remove vent tube support
self-locking fasteners, cotter pins, etc.).
3. Detach vent tube.
Hoses, cables or locking ties removed during a 4. Remove vent tube support.
5. On GTX 215, remove supercharger air inlet
dards.
hose.
PROCEDURES RXT 260/RXT-X 260

6. Remove seat.
DRIVE SHAFT 7. Detach coolant expansion reservoir from vent
tube support then move away.
Drive Shaft Access (GTS/GTl/Wake)
8. Remove muffler hose.
Remove seat.
9. Remove intercooler inlet and outlet air hoses.
Drive Shaft Access 10. Remove supercharger air inlet hose.
(RXT/GTX/Wake Pro)
RXT-X as 260, GTX iS 215 and GTX Ltd iS 260
GTX 155/215
1 . Open seat.
1 Remove seat.
2. Remove the deck extension. Refer to BODY
.
2. Detach coolant expansion reservoir from vent (RXT/GTXll/VAKE PRO} subsection.

tube support then move away.
1. Deck extension
smr2011-036 541
3. Lower the moving deck onto the fixed deck and

install a few hexagonal screws on the rear sus
pension arm to hold the deck steady for the du
ration of the procedures.
GTX iS 215
4. Remove air intake silencer.
5. Remove supercharger air inlet hose.
RXT-X aS 260 and GTX Ltd tS 260

6. Remove air intake silencer.
7. Remove muffler hose.
8. Remove intercooler inlet and outlet air hoses.
9. Remove supercharger air inlet hose. 1mr20 1 l -03S.
O< J2 _a
1 Fork against floating ring

2. Adjustable arm
Drive Shaft Removal
Preparation 3.3 Move the tool handle toward the front of
vehicle to push floating ring rearward.
Refer to DRIVE SHAFT ACCESS to remove re
quired parts according to model.
To minimize oil spillage, syphon oil in engine PTO
area. Refer to PTO HOUSING REMOVAL in PTO
HOUSING AND MAGNETO subsection.
Procedures
NOTE: Ensure jet pump is installed before begin
ning this procedure.
1. Disconnect EGTS sensor as necessary.
2. Lift rubber protector to expose PTO seal as
sembly.
3. Confirm the floating ring is not stuck on drive
shaft as follows:
REQUIRED TOOL ww20 1 1-03&-003_a
DRIVE SHAFT C-CLIP REMOVER

NOTE: Do not remove circlip at this time.
(PIN 529 036 026)
3.4 Remove the drive shaft C-clip remover.
4. Install the following tool on drive shaft with its
largest opening on PTO side.
REQUIRED TOOL
FLOATING RING TOOL (TYPE I) (P/N 529 035 841)
52900 00 26
3.1 Place the fork of drive shaft circlip remover

against floating ring.
3.2 Place the adjustable arm on engine.
542 smr2011-036
Subsection 04 {DRIVE SHAFT)
F18l00A 1
TYPICAL
1. Largest opening on PTO seal side
smr201 MX36-031 _�
TYPfCAL
1. Telltale groove
2. Lubricate this a r ea
A 18 mm (.71 in)
sm<2011-036-0 3 0_a
TYPICAL 7. Remove the floating ring tool.

1. Largest opening here
8. Install the following tool to PTO seal assembly.
5. Turn tool screw CLOCKWISE until the following
REQUIRED TOOL
gap is obtained.
PTO SUPPORT TOOL (P/N 529 035 842)
GAP BETWEEN TELLTALE GROOVE AND
TOOL EDGE
18mm (.71 in)
NOTE: This will expose the 0-ring contact area.

6. Lubricate 0-ring contact area with XPS LUBE
(P/N 293 600 016).
NOTE: This is necessary to ease drive shaft re
moval later in this procedure.
529035842
smr20·11-036 543
TYPICAL
1. Largest opening here
2. Floating ring
3. PTO seal support tool
1. Insert in groove of PTO seal assembly 4. Remove circlip
tiff,JmJj Strictly follow this procedure other 12. Remove the f l oati n g ring tool.
wise damage to component might occur. 13. Place rags under PTO housing to prevent
spillage. If spillage occurs, clean immediately
9. Reinstall the floating ring tool as shown.
with the PULLEY FLANGE CLEANER (P/N 413
711 809) to prevent oil stains.
14. Remove jet pump. Refer to JET PUMP sec-
tion.
15. Remove drive shaft.
NOTE: A slight jer k to the rear may be required to
remove the drive shaft from the PTO seal assem
bly.
Drive Shaft Inspection

Drive Shaft
Inspect condition of circlip groove. If there is any
F 18IOOA 1 damage or severe wear, replace drive shaft.
TYPICAL
1. Largest opening on PTO seal side
10. Turn screw of tool clockwise to push floating

ring rearward to expose circlip.
11 . Remove and discard circlip.
1. Circflp groove
Inspect condition of drive shaft splines. If spli nes

are damaged, replace drive shaft.
With your finger nail, feel machined surface of
drive shaft. If any i rreg u la r surface is found, re
new drive shaft.
544 smr201 1-036

1 2
smr200&-028 006..B
TYPICAL
1. Surface condition
2. Splines condition
F 1 8101(A
Excessive deflection could cause vibration and

1. O·rings
damage to drive shaft splines, im peller or floating 2. Contact surface
ring.
Place drive shaft on V-blocks and set-up a dial
Drive Shaft Installation
gauge in center of shaft. Slowly rotate shaft; dif Before installing drive shaft, discard both 0-rings
ference between highest and lowest dial gauge inside PTO seal and install NEW ones.
reading is deflection. Refer to the following illus
tration.
F18C01A
7. 0-rings
Inspect PTO seal assembly. The inner sleeve

must be flush with outer circumference of the
MEASURING DRIVE SHAFT DEFLECTION
1. Dial gauge assembly. Otherwise, gently push or tap on inner
2. V-blocks
sleeve until flush.
Maximum permissible deflection is 0.5 mm

(.020 in).
Floating Ring
Inspect condition of 0-rings and contact surface
of floating ring.
Replace as required.
f1810EA
CORRECT POSITION
1. Inner sleeve flush with outer circumference
smr2011-036 545
Subsection 04 ( DRIVE SHAFT)
F1810HA 1 2 3
F18IOFA 1 1. PTO seal support

2. Drive shaft end
INCORRECT POSITION 3. Insert floating ring on shaft end
1. Inner sleeve not flush with outer circumference
Continue pushing drive shaft towards engine care
Remove the damper at the end of drive shaft and fully guiding it in the PTO seal then in crankshaft
replace it with a NEW one. splines. It may be necessary to move PTO seal
assembly up and down to position it in the same
axis as the drive shaft.
NOTE: If drive shaft does not enter into the PTO
seal, check engine alignment.
smr 20�8.004 a
1. Damper
Install the PTO SUPPORT TOOL (P/N 529 035 842) on

PTO seal assembly.
Apply a thin coat of XPS SYNTHETIC GREASE
{P/N 293 550 01 OJ on the floating ring 0-rings. Do
not get grease on floating ring contact surface.
f 18I02A
TYPICAL
Maintain PTO seal assembly in the proper position

and tap shaft end until it bottoms against engine.
2
At this time, the telltale groove MUST NOT be vis
ible. This validates the correct position.
IW•lmJj If the telltale groove is exposed, the

installation is wrong and PTO seal assembly
F18tOK.A
will be pressed into crankshaft splines which
could rub a hole in seal thus creating an oil
1. XP-S synthetic grease on 0-rings
leak.
2 No lubrication on contact surface
Slide drive shaft far enough to install floating ring.
546 smr201 l-03S

F1810N A 1
TYPICAL
7. Largest opening on through-huff fitting side
NOTE: Ensure PTO seal support is still in place.

Push floating ring rearwards and install a NEW cir
clip.
F18101A 2
CORRECT INSTALLATION
1. PTO seal assembly
2 Shah pushed m, hiding telltale groove
3. Inner sleeve flush with outer circumference
3 1
F16C02A
TYPICAL
1. Largest opening
2. Floatn i g ring
3. PTO seal support tool
4. Ins tall circlip
Remove floating ring tool and PTO seal support.

NOTE: Pulling drive shaft boot rearward will ease
removal of PTO support tool.
f18IOJA 2
Ensure everything is properly positioned:
IMPROPER INSTALLATION - Telltale groove is not visible
1. PTO seal assembly
2. Telltale groove v1s1ble - Inner sleeve is flush with outer circumference
3. Inner sleeve NOT flush with outer circumference
of PTO seal assembly
Temporarily install the jet pump. - Circlip is not exposed.
Install a new circlip using the following procedure If telltale groove is visible, pull PTO seal assembly
and tools. rearwards to fully extend it.
If inner sleeve is not flush, gently tap it until it is
REQUIRED TOOL
flush.
FLOATING RING TOOL (TYPE I)
Reposition rubber protector.
(P/N 529 035 841)
Reconnect EGTS sensor if applicable.
smr201 I·OJ(l 547

Permanently install jet pump. Refer to JET PUMP

section.
Check engine oil level. Refill as necessary.
Test watercraft then ensure there is:
- No oil leak in PTO seal area
- No water intrusion by the thru-hull fitting area.
sm�OOS-030-003_ •
DRIVE SHAFT BOOT 7. Drive shaft boot

2. Carbon nng
Drive Shaft Boot Inspection

Carbon Ring Installation
Inspect the condition of boot. If there is any dam
age or evidence of wear, replace it. The installation is the reverse of the removal pro
cedure.
Drive Shaft Boot Removal
Remove drive shaft. Refer to DRIVESHAFTtn this
subsection.
Loosen gear clamp holding boot. then carefully
pull boot and carbon ring from hull insert.
TYPICAL
2. Drive shaft boot
Drive Shaft Boot Installation

cedure.
CARBON RING
Carbon Ring Removal
Remove DRIVE SHAFT BOOT. See procedure in
this section.
Loosen gear clamp then pull carbon ring from
drive shaft boot.
548 smr2011-036
Section 07 BODY AND HU LL
Subsection 01 (SUSPENSION (aS))
SUSPENSION (aS)
SERVICE TOOLS
SUPERTANIUM DRILL BIT 3/16"
. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529 031 800 ......................................... 560
smr2011-037 549
Section 07 BODY AND HULL
FRONT SUSPENSION ARM
48 N•m nr.rr.n
(351bf.ft) �
10 N•m
(89 lbfoin)
12 N•m
(106 lbMn)
!--..... 25N•m
11 I (18 1bMtl
� I- l___
------ ��>·
--
----- .
"- ...':!.-�
25 N•m"-. nr.rr.n
···
........
···
------
�
·
····
�
.-
(18 lbf•ft) ----- - , l ····
10 N•m
. .
···
··
(89 lbfoin)
··
··
mm
····
See I I
tightening j j
sequence , ,
I
48 N•m
(35 lbf•ft)
mlm =Component must be replaced when removed.

s m rlOl l-037- 1 00_ 1
550 smr2011·037
SHOCK ABSORBER
<3>
..
mm
75 N•m
(55 lbfeft)
mm
25 N•m
(18 lbMt)---�
mg • Component must be replaced when removed.

smr201HX.l1·101_e
smr2011-037 551
.
Sect10� BODY AND HULL
0701 (SUSPENSION (aS))
Subsection
REAR SUSPENSION ARM
(18J�,��l !�r(891�
lbfoftl. �
lbfoin)
sm
r2009-04' -002_a
552 smr2011·037
Section07 BODY AND HULL
GENERAL
complete procedure.
lifttJltflj When applying threadlocker prod

ucts {anaerobic products), pay attention so
that it does not come in contact w ith ABS plas
tic parts {painted parts). It could lead to plastic
cracks or other damage. Gdd2 009.001-2 02
TYPICAL • FIXED DECK
A WARNING Spring Preload Adjustment

The spring preload can be easily adjusted using a
1/2" drive ratchet wrench with an extension.
tabs, elastic stop nuts, self-locking fasteners, The spring preload adjuster is located under the
cotter pins, etc.) must be replaced with new seat.
one.
Wl1)i[ll]j Hoses, cables or locking ties re

SYSTEM DESCRIPTION
The adjustable Suspension {aS) allows the moving
deck to move independently from the fixed deck,
isolating rider and passenger from the impact of
rough water.
With the aS feature, the moving deck may be
adjusted mechanically to absorb (dampen) water
SPRING PRELOAD ADJUSTMENT
shocks according to the driver riding style and
water conditions. NBR OF CLICKS
RIDERS TOTAL WEIGHT ON SPRING
(KG/LB) ADJUSTER
(CLOCKWISE*)
57 kgf (125 lbf) 0
73 kgf (160 lbf) 2
89 kgf (195 lbf) 4
105 kgf (230 lbf) 6
120 kgf (265 lbf) 8
136 kgf (300 lbf) 10

smt20
0 9-041-080
TYPICAL • MOVING DECK 152 kgf (335 lbf) 12
168 kgf (370 lbf) 14
184 kgf (405 lbf) 16
200 kgf (440 lbf) 18
* 0 is set at fully unscrewed position

(counterclockwise).
smr2011-037 553
Damping Adjustment SUSPENSION MOVES ERRATICALLY

The aS Suspension damping may be personally 1. Defective shock absorber.
adjustable according to the driving preferences
- Replace the shock absorber.
and water conditions.
2. Broken spring.
Damping adjustment is carried out via the remote
- Replace spring.
nitrogen reservoir in the glove box.
A blue knob located in glove box allows damper SUSPENSION NOISE (DURING A TURN)
adjustment for this purpose.
1. Front or rear suspension arm shaft supports po
sition.
- Supports must be flushed against both ends of
shaft. Reposition shaft in its supports.
2. Worn arm shaft bushings.

- Check front and rear arm shaft bushings condition
and replace as required.
3. Snap rings on both sides of the rear lower arm

shaft are not properly positioned.
- Reposition shaft in its supports. Refer to SUS
PENSION ARM SHAFTS.
SUSPENSION NOISE (FRONT OF SEAT)
1. Holder retaining screws are loose.

Jm02()1 1 -002 -00G_a.
- Tighten shock absorber holder screws to recom
1. Blue knob
2. Nitrogen gas damp&r
mended torque.
2. Shock absorber screws are loose.

NBR OF CLICKS ON
TYPICAL CONDITIONS DAMPER ADJUSTER - Tighten shock absorber screws to recommended
(CLOCKWISE*) torque.
0 SUSPENSION BOTTOMS HARD

Calm water
5 1. Spring out of specification or broken.
10 - Replace spring.
Rough water
15 2. Shock absorber is damaged.
Offshore 20 - Check shock absorber resistance. Replace shock

absorber.
11 0 is set at fully unscrewed position
(counterclockwise). 3. Bump stops damaged or worn.
- Replace both bump stops.
NOTE: These adjustments are provided as guide
lines to ensure optimum suspension perfor
mance. Personal preference may dictate differ
ent settings than those recommended.
TROUBLESHOOTING
DIAGNOSTIC GUIDELINES
lems.
554 smr2011-037
PROCEDURES
SHOCK ABSORBER
Shock Absorber Location
.s mr20 l 1-03i-004 ,..a
MOUNTING PLATE REMOVAL
4. Remove spring and lower spring bushing.
s mr2011-03 7 ·002-•
1. Mounting plate
2. Shock absorber
3. Shock holder
Shock Absorber Removal

1. Remove moving deck. Refer to BODY subsec
tion.
2. Remove shock absorber upper bolt.
sm120 1 1 .037-01 0_a
1. Spring
2. Lower spring bushing
5. Remove shock holder retaining screws.
smr2011·037-003.
a
1. Shock absorber upper bolt
3. Remove mounting plate by pulling it upwards.
s mr201 l-037-005 .a
TYPICAL
1. Shock holder retaining screws
6. Remove locking tie securing remote reservoir

hose.
smr2011·037 555
Subsect ion 01 (SUSPENSION (aS})
omr1 011-03?.00S_
o
s mr20 1 1-03 7.00 9 •
1. Locking tie securing remote reservoir hose
7. Shock absorber lower bolt
7. Remove bellows of remote reservoir hose from

deck. Shock Absorber Inspection
8. Insert remote reservoir into deck hole. NOTE: Because of gas pressure, strong resis
tance is felt when compressing shock.
To inspect shock operation, or if suspecting an in
ternal leak between oil chamber and gas chamber,
check shock as follows:
1. Grab the shock absorber body firmly and press
the rod end against a firm surface.
1 .1 Verify the compression stroke when the
rod is fully extended.
1.2 Make sure that shock absorber rod can be
completely inserted in the shock body.
2. The shock should extend unassisted. Rod must
come out at a steady speed.
If any problem is detected, replace the shock ab
sm1 2011-031.007_ o
sorber.
1. Bellows of remote reservoir hose
2. Deckhole
3. Remote reservoir Shock Absorber Installation
9. Remove shock absorber and remote reservoir.
Secure shock absorber using NEW bolts.
Tighten shock absorber bolts to specification.
TORQUE
Shock absorber bolt I 75 N•m (55 lbf•ft)
Install NEW shock holder screws.

Tighten shock holder screws to specification.
TORQUE
Shock holder screw I 25 N•m (18 lbf•ft)
o mr2Dl1.al 7-0'J9
SHOCK ABSORBER REMOVAL
10. Remove shock holder from shock absorber.
556 smr2011-037
SPRING
Spring Location
ssn1 2011.037-011_1
1. Spring holder retaining screws
5. Remove screw securing spring holder to link

arm.
sm12011.03 7.01 S_ a
1. Spring
Spring Removal
1. Remove moving deck. Refer to BODYsubsec
tion.
2. Remove shock holder from its location. Refer
to SHOCK ABSORBER in this subsection.
smr2011-03i· Ol6 _
1
TYPICAL - SOME PARTS REMOVED FOR CLARITY

1. Screw securing spring holder to lmk arm
6. Remove spring holder.
s mr20 1 1-037-005_•
TYPICAL
1. Shock holder retaining screws
3. Move shock holder aside.

4. Remove spring holder retaining screws.
smr2011-037-012
SPRING HOLDER REMOVAL
smr2011-037 557
Spring Inspection TORQUE

Inspect spring and replace if one of the following Shock holder screw 25 N•m (18 lbf•ft)
damage is detected:
Spring holder screw 25 N•m (18 lbf•ft)
- Crack in the paint
- Rust
If spring supports were disassembled, pay atten
- Other visible damages. tion to the following.
NOTE: If rust is limited to a 1/4 of the first coil, the Install NEW upper spring support screws.
spring should not be replaced.
Tighten upper spring support screws to specifica
tion as per the following sequence.
TORQUE
I
Upper spring support
6 N•m (53 lbfeinl
screw
7. Zone where presence of rust is normal
Check the curve line of spring.
SPRING SHAPE
Maximum
I 7 mm (9/32 in)
srrv20 11.0
3 Hl13_•
TIGHTENING SEQUENCE
A Tighten upper wear ring retaining screws to spec

� 1 .()4 1 .Jj
ification as per the following sequence.
A. 7 mm (9132 m) maximum
TORQUE
Replace spring if out of specification.
I
Upper wear ring retaining
screw
Spring Installation
Secure shock absorber using NEW bolts.
Tighten shock absorber bolts to specification.
TORQUE
Shock absorber bolt I 75 N•m (55 lbf•ft)
Install NEW shock holder screws and spring

holder screws.
Tighten shock and spring holder screws to speci
fication.
smr 2011-037· 0 14_

a
TIGHTENING SEQUENCE
558 smr2011-037
LINK ARM
Link Arm Access
Refer to BODYsubsection and remove:
- Moving deck
- Deck extension.
Link Arm Removal

1. Remove spring holder. Reter to SPRING RE smt20 1<>-0'5-01 l_a
MOVAL in this subsection. 1. Lateral suppons
2. Remove link arm lower retaining bolt.
Lateral Support Removal
NOTE: The following instruction can be used for
RH or LH support.
1. Remove the moving deck. Refer to BODYs ub
section.
2. Cut the Oetiker clamp retaining lateral bellows
to lateral support.
s mr'2011-037-017_a
TYPICAL SOME PARTS REMOVED FOR CLARITY

•
1. Link arm lower retaining bolt
Link Arm Installation

The installation is the reverse of the removal pro s mt"20()9.-041-022_a
cedure. However, pay attention to the following. 1. Lateral support

2. Oetiker clamp
Secure link arm using NEW bolts.
3. Remove the lateral support screw.
Tighten link arm bolts to specification.
TORQUE
Link arm bolt

LATERAL SUPPORT
Lateral Support Location
The lateral supports are located on both side of the
fixed deck to support the moving deck.
s m r2009- 041-02J_a
1. Lateral support screw
4. Remove lateral support from lateral bellows.
Lateral Support Installation

cedure. However. pay attention to the following.
smr2011-037 559
Apply soapy water solution on bellows opening

and insert the lateral support.
Index lateral supports with the front suspension
shaft ends. Lateral supports can be inserted in
one position only.
Install new lateral support screw.
Tighten lateral support screw to specification.
TORQUE
Lateral support screw I 48 N•m (35 lbf•ft)
Install a new Oetiker clamp. Position the ear of

2. Detach lateral support from suspension shaft.
clamp rearwards.
3. Using the SUPERTANIUM DRILL BIT 3/16'
(P/N 529 031 800), remove all rivets (12) se
curing the lateral bellows ring to body.
smr2009-00 1 -066_o
RH SIDE SHOWN
1. Ear of clamp rearwards
LATERAL BELLOWS
Lateral Bel lows Location
The lateral bellows are located on each side of the 1. Rivet location
fixed deck.
4. Remove lateral ring.
5. Cut Oetiker clamp securing bellows to lateral
support.
6. Separate lateral support from bellows.
Lateral Bellows Installation

•mr2010-04S-012_t Index suspension shaft with the lateral support.

1. LH lateral bellows shown The lateral support can be inserted in one position
only.
Lateral Bellows Removal Install the retaining ring. Align the ring pin with
1 Remove lateral support screw.
. holes in bellows and body.
560 smr2011·037
FRONT SUSPENSION ARM

Front Suspension Arm Location
1. Ring pin
2. Bellows alignment hole
3. Body hole
Install new rivets. If the head of rivet tool can

not be inserted in ring opening, use the sleeve
(P/N 707 000 181) to offset the rivet tool and well
smr 2010-045.o1 3_a
TYPICAL FIXED DECK REMOVED FOR CLARITY

lean the rivet head against ring.
•
1. From suspension arm

shaft ends. Lateral supports can be inserted in Front Suspension Arm Removal
one position only. 1. Remove the moving deck. Refer to BODYsub
Install new lateral support screw. section.
Tighten lateral support screw to specification. 2. Remove the engine. Refer to ENGINE RE
MOVAL AND INSTALLATION subsection.
TORQUE
3. Remove both lateral support screws.
Lateral support screw I 48 N•m (35 lbf•ft)

clamp rearwards.
RH SIDE SHOWN
4. Detach lateral supports from suspension arm

smr20W-04HlG6_t shaft.
RH SIDE SHOWN
5. Remove screws securing both shaft supports
to suspension base.
smr2011-037 561
Su b section 01 (SUSPENSION (aS))
SUSPENSION BASE
Suspension Base Location
smr'.2009-041 -063_1
1. Shaft support (one on eech side)
6. Move front suspension arm rearward to re

move it.
Front Suspension Arm Installation TYPICAL - FIXED DECK REMOVED FOR CLARITY
1. Suspension base
Suspension Base Removal
If a shaft support has been loosened from the
1. Refer to the appropriate proced u res and re
suspension arm shaft, see SUSPENSION ARM
move the following parts:
SHAFTS for proper installation procedure.
- Moving deck
- Engine
- Shock absorber and spring.
2. Using a marker, trace the sh ape of suspension
base at the bottom of the hull to reposition it
at the same place.
to suspension base.
1. Shaft support (one on each side)
Install NEW shaft support screws.

Tighten shaft support screws to specification.
TORQUE
Shaft support screws I 25 N•m (18 lbf•ft)
4. Remove and discard suspension base screws.
562 smr2011·037
1.3 lighten suspension base screws to speci

fication as per the following sequence.
TORQUE
Suspension base screws I 25 N•m (18 lbf•ft)
TYPICAL - STARBOARD SIDE

1. Suspension base screws
s mr2C09-04 1-0G6
...a
TIGHTENING SEQUENCE
2. Install NEW shaft support screws to secure

front suspension arm.
3. lighten shaft support screws to specification.
TYPICAL - PORT SIDE
1. Suspension base screws TORQUE
5. Remove suspension base with the rear vent Shaft support screws I 25 N•m (18 lbf•ft)
duct.
4. Refer to the appropriate procedures and install
all other removed parts.
- Shock absorber and spring
- Engine
- Moving deck.
Suspension Base Installation without

Reference Marks
1. Install the suspension base on watercraft using
NEW screws. Do not tighten them yet.
2. Install NEW shaft support screws to secure
s m r20-09-041.033_• front suspension arm.
TYPICAL 3. lighten shaft support screws to specification.
1. Suspension base
2. Rear vent duct
TORQUE
Suspension Base Installation Shaft support screws I

4. Install lateral supports.
4.1 Index lateral supports with the front sus
1. Install the suspension base.
pension shaft ends. Lateral supports can
1 .1 Position the base in accordance with the be inserted in one position only.
reference marks previously drawn at the
4.2 lighten lateral support screws to specifica
bottom of the hull.
tion.
NOTE: If no marks are available, see SUS
PENSION BASE INSTALLATION WITHOUT
REFERENCE MARKS.
1.2 Install NEW suspension base screws.
sml2011-037 563
TORQUE REAR SUSPENSION ARM

Lateral support screws I 48 N•m (35 lbf•ft) Rear Suspension Arm Location
5. Align suspension base on watercraft.

5.1 On both sides, measure the distance be
tween the end of lateral support and fixed
deck.
S11Y 201 O.o&S.O t S_a
1. Rear suspension arm
Rear Suspension Arm Removal

A. Same distance on LH and RH sides 2. Remove bolts securing both rear suspension
arm covers.
5.2 If required, move suspension base until
both distances are equal.
5.3 Tighten suspension base screws to speci
fication as per the following sequence.
TORQUE
Suspension base screws I 25 N•m (18 lbf•ft)
1. Rear suspension arm cover
3. Unclip and remove both lateral rear panels.
Sf!1'2009·04 1 -065..Jl
TIGHTENING SEQUENCE

- Shock absorber and spring
- Engine
- Moving deck.
1. RH lateral rear panel
564 smr2011-037
4. Mark position of rear suspension arm brackets 3. Carefully lower and secure the rear suspension
for proper reinstallation. arm to the fixed deck.
5. Remove and discard screws securing rear sus 3.1 Position the rear suspension arm brackets
pension arm to fixed deck. in accordance with the reference marks
previously draw on fixed deck.
*•!l•liMj If no mark was traced, refer to

REAR SUSPENSION ARM INSTALLATION
WITHOUT REFERENCE MARKS for proper
procedure to install and align the rear sus
pension arm.
3.2 Install NEW screws to secure rear suspen

sion arm brackets.
3.3 Tighten rear suspension arm screws to
specification.
1. Rear suspension arm screws TORQUE
I
6. Remove and discard screws securing the top of Rear suspension arm
25 N•m (1 B lbf•ft)
rear suspension arm. screws
Rear Suspension Arm Installation Without

Reference Marks
1. Lower the rear suspension arm on fixed deck.
2. Position the square openings of rear suspen
sion arm brackets so that the threaded inserts
in fixed deck are centered.
smr2009-0� 1 -075_a
1. Retaining screws
7. Remove the rear suspension arm from water

craft.
Rear Suspension Arm Installation

1. Using NEW screws, install the top of rear sus-
pension arm. Smt2009-04 1 ·0?6_0
1. Square opening
NOTE: If the upper arm shaft or one of its arm 2. Threaded insert
shaft support has been removed or loosened, re
fer to SUSPENSION ARM SHAFTS for proper in 3. On each bracket, install the retaining plate and
stallation procedure. one screw.
2. Tighten upper arm support screws to specifica 4. Install a weight of 90 kg (200 lb} on vehicle to
tion. lower the moving deck.
5. Check moving deck position in comparison to
I
TORQUE
fixed deck.
Upper arm support 25 N• m (18 lbf•ft) 5.1 Check the gap between moving deck
screws
wipers and fixed deck. It should be the
same on both sides.
5.2 Check front and rear gaps. Moving deck
should be able to move without having
contact with the fixed deck.
sm<201 '-037 565

5.3 Reposition rear suspension arm brackets

on fixed deck until positioning of moving
deck is satisfactory.
6. Secure the rear suspension arm to the fixed
deck.
sion arm brackets .
6.2 RemovA Find replace screws installed dur
ing alignment.
6.3 lighten rear suspension arm screws to
1. Arm shaft against its support
specification.
TORQUE 6. Install NEW support screws and tighten them

to specification.
Rear suspension
screws
arm I 25 N•m (1 S lbf•ft)
TORQUE
Shaft support screw s I 25 N•m (18 lbf•ft)
SUSPENSION ARM SHAFTS

7. Secure both supports to shaft using NEW
Removal of Front Suspension Arm socket screws.
Shaft 8. lighten shaft screws to specification.
1. Remove the FRONT SUSPENSION ARM, see
TORQUE
2. Remove and discard socket screws securing
Shaft screws I 12 N•m (106 lbf•inl
supports to shaft.
Removal of Rear Suspension Arm
3. Separate arm shaft supports from arm shaft.
Upper Shaft
Installation of Front Suspension Arm 1. Unclip and remove both lateral rear panels.
Shaft
1. In sert shaft in the suspension arm.
2. Install a support on each end of shaft.

3. Secure the LH arm shaft support to suspension
base using NEW support screws .
NOTE: Make sure to insert the support pin into
suspension base hole.
4. lig h ten the LH support screws to specification.
TORQUE
Shaft support screws I 25 N•m (18 lbf•ft)
5. Apply a force on the RH support to move it on

sm(2009.()4 1.073_a
the left side.
Ql11mJj Make sure arm shaft is fully inserted,

2. Remove arm shaft support screws.
it mu st lean against the arm shaft support .
566 smr2011-037
sm r2009-04 t -Otl7 •
.s mr2009-04 1 -077_a 1. Arm shaft against its support

1. Arm shaft support screws
6. Install NEW support screws and tighten them
3. Remove and discard socket screws securing to specification.
supports to arm shaft.
TORQUE
4. Separate arm shaft support from arm shaft.
I
Upper arm support
25 N•m (181bf•ft)
Installation of Rear Suspension Arm screws
Upper Shaft
7. Secure both supports to shaft using NEW
1. Insert shaft in the rear arm. socket screws.
2. Install a support on each end of shaft. 8. lighten upper shaft screws to specification.
3. Secure the LH support to rear arm holder using
TORQUE
NEW support screws.
Upper shaft screws I 12 N•m (106 lbf•in)
holder hole.
smr2009-041 -078_a
sm12009-041 ·079.Jl
1. Support pin
1. Bare/amp
2. Holder hole
2. New socket screws
4. lighten the LH support screws to specification.

TORQUE Lower Shaft
I
Upper arm support 1. Open the boarding platform.
25 N•m (18 lbf•ft)
screws
2. Remove bolts securing both rear suspension
arm covers.
5. Apply a force on the RH support to move it to
the left side.
NOTE: A bar clamp can be used to compress both
supports together.
1,t[,Ji@j Make sure arm shaft is fully inserted,

it must flush against the arm shaft support.
smr2011-037 567
Subsection 01 (SUSPENSION {aS))
sm<200io04 1.070.
a
1. Circlip
o m r2009-04 1 -0n_.
1. Rear suspension arm cover Installation of Rear Suspension Arm

3. Mark position of rear suspension arm brack
Lower Shaft
ets for proper reinstallation. 1. When reassembly the rear bracket on shaft
end, press bracket on bushing to install the
4. Remove and discard screws securing rear sus
circlip.
pension arm to fixed deck.
2. When both brackets are installed on shaft, pull
brackets outside to position circlips against
brackets.
1. Rear suspension arm screws

rear brackets to arm shaft ends. s m-1009'-041.071.•
1. Bad installation
2. Good installation

4. Tighten NEW socket screws to specification.
TORQUE
Lower shaft screws I 10 N•m (89 lbf•in)
5. Refer to REAR ARMfor reinstallation.
sm r2009-0ol1-0S9.a
1. Socket screw
2. LH rear bracket
6. Press one rear bracket against the suspension

arm bushing and remove the circlip. Repeat for
the other side.
568 smr2011·037
Subsection 02 (SUSPENSION OS))
SUSPENSION (iS)
SERVICE TOOLS
FLUKE 115 MULTIMETER . .. ..... .. . .. .. .
....... . .. . . ... . .. .. 529 035 868 ......................... 582-585, 587
. . . . . . .......... . . .. . . ..
MAGNETO HARNESS 6 PINS . . .. . .. .. .

......... 295 000 136 ......................................... 582
.................... ... . . . . ... ......
SUPERTANIUM DRILL BIT 3/16°. . . .. . . . ..... .. . .. ..... .. 529 031 800 ......................................... 594
.. . . .... . ... .. . . ... .... . ..
SERVICE PRODUCTS
DIELECTRIC GREASE ... .. ... ...... .
. ... . . . . .. ...... . .... .. . ..
. .. . .. ..... . ..
.. ... .. ..
.. . 293 550 004 ......................................... 576
LOCTITE 243 (BLUE) . . . . . . . . . . . . . .................... . . . . . . . . . . . . . . . .......... . . . . . . . . . . . 293 800 060 ................................. 591, 593
smr2011-038 569
Subsection 02 (SUSPENSION (iS))
FRONT SUSPENSION ARM AND HYDRAULIC PUMP
mm� mm ... .,,

�v .
48 N · �. '!:.
(35 lbf·ft _j
mm
10 N·m
(89 lbf•in)
. t-�
mm
12 N•m
(106 lbfoin)
)
mm
10 N•m
(89 lbfoin)
570 smr201 l-038

ACTUATOR AND SHOCK ABSORBER
mm
75 N•m
(55 lbf.ft)
6 N•m
(53 lbf-in)
mm
75 N•m
(55 lbf.ft)
mm
smr2011.()38 571
Sect·on 07
•
BODY AND HULL
Subsection 02 (SUS PENSION (iS))
R SUSPENSION ARM
R EA�
----
-
12mim
N•m
(1os 1br l�
25N•m
(18 lbMt)
�..�
'
, \
25 N•m
\1�(18 lbfoft)
@-¥7
� 11825N•m
·�
lbf·ftl
� 10N•m
�
i -m.B (89 lbfoin)
572 smr2011038
GENERAL
NOTE: For a complete overview of the electrical
system, refer to POWER DISTRIBUTION AND
GROUNDS subsection.
It is highly recommended to disconnect the bat
tery when replacing any electric or electronic com
ponent.
A WARNING
Always disconnect battery exactly in the sdd2009- 001·206_b

specified order, BLACK(-) cable first, RED (+)
2. Front suspension arm
cable last. Always reconnect BLACK(-) cable 3. Springs
last. Do not place tools on battery. 4. Shock absorber
An actuator is mounted underneath the springs to

SYSTEM DESCRIPTION control the spring preload and therefore the sus
(COMPONENTS) pension height.
The intelligent suspension is a mechanical system

composed of two springs and one shock absorber
installed in the fixed deck which connects to the
moving deck to isolate the riders from the rough
water.
s m r 2 0 09-041-038_a
1. Springs
2. Actuator
The iS module controls the electric motor of the

hydraulic pump to adjust the actuator height. It
smr2009 ·04 1 -080
also sets the suspension height according to the
MOVING DECK
active mode of operation and input signals .
.o<:fd2009-001 -202
FIXED DECK
REAR STARBOARD SIDE

1. iS module
iS Module
The iS module communicates via CAN protocol
with the multifunction gauge.
smr2011·038 573
The iS module receives information from the mul SYSTEM OPERATION

tifunction gauge and a comparison is made with
the input from the suspension position sensor. If The occupants sit on what is known as the mov
the suspension is not in the proper position, the iS ing deck. When the suspension system is active,
module will send an output signal to the hydraulic the moving deck is usually in an "up" position. This
pump to either raise or lower the suspension to means the moving deck is raised above the fixed
pre-programmed positions. deck sufficiently for the suspension system to ab
sorb the up and down movement of the water
iS Button craft as it travels through the water.
The iS module is programmed with various param
eters that it compares to the input signals and in
formation it obtains through the CAN bus from the
other electronic modules.
The suspension can be set to the AUTO or MAN
UAL mode.
In AUTO mode, suspension height is factory
preset and the iS module constantly monitors
the stroke of the suspension and it automatically
readjusts suspension height for changing water
conditions and passenger load.
In MANUAL mode, the driver may choose to set
1. iS buttons
the suspension higher or lower by using the UP
and DOWN s on the handlebar.
The iS button contain a series of 4 diodes for the
UP and DOWN arrow switches. The iS system incorporates a function known as
DOCK MODE. When activated manually or auto
The center wire to the switches (pin Cl, is com
matically, DOCK MODE moves the suspension
mon for iS button and VTS button. The other two
down to lower the center of gravity of the water
wires (pins A and Bl, act as signal wires for each
craft. This function is useful when transporting
set of switches to the gauge.
the watercraft, operating at slow speed or when
Each diode (in circuit) drops a nominal 0.6 Vdc O.T.A.S. is activated as it reduces the possibility
when conducting electricity. If the circuit current of capsizing.
passes through all four diodes (if the iS switch
is open), a drop of 2.4 Vdc would be measured Suspension Adjustment
across the 4 diodes (pin B to pin Cl. This 2.4 Vdc
Th� suspension height (up position) is factory
at pin B tells the gauge the iS switch is open.
calibrated to a preset height for most riding con
If the iS UP switch is pressed, 2 diodes are by ditions while cruising in AUTO SUSPENSION
passed. The remaining two diodes in the circuit MODE. The factory calibrated height is the same
drop 1.2 Vdc (at pin 8). regardless of the number of passengers or weight
If the iS DOWN switch is pressed, 1 diode is by on the moving deck.
passed. The remaining three diodes in the circuit
drop 1 .8 Vdc (at pin Bl. A WARNING
The gauge senses these voltages through pin 14 Do not overload the watercraft or take on
of its connector. and interprets them as signals more passengers than designated. Refer to
that tell it which switch is activated. SPECIF/CATIONSfor details.
The command generated by the closure of a

The iS button is primarily used to manually
switch is transmitted to the iS module through
fine-tune the suspension height to operator
CAN .
preference.
Suspension Position Sensor Using the iS button to change the suspension

height overrides the AUTO SUSPENSION MODE
The suspension position sensor is a potentiome
function. The iS system switches to MANUAL
ter that sends a signal to the iS module which is
SUSPENSION MODE and the operator can select
proportional to the front suspension arm angle.
a different suspension height as preferred in ac
cordance with riding style and riding conditions.
574 smr2011-038
Suspension height and mode of operation is in Selecting Auto Suspension Mode
dicated in the information center (gauge) digital To revert back to AUTO selection mode, double
screen. click the iS UP arrow button.
Manually Adjusting Ride Height The following indications of automatic suspension
Press the iS UP or DOWN arrow button once mode can be observed in the digital screen of the
to move the suspension to the next height in information center:
crement, or press and hold the button until the - A scrolling message in the digital screen stating
desired ride height is obtained. AUTOMATIC SUSPENSION.
- The AUTO indication in the iS display will ap
pear.
- All segments of the suspension position indica
tor will be on.
3��--2
sdd2009-00 1 -0 l 9_d
�s
1-1r1 T 1 \\fl
.. r
l.
1n 1c
. 1LJ 1 .
TYPICAL
1. iS UP arrow button
2. iS DOWN arrow button
The following indications of manual suspension

mode can be observed in the digital screen of the
information center:
smo2009-00 2-1 t 4_h
- A scrolling message in the digital screen that 1. AUTOMATIC SUSPENSION message

states MANUAL SUSPENSION. 2. AUTO mode indicator ON
3 . A ll segments o f suspension position indicator ON
- The AUTO indication in the iS display will disap
pear.
- The suspension position indicator will indicate
TROUBLESHOOTING
the relative suspension height (only one seg
ment of the indicator will be on). DIAGNOSTIC TIPS
It is important to determine first if the problem is
electrical or mechanical related. If you hear the
hydraulic motor running when pressing the UP or
DOWN suspension button, check for related me
chanical problem.
NOTE: It is a good practice to check for fault
codes using B.U.D.S. software as a first trou
bleshooting step. If a problem occurs with the
suspension, several fault codes pertaining to the
suspension position sensor may be generated.
IMPORTANT: When troubleshooting an electrical
system fault, check battery condition, cables and
connections first.
sm o2009-002-11 4 _g Electrical System Activation

1. MANUAL SUSPENSION message
2. AUTO mode indicator OFF 1. Press the START/STOP button.
3. Relative suspension position indication
smr2011-038 575
NOTE: Pressing the START/STOP button without SUSPENSION DOES NOT MOVE
the D.E.S.S. key installed on its post will turn on
1. Check gauge display for iS informations.
electrical power without starting the engine; the
information center will cycle through a self-test - No information, refer to the diagnostic flow chart
(electrical) in this subsection.
function and shut off its display after a few sec
- iS information appears, refer to the diagnostic
onds. However. the electrical system will stay
flow chart (hydraulic/mechanical) in this subsec
powered up for approximately three minutes after tion.
the START/STOP button was depressed.
2. Install D.E.S.S. key to activate ECM and the in SUSPENSION DOES NOT LOWER IN
formation center when testing procedures re DOCK MODE POSITION
quire the device or system to be supplied with 1. Somet hing stuck under moving deck.
electrical power.
- Remove object(s) between moving deck and
NOTE: When using B.U.D.S.,briefly press the fixed deck.
START/STOP button to initiate back the commu
2. PWC is not level.
nication after the electrical system has shut off.
- Place PWC level
Circuit Testing 3. Hydraulic fluid level too low.
Check the related-circuit fuse condition with a - Refill hydraulic pump reservoir and check for
fuse tester or test light (relying solely on a visual leaks.
inspection could lead to an incorrect conclusion).
4. Shock absorber is damaged.
- Replace shock absorber.
Electrical Connection Inspection
When replacing an electric or electronic compo 5. Leak in hydraulic circuit.
nent, always check electrical connections. Make - Repair or replace defective part(s).
sure they are tight, make good contact, and are
6. Faulty suspension position sensor.
corrosion-free. Dirty, loose or corroded contacts
are poor conductors and are often the source of a - Test sensor and replace as required.
system or component malfunction. 7. Actuator is damaged.

Pay particular attention to ensure that pins are not - Replace the actuator.
bent or pushed out of their connectors.
8. Hydraulic pump cannot build enough pressure.
Ensure all wire terminals are properly crimped on - Replace hydraulic pump.
wires, and connector housings are properly fas
tened. SUSPENSION MOVES ERRATICALLY
Check for signs of moisture, corrosion or dullness. 1. Defective shock absorber.
Clean pins properly and coat them with DIELEC
- Replace the shock absorber.
TRIC GREASE (P/N 293 550 004) or other appropri
ate lubricant (except if otherwise specified) when 2. Broken spring(s).
reassembling them. - Replace spring(s).
Pay attention to the ground wire connections.
Make sure they are clean, tight and free of corro SUSPENSION NOISE (DURING A TURN)
sion. 1. Front or rear suspension arm shaft supports po
sition.
DIAGNOSTIC GUIDELINES - Supports must be f/ushe against both ends of
shaft. Reposition shaft in its supports.
probable source of troubles. It is a guideline and 2. Worn arm shaft bushings.
it should not be assumed to list all possible prob - Check front and rear arm shaft bushings condition
lems. and replace as required.
3. Snap rings on both sides of the rear lower arm

shaft are not properly positioned.
- Reposition shaft in its supports.
576 smr2011-038
SUSPENSION NOISE (FRONT OF SEAT)
1. Holder retaining screws are loose.

- Tighten shock absorber and actuator holder
screws to recommended torque.
2. Shock absorber screws are loose.

- Tighten shock absorber screws to recommended
torque.
3. Link under actuator holder loosened or not in

stalled.
- Install link properly.
- Tighten bolts to recommended torque.
SUSPENSION IS LOWER THAN THE DOCK

MODE POSITION
1. Spring (s) out of specification or broken.
- Replace the defective spring(s).
2. Bump stops damaged or worn.

SUSPENSION BOTIOMS HARD

1. Spring(s) out of specification or broken.
- Replace the defective spring(s).
2. Shock absorber is damaged.

- Check shock absorber resistance. Replace shock
absorber.
3. Bump stops damaged or worn.

SUSPENSION QUIT WORKING BUT

MAY OPERATE MOMENTARILY AFTER
RESTARTING THE ENGINE
1. Hydraulic pump current draw is too high.

- Check hydraulic pump.
2. Internal problem within iS module.

- Replace iS module.
smr2011·0Ja 577
DIAGNOSTIC FLOW CHARTS
iS Electrical Troubleshooting
Suspension does not move
NO
Check for
hydraulic
or mechanical
YES NO
proble m see iS ,
hydraulic/mechanical
troubleshooting
flowchart
Install the latest System isok

version of B.U.D.S.
software and
check fault codes
YES Follow service

action
In B.U.D.S. activation
page, activate iS UP NO
and iSDOWN
buttons
Check the
System is ok
suspension position YES
sensor and
the iS buttons
NO Perform hydraulic
pump operation test Perform iS
module test
System is ok
YES
NO
* If all input voltage tests are good, but suspension

does not activate with switches but does with
System is OK
B.U.D.S suspect gauge issue.
.•
smt200 9--0 4 1 - 1 00_ en
578 smr2011-038
Subsection 02 (SUSPENSION OS))
iS Hydraulic/Mechanical Troubleshooting
Suspension does not move
Check for
an electrical
problem, see
iS electrical
trn11blashootino
flow chart
Level
vehicle
NO NO
System is OK Check hydraulic fluid level
NO
NO
Check for leak(s)
Repair or replace YES

System is OK
defective part(s)
�-_ NO
___ ____
----j
� Check hydraulic cylinder
Replace hydraulilc
cylinder
_
System is OK
NO
NO
System is OK
1 m r200 9-041 ·101 _en
smr2011·038 579
Subsection 02 (SUSPENSION (iS})
PROCEDURES
SHOCK ABSORBER
Shock Absorber Location
1. Rear retaining screws
5. Remove shock absorber with mounting plate

and shock holder.
smt20 1 0-045·004_a
NOTE: Take care not to let the spring protector fall
1. Shock absorber
into the hull.
2. Shock holder
3. Mounting plate
6. Remove and discard the screw securing shock
absorber to shock holder.
Shock Absorber Removal
1. Remove the moving deck. Refer to BODYsub
section.
2. Remove tapes securing central bellows to
mounting plate.
2
3. Move down central bellows to reach shock
holder screws.
4. Remove and discard the four screws securing
the shock holder.
NOTE: Using lateral supports, raise front arm to
reach front screws. smr2009-041·00 6Jl
1. Shock absorber lower screw (discard)

2. Shock holder
7. Detach the top of shock absorber from mount

ing plate. Discard screw.
sm r2009-04 1 -003_a
1. Front retaining screws

sm12C09-()..1 1-006_a
1. Shock absorber upper screw (discard)

2. Mounting plate
Shock Absorber Inspection

NOTE: Because of gas pressure, strong resis
tance is felt when compressing shock.
580 smr2011-038
To inspect shock operation, or if suspecting an in

ternal leak between oil chamber and gas chamber,
check shock as follows:
1. Grab the shock absorber body firmly and press
the rod end against a firm surface.
1.1 Verify the compression stroke when the
rod is fully extended.
1 .2 Make sure that shock absorber rod can be
completely inserted in the shock body.
2. The shock should extend unassisted. Rod must smr2009-041-007_t
come out at a steady speed. 1. Spring prorector

2. Long spring
If any problem is detected, replace the shock ab 3. Spacer
4. Short spring
sorber. 5. Spring holder
Shock Absorber Installation Spring Inspection

The installation is the reverse of the removal pro Inspect both springs and replace if one of the fol
cedure. However, pay attention to the following. lowing damage is detected:
Secure the shock absorber using NEW screws. - Crack in the paint
Tighten screws to 75 N•m (55 lbf•ft). - Rust
Install NEW shock holder screws and tighten - Other visible damage.
them to 25 N•m (18 lbf•ft). NOTE: If rust is limited to a 1/4 of the first coil, the
spring should not be replaced.
SPRINGS
Spring Location
1. Zone where presence of rust is normal

1
Check the curve line of the long spring.
LONG SPRING SHAPE
Maximum
I 7 mm (9/32 in)
1. Springs
Spring Removal
1 . Remove SHOCKABSORBER, see procedure in
this subsection.
2. Remove the spring protector, the long spring,
the spacer, the short spring and the spring
holder. A
smr200l).()4 l-0•1_a
A. 7 mm (9132 in) maximum
Replace spring if out of specification.
smr2011 ·03.9 581

Spring Installation NOTE: If the seat is moving up and the number

The installation is the reverse of the removal pro does not increase in B.U.D.S. but it is between 10
cedure. and 100%, check the suspension position sensor
fork.
SUSPENSION POSITION 3. Unplug the 6-pins connector from the iS mod

ule. The module is located in front of the bat
SENSOR
tery in the same compartment.
Suspension Position Sensor Location
The suspension position sensor is located on sus
pension base, under the hydraulic pump reservoir.
s m r 2 0 09-0d 1 -009_i
1. Suspension position sensor connector on iS module
'
smW 1 0 · 045-000_a
4. Connect the MAGNETO HARNESS 6 PINS
r
1. Suspension position sensor (P/N 295 000 136) to iS module for voltage
checks.
Suspension Position Sensor Input
Voltage Test
At Sensor Connector
SUSPENSION POSITION
VOLTAGE
SENSOR CONNECTOR
2950001 36
Pin 1
I Pin 2 5 Vdc
5. Using the FLUKE 115 MULTIMETER (P/N 529 035
Using the 6-pin Magneto Harness Tool 868), check voltage as per the following table.
1. Connect B.U.D.S. Refer to COMMUNICATION

TOOLS AND B.UD.S. subsection.
2. Using B.U.D.S., raise suspension to the fully up
position.
529
30 5868
.�. r-��-
s m r2009-04 1 -053_!::
ACTIVATION AND IS TABS

1. iS UP
2. iS dcvvn
582 smr2011-038
Sub section 02 (SUSPENSION (iS))
SUSPENSION MAGNETO SUSPENSION iS MODULE

VOLTAGE
POSITION HARNESS POSITION (6-pin RESISTANCE n
(Vdcl
(% in B.U.D.S.) (wire lead color) (%in B.U.D.S.) connector)
All positions BK BK/YL 4.99 All positions 4 6 1803 - 2203
100% WH BK/YL 3.23 100% 5 6 1957 - 2391
100% BK WH 1.75 100% 4 5 1361 - 1663
88% WH BK/YL 3.09 88% 5 6 1904 - 2327
88% BK WH 1.89 88% 4 5 1410 - 1724
75% WH BK/YL 2.99 75% 5 6 1871 - 2287
75% BK WH 1.98 75% 4 5 1448 - 1770
53% WH BK/YL 2.81 53% 5 6 1799 - 2199
53% BK WH 2.16 53% 4 5 1516 - 1852
35% WH BK/YL 2.68 35% 5 6 1752 - 2142
35% BK WH 2.30 35% 4 5 1565 - 1913
6. Remove the 6-pin magneto harness tool.

Suspension Position Sensor
Replacement
Suspension Position Sensor
Resistance Test 1. Remove the deck extension. Refer to BODY
subsection.
At iS Module Connector
2. Remove the air intake tube. Refer to AIR IN
1. Using the FLUKE 115 MULTIMETER (P/N 529 035 TAKE SYSTEM subsection.
868), check resistance values on iS connector
3. Unplug the suspension position sensor connec
as per the following table.
tor.
52W35S68
1. Sensor connector
2. Hydraulic pump reservoir
4. Remove screws securing the suspension posi

tion sensor.
smr2011·038 583
smr2009-041-0 12_8
smr2009-041-01 4 ...a
1. Retaining screws
1. Lever
5. Remove bolts securing the sensor and its cover 2. Lever shaft
3. Sensor
to the sensor support and the sensor lever.
8. Reinstall and connect the sensor in PWC.
iS MODULE
1
iS Module Location
The iS module is located inside hull, in front of the
battery.
smr2009-041 -01 3_•
1. Retaining bolt
2. Sensor
3. Support
4. Lever
5. Cover
6. 0-rings
NOTE: If water is present in the sensor always

replace sensor even if it seems in good condition.
snvW! 0-04 5-00 7_a
6. Check condition of 0-rings on sensor and sen-
1. iS module
sor lever.
7. Reinstall all parts. iS Module Input Voltage Test
NOTE: When reassembling parts, index sensor (Switched Power)
lever shaft with sensor inner slot. The sensor Make sure fuse F1 is powered and in good condi
lever must be positioned to 180° with the sensor tion.
electrical connector.
electrical system.
Install the D.E.S.S. key.
868), perform the following test.
VOLTAGE
MULTIMETER LEAD POSITION
(VDC)
Pin 1 of
Negative
iS module 6-pin Battery voltage
battery post
connector
584 smr2011·038
iS MODULE
3-PIN BATTERY RESULT
CONNECTOR
Pin 2 Negative post Bright light
If tests succeed, carry out iS MODULE GROUND

TEST.
If tests fails, check wiring and connectors be
tween fuse box pin A2 and module 3-pin connec
tor pin 2.
s mr2 0 09-0d 1 -055_ a

iS Module Ground Test
Repeat the test using a test light. Using the FLUKE 115 MULTIMETER (P/N 529 035
868), perform the following test.
TEST LIGHT POSITION RESULT
Pin 1 of
Negative
iS module 6-pin Brig ht lig ht
battery post
connector
If tests succeed, carry out the iS MODULE INPUT

VOLTAGE TEST
(BATTERY POWER).
If tests fail, check wiring and connectors between
fuse box pin AB and module 6-pin connector pin 1 .
iS Module Input Voltage Test

(Battery Power)
PIN 7 TO BATTERY POSITIVE POST
Make sure fuse F7 is powered and in good condi
tion. iS MODULE
Using the FLU KE 115 MULTIMETER (P/N 529 035 3-PIN BATTERY RESULT
868), perform the following test. CONNECTOR
Pin 1 Positive post Battery voltage

iS MODULE
VOLTAGE
3-PIN BATTERY
(VDC) Repeat the test using a test light.
CONNECTOR
Pin 2 Negative post Battery voltage iS MODULE

3-PIN BATTERY RESULT
CONNECTOR
Pin 1 Positive post Bright light
If tests succeed, carry out 1S BUTTON TEST US

ING B.U.D.S.
If tests fails, check wiring and connectors module
3-pin connector pin 1 and engine ground.
iS Module Output Voltage Test

At the hydraulic pump motor connector, connect
multimeter leads.
s m r200 9-04 1-057_ b
Activate the iS either UP and DOWN with
PIN 2 TO BATTERY NEGATIVE POST
B.U.D.S. or with iS button on steering.
Repeat the test using a test light. There will be either a positive 12 Vdc or a negative
12 Vdc reading.
smr2011-03B 585
Activate the opposite UP or DOWN and the read

ing should reverse polarity.
If the voltage is as specified. carry out the same
test using a 12 V test light to ensure the circuit
can supply enough current to operate the hy
draulic pump.
The light should be bright in both the UP or DOWN
positions.
If tests fail, carry out the tS MODULE INPUT VOLT
AGE TEST (SWITCHED POWER).
1. Hydraulic motor connector
iS Module Removal
1. Open boarding platform and remove the star 5. Disconnect the iS module input voltage connec
board storage bin. tor.
2. Disconnect the suspension position sensor

connector from the iS module.
1mt20� 1-037_a
1. iS module input voltage connector
NOTE: The locking tab of input voltage connector

is located underneath.
1. Suspension position sensor connector
6. Remove the iS module from PWC.
3. Detach the retaining strap.
iS Module Installation
cedure.
iS BUTTON
iS Button Test Using B.U.D.S.
1. Connect PWC to 8.U.D.S. Refer to COMMUNI
CATION TOOLS AND 8.U.D.S.
2. Select Monitoring and Cluster tabs.
3. Press START/STOP button to activate the elec
omr2009.04 1 -035_
a trical system.
7. Retaining strap
4. In the Cluster Lamp Active box, monitor the
4. Disconnect the hydraulic motor connector. Suspension UP and Suspension Down indica
tors while pressing the buttons.
586 snv2011·038
Subsection 02 (SUSPENSION {iS))
Cluster Lamp Active 5. Test as follows.

VTSUP:
iS SWITCH TEST
VTSDovKI
MULTIMETER
SWITCH
LEAD/GAUGE VOLTAGE
POSITION
CONNECTOR
$t012011-039-001_ a RED lead/Pin 14

Approx. 2 Vdc
CLUSTER LAMP ACTIVE Switch BLACK l ead/Pin 15
1. UP and Down button indicators
released BLACK lead/Pin 14
OL
If test fails, carry out the 1S BUTTON TEST USING RED lead/Pin 15
A MULTIMETER.
RED lead/Pin 14 Approx.
UP BLACK lead/Pin 15 1.1 Vdc
iS Button Test Using a Multimeter
depressed BLACK lead/Pin 14
1. Press START/STOP button to activate the elec OL
RED lead/Pin 15
trical system.
RED lead/Pin 14 Approx.
2. Remove the gauge support cover.
BLACK lead/Pin 15 1.6 Vdc
DOWN
depressed BLACK lead/Pin 14
OL
RED lead/Pin 15
If any reading is significantly out of specification,

carry out the same test at the switch connector.
If the same results are obtained at the switch con
nector, replace the switch assembly.
If results are as per spec ifi cation at the switch con
nector. check wiring and connectors.
HYDRAULIC PUMP
Hydraulic Pump Location
The hydraulic pump is located at the rear of the
1. Gauge connector suspension base.
2. Slide out gauge connector tab to unlock
4. Set the FLUKE 115 M ULTIME TE R (P/N 529 035

868) to diode test function.
1. Hydraulic pump
Hydraulic Pump Recommended Fluid

Always use automatic transmission fluid (ATF)
Dexron Ill.
iittoit;j Use ATF Dexron Ill only. Do not use

fluids other than the recommended one, nor
vmr2006·020-00 5
mix different types of fluids.
smr2011-038 587
Hydraulic Pump Fluid Level Reinstall reservoir plug and tighten it to 1 N•m
Verification (9 lbf•in).
NOTE: The fluid level will drop slightly during
Hydraulic Pump Operation Test
break-in period because the actuator uses a small
amount of fluid to lubricate its moving parts. If a Connect a 30 A fused jumper from a 12-volt bat
large amount of fluid is required, check compo tery positive terminal and one pin of the hydraulic
nents for leaks. pump 2-pin connector .
Connect a jumper from battery negative terminal
Reservoir in VP.hide
and the other pin of the hydraulic pump 2-pin con
Place the PWC level (longitudinally and trans nector .
versely). Make sure suspension is in DOCK
The hydraulic pump should activate and suspen
MODE position.
sion should go up or down.
The fluid should be near reservoir plug.
Reverse the jumpers position at the pump con
nector. The suspension should reverse direction.
If the hydraulic pump does not run, replace hy
draulic pump.
If hydraulic pump turns, carry out the HYDRAULIC
PUMP CURRENT DRAWtest to confirm pump op
eration.
Hydraulic Pump Current Draw

If the current draw is to high, the iS module acti
vates an internal protection.
Connect PWC to B.U.D.S. Refer to COMMUNI
'm r2 009-04 J -043 _.
CATION TOOLS AND B.U.D.S. subsection.
1. Fluid level
Select ACTIVATION and iS tabs.
Reservoir Out of Vehicle
Activate the suspension by pressing iS UP and
Place the reservoir vertically. iS DOWN and check monitor the ammeter in the
Using a ruler, measure the fluid level. The B.U.D.S. page.
:(ff
reservoir is full when fluid level reaches
130mm ± 5mm (5-1/8in ± 13/64in).
1
�. .--��-
sm r2009-041-053_1
1. B.U.O.S. page ammeter

2. iS UP button
3. iS DOWN button
SWITCH POSITION CURRENT
omr2009-04 1 -044_e
iS UP 16 - 20 A
A. 130mm ± 5mm (5-1/Bin ± 13/64m) iS DOWN 15- 18A
To Add Fl u id
If current is as per specification, carry out the 1S
Remove the plug on the end of reservoir. MODULE OUTPUT VOLTAGE TEST
Using a syringe, fill up the reservoir to the recom If current draw is low. check connections and
mended level. wires.
588 smr2011-03B
If the current draw is excessive, replace the hy

draulic pump.
Hydraulic Pump Removal ,

(as a Unit with Actuator)
To work on many parts of suspension system, the
removal of the hydraulic pump and actuator as an
unit is necessary.
1. Remove SHOCK ABSORBER and SPRINGS
See procedures in this subsection.
7. Actuator holder screws
2. Unplug the hydraulic pump connector from the
iS module. 7. Remove the suspension position sensor to
3. Cut any locking ties securing the pump harness avoid damaging it.
to PWC harness. 8. Remove screws securing both rear ends of
4. Remove clamp and bolt securing the hydraulic front suspension arm to suspension base.
pump from suspension base.
1. Hydraulic pump clamp

2. Retaining bolt 1. Retaining screws
5. Remove actuator link bolt. 9. Lift the rear of the front suspension arm to
make room for hydraulic pump.
10. Remove hydraulic pump with actuator by
lifting them through the suspension bellows
opening.
Hydraulic Pump Installation

(as a Unit with Actuator)
moval procedure. However, pay attention to the
following.
Make sure to secure the actuator link to suspen
sion base. lighten actuator link bolt to 25 N•m
1. Actuator link bolt
2. Link support on the top of suspension base ( 18 lbf•ft).
6. Remove screws retaining the actuator holder. fi+Z1Jitij Failure to do so might result in
spring failure.
Hydraulic hose routing is very critical to avoid

problems with hydraulic unit. Use the following
illustration to route and attach the hydraulic hose
properly.
smr2011-038 589
1. Cut this lockmg tie

2. Hydraulic hose
VIEW FROM THE REAR OF PWC
1. Secure hydraulic hose to hydraulic pump 6. Unscrew the retaining clamp completely and re
2. Secure hydraulic hose, fuel hose and PWC wiring harness
move it.
smr2009-041411_a
s nv2009-0.
11-048. •
VIEW FROM THE FRONT OF PWC 1. Retaining clamp

1. Position both ends of hydraulic hose on same side 2. Hydraulic pump
Install the FRONT SUSPENSION ARM See pro 7. Remove hydraulic pump retaining bolt.
Hydraulic Pump Removal

(Without Actuator)
1. Remove the deck extension. Refer to BODY
subsection.
2. Remove the air intake tube. Refer to AIR IN
3. Unplug the hydraulic pump connector from the
iS module.
smr2 009'041-01 8 .•
4. Cut any locking ties securing the pump harness
1. Retaining bolt
to PWC harness. 2. Hydraulic pump
5. Cut locking tie securing the hydraulic hose to

8. At the bottom of pump housing, remove socket
pump.
screw securing hydraulic hose lock.
590 smr20l 1-038

smr201 0•045-020
1. Socket screw RECOMMENDED POSITION

2. Hydraulic hose lock
9. Remove hose from pump and plug hose to threads of lock screw.
avoid oil spillage.
3. lighten screw to 8 N•m (71 lbf•in).
10. Place your finger on pump opening and re -
4. Secure hydraulic pump to suspension base.

move pump from PWC.
NOTE: Wipe any oil sp illage.
4.1 I nstall pump retaining screw and tighten it
to 10 N •m (89 lbf•in).
Hydraulic Pump Installation 4.2 Install retaining clamp and tighten it to
(Without Actuator) 2 N•m (18 lbf•in).
1. Install hydraulic hose on pump and secure hose 5. Secure hose to reservoir with a new locking tie.
using the hydraulic hose lock. 6. Route pump harness and secure it with new
NOTE: The hose must turn freely. Do not insert locking ties.
hose into lock hook. 7. Connect the hydraulic pump connector to iS
module.
8. Instal l a weight of 90 kg (200 lb) on moving
deck and using su spensi on controls on steer
ing, cycle the suspension fully up and f ully
down 3 times. This action will remove air
bubbles trapped into hose and pump during
installation.
9. Check for leaks.
smr200S-041 ·020_ a ACTUATOR

WRONG POSITION
Actuator Location
The actuator is located at the front of the suspen
sion base under suspension springs.
smr2011-038 591
1. Retaining screws
2. Alignment support
smr20 1 0-04&-010_
a
1. Actuator
4. Turn actuator up side down and remove hy
draulic hose.
Actuator Inspection
Check actuator for leaks at hose opening and
around inner piston.
Replace actuator if any leak is detected.
Actuator Removal
1. Refer to HYDRAULIC PUMP REMOVAL (AS A
UNITWITHACTUATOR)and remove the pump
from the PWC.
2. Remove and discard the screw securing actua
tor link to alignment support. 1. Retaining socket screw
2. Hydraulic hose lock
5. Remove and discard the three socket screws

securing actuator holder halves and split the ac
tuator holder.
.n<2009-04 1-001 _.
I. A ctuator link
2. Retaining screw
3. Alignment support
smr2()()9.()4 1.Q50_
a
3. Remove the alignment support from actuator
1. Socket screws
holder. Discard screws. 2. Actuator holder halves
Actuator Installation
Install hydraulic hose in accordance with the fol
lowing illustration.
592 smr2()11·038
Subse cti on 02 (SUSPENSION (iS))
2. Cut the Oetiker clamp retaining lateral bellows

to lateral support.
•mr2 009-04 1 .0 5 2_a
7. Hose fully inserted in lock slot

2. Position hydroulic hose in lock hook

threads of lock screw. 1. Lateral support
2. Oetiker clamp
lighten screw to 8 N•m (71 lbf•in).
Install the hydraulic pump in PWC. Make sure 3. Remove the lateral support screw.
to route the hydraulic hose properly. See HY
DRAULIC PUMP INSTALLATION (AS A UNIT
WITH ACTUATOR) in this subsection.
Install a weight of 90 kg (200 lb) on moving deck
and using suspension controls on steering, cycle
the suspension fully up and fully down 3 times.
This action will remove air bubbles trapped into
hose and pump during installation.
Check for leaks.
- · -0?3-•
LATERAL SUPPORT 1. Lateral support screw
Lateral Support Location 4. Remove lateral support from lateral bellows.
The lateral supports are located on both side of the

Lateral Support Installation
fixed deck to support the moving deck.
shaft ends. Lateral supports can be inserted in
one position only.
lighten lateral support screw to 48 N•m
(35 lbf•ft).
smr201 0-ll45-0I Ul Install a new Oetiker clamp. Position the ear of
7. Lateral supports clamp rearwards.
Lateral Support Removal

NOTE: The following instruction can be used for
RH or LH support.
section.
smr2011-038 593
RH SIDE SHOWN
LATERAL BELLOWS
1. Rivet location
Lateral Bellows Location

4. Remove lateral ring.
The lateral bellows are located on each side of the
5. Cut Oetiker clamp securing bellows to lateral
fixed deck.
support.
6. Separate lateral support from bellows.
Lateral Bellows Installation

Index suspension shaft with the lateral support.
The lateral support can be inserted in one position
only.
Install the retaining ring. Align the ring pin with
1. LH lateral bellows shown
holes in bellows and body.
Lateral Bellows Removal
1 Remove lateral support screw.
.
smr2009-04. 1 -026_a
1. Ring pin
2. Bellows alignment hole
3. Body hole

Install new rivets. If the head of rivet tool can
not be inserted in ring opening, use the sleeve
2. Disconnect lateral support from suspension (P/N 707 000 181) to offset the rivet tool and well
shaft. lean the rivet head against ring.
3. Using the SUPERTANIUM DRILL BIT 3/16° Index lateral supports with the front suspension
(P/N 529 031 800), remove all rivets (12) se shaft ends. Lateral supports can be inserted in
curing the lateral bellows ring to body. one position only.
594 smr201 l·038

Tighten lateral support screw to 48 N•m

(35 lbf•ft).
clamp rearwards.
RH SIDE SHOWN
1. Lstersl support screw
4. Disconnect lateral supports from suspension

arm shaft.
5. Refer to HYDRAULIC PUMP REMOVAL (,4S A
UNIT WITH ACTUATOR) and remove the pump
RH SIDE SHOWN
1. Ear of clamp rearwards from the PWC.
FRONT SUSPENSION ARM to suspension base.
7. Move front suspension arm rearward to re
Front Suspension Arm Location
move it from the PWC.
Front Suspension Arm Installation

If a shaft support has been loosened from the
suspension arm shaft, see SUSPENSION ARM
SHAFTS for proper installation procedure.
smt201 0-045-013
.,.a
FIXED DECK REMOVED FOR CLARfTY

1. Front suspension arm
Front Suspension Arm Removal

section.
2. Remove the engine.Refer to ENGINE RE
MOVAL AND INSTALLATION subsection.
3. Remove both lateral support screws.
smr2011-038 595
SUSPENSION BASE
Suspension Base Location
m r2009-041·
• 03l. •
PORT SIDE
1. Suspension base screws
4. Remove suspension base along with the rear

vent duct.
s m r20l il415-01 4 .J
FIXED DECK REMOVED FOR CLARITY

7. Suspension base
Suspension Base Removal

1. Refer to the appropriate procedures and re
move the following parts:
- Moving deck
- Engine
- Shock absorber and springs
- Hydraulic pump (with actuator) 1. Suspension base
2. Rear vent duct
- Suspension position sensor.
2. Using a marker, trace the shape of suspension Suspension Base Installation
base at the bottom of the hull to reposition it
at the same place.
3. Remove and discard suspension base screws.
1. Install the suspension base.
1.1 Position the base in accordance with the
reference marks previously drawn at the
bottom of the hull.
NOTE: If there is no mark, see SUSPEN
SION BASE INSTALLATION WITHOUT REF
ERENCE MARKS.
1.2 Install NEW suspension base screws.
1.3 Tighten suspension base screws to
25 N•m (18 lbf•ft).
• m r2D!lS.04 1 .Q31 . a
STARBOARD SIDE
1. Suspension base screws - Actuator and hydraulic pump
- Front suspension arm
- Shock absorber and springs
- Engine
- Moving deck.
696 smr2011·038
Suspension Base Installation without - Shock absorber and springs

Reference Marks - Engine
1. Install the suspension base in PWC using NEW - Moving deck.
screws. Do not tighten them yet.
2. Install the front arm on suspension base and REAR SUSPENSION ARM
tighten screws to 25 N•m (18 lbf•ft), use the
OLD screws. Rear Suspension Arm Location
3. Install lateral supports.
3.1 Index lateral supports with the front sus
pension shaft ends. Lateral supports can
be inserted in one position only.
3.2 Tighten lateral support screws to 48 N•m
(35 lbf•ft).
4. Align suspension base in PWC.
4.1 On both sides, measure the distance be
tween the end of lateral support and fixed
deck.
"'"'2010.00 5-0I S_a
1 Rear suspension arm
Rear Suspension Arm Removal

arm covers.
�1.Q64_ a
A. Same distance on LH and RH sides
4.2 If required, move suspension base until

both distances are equal.
4.3 Tighten suspension base rear screws to
25 N•m (18 lbf•ft).
smr20l&04 1 -072..•
i
1. Rear suspens on arm cover
3. Unclip and remove both lateral rear panels.
smr2�4 1066J
TIGHTENING SEQUENCE

- Actuator and hydraulic pump
smr2011-0JS 597
NOTE: If the upper arm shaft or one of its arm

shaft support has been removed or loosened, re
fer to SUSPENSION ARM SHAFTS for proper in
stallation procedure.
2. Tighten screws to 25 N•m (18 lbf•ft).
3. Carefully lower and secure the rear suspension
arm to the fixed deck.
3.1 Pu:silion the rear suspension arm brackets
in accordance with the reference marks
previously draw on fixed deck.
W1Jiti1j If no mark was traced, refer to

REAR SUSPENSION ARM INSTALLATION
WITHOUT REFERENCE MARKS for proper
procedure to install and align the rear sus
4. Mark position of rear suspension arm brackets pension arm.
for proper reinstallation.
5. Remove and discard screws securing rear sus sion arm brackets.
3.3 Tighten screws to 25 N•m (18 lbf•ft).
Rear Suspension Arm Installation Without

Reference Marks
2. Position the square openings of rear suspen
sion arm brackets so that the threaded inserts
in fixed deck are centered.
6. Remove and discard screws securing the top of

rear suspension arm.
o mr2009-04 1 -076_
o
1. Square opening
2. Threaded insert
3. On each bracket, install the retaining plate and

one screw.
4. Install a weight of 90 kg (200 lb) on PWC to
lower the moving deck.
s m :200i).() 4 l -076 ..ll
5. Check moving deck position in comparison to
7. Retaining screws
fixed deck.
7. Remove the rear suspension arm from PWC. 5.1 Check the gap between moving deck
wipers and fixed deck. It should be the
Rear Suspension Arm Installation same on both sides.
1. Using NEW screws, install the top of rear sus 5.2 Check front and rear gaps. Moving deck
pension arm. should be able to move without having
contact with the fixed deck.
598 smr20 I 1-038

5.3 Reposition rear suspension arm brackets 6. Install NEW support screws and tighten them
on fixed deck until positioning of moving to 25 N•m (18 lbf•ft).
deck is satisfactory. 7. Secure both supports to shaft using NEW
6. Secure the rear suspension arm to the fixed socket screws. lighten them to 12 N•m
deck. (106 lbf•in).
sion arm brackets.
Upper Shaft
6.2 Remove and replace screws ins ta l led dur
ing alignment. 1. Unclip and remove both lateral rear panels.
6.3 lighten screws to 25 N•m (18 lbf•ft).
SUSPENSION ARM SHAFTS

Removal of Front Suspension Arm
Shaft
1 . Remove the FRONT SUSPENSION ARM. see
supports to shaft.
3. Separate arm shaft supports from arm shaft.
lnstallation of Front Suspension Arm

Shaft
1. RH lateral rear pa111!l
1. To reinstall the shaft, insert it in the suspension
arm. 2. Remove arm shaft support screws.
2. Install a support on each end of theshaft.
3. Secure the LH arm shaft support to suspension
base using NEW support screws.
suspension base hole.
4. lighten the LH support screws to 25 N•m
(18 lbf•ft).
5. Apply a force on the RH support to move it on
the left side.
INoi(llj Make sure a r m shaft is fully i nserted,

it must lean against the a r m shaft support.
1 Arm shaft support screws

supports to arm shaft.
4. Separate arm shaft support from arm shaft.
Installation of Rear Suspension Arm

Upper Shaft
1. To reinstall the shaft, insert it in the rear arm.
2. Install a support on each end of shaft.
3. Secure the LH support to rear arm holder using
smr200�4 1 �7- •
NEW support screws.
1. Arm shaft against !rs support
holder hole.
smr2011-<r.JS 599
smr2Q09.Ci1 -07B_a
1. Support pin
•ma009·041-079_ a
2. Holder hole
7. Bar clamp
4. Tighten the LH su pp ort screws to 25 N•m 2. New socket screws
(181bf•ft).
5. Apply a force on the RH support to move it to
Lower Shaft
the left side.
NOTE: A bar clamp can be used to compress both
supports together. 2. Remove bolts securing both rear suspension
arm covers.
Rtoi[ij Make sure arm shaft is fully inserted,
it must flush against the arm shaft support.
1. Arm shaft against its support 1. Rear suspension arm cover
6. Instal l NEW s upport screws and tighten them 3. Mark position of rear suspension arm brack
to 25 N•m (18 lbf•ft). ets for proper reinstallation.
7. Secure both supports to shaft using NEW 4. Remove and discard screws securing rear sus
socket screws. Tighten them to 12 N•m pension arm to fixed deck.
(106 lbf•in).
smr:>009·041-07•_•
600 smr2011-038

rear brackets to arm shaft ends.
s m r'2 009-0.01-07t _a
1. Bad installation
2. Good installation
s mr20 0 9-04 1 -0ll9_a

1. Socket screw
2. LH rear bracket 4. Tighten NEW socket screws to 10 N•m
(89 lbf•in).
6. Press one rear bracket against the suspension
arm bushing and remove the circlip. Repeat for 5. Refer to REAR ARM for reinstallation.
the other side.
• m 1 2009-04 1 -070_•
1. Circlip
Installation of Rear Suspension Arm

Lower Shaft
1. When reassembly the rear bracket on shaft
end, press bracket on bushing to install the
circlip.
2. When both brackets are installed on shaft, pull
brackets outside to position circlips against
brackets.
smr2011·038 601
602
Subsection 03 (BODY (GTS/GTl/WAKE))
BODY (GTS/GTIJWAKE)
SERVICE TOOLS
SUPERTANIUM DRILL BIT 3/16'................................................... 529 031 800 ......................... 615-616, 619
SERVICE PRODUCTS
Description Part Number Pa ge
LOCTITE 243 (BLUEi . . . . . . . . . . ................................ .......................... . 293 800 060 ......................................... 618
XPS MULTI-PURPOSE CLEANER ................................................ . 219 701 709 ......................................... 617
XPS SYNTHETIC GREASE............................................................ . 293 550 010 ................... ......... ... 621-622
BODY PARTS NOMENCLATURE
9
s m o201 1-00J.0 02_c
1. Storage compartment cover

2. Mirror support
3. Gauge tnm
4. Lateral trim panel
5. Console
6. Glove box cover
7 Seat
8. ReBr handle
9. Bumper
smr2011·0J9 603
STORAGE COMPARTMENT COVER
See tightening
sequence
0
2. 0 N•m
(18 lbf•in)
See tightening
sequence
�
8 N•m
(7
1
1
'
'-... _ -
�-
604 smc2011-039
BODY PARTS
1.5 N•m
(13 lbfoin)
s mr20 11 -039- 1 01 . •
smr2011·039 605
Subsection 03 (BODY (GTS/GTl;WAKE))
BODY PARTS
8 N•m
{71lbf•in)
See tightening
sequence
4.5 N•m
(40 !bf.in)
-----11{102�s-N·�-�:
:-LTD -
:�
I
lbfein)
I
I
I
I •
I
---- - ----
�- - - - - '
4.5 N•m
{40
lbfoin)
See tightening
sequence
smr2011-03&-102,JI
606 smr2011-039
VENTILATION
amr201 1-03&-103
6m'2011-039 607
Subsection 03 (BODY {GTS/GTl/WAKE))
SEAT
.sml'2011-0J9.104_1
608 smr2011-039
WAKEBOARD RACK AND WAKE PYLON

Wake 155
6N•m
(53 lbfoin)
Loctite
5150
(silicone
sealant)
&
XPS
synthetic
grease
<)
_.....,
/ '
·/· ,
r
I
I
I
I
'
�
I
·/'
1./
""2011.Q40.100_1
s
smr2011·03S 609
GENERAL
Verify hinges condition and latching mechanisms
condition and operation. Replace any damaged
components.
complete procedure.
W1)i@j When applying threadlocker prod

ucts (anaerobic products), pay attention so
that it does not come in contact with ABS plas
tic parts (painted parts). It could lead to plastic
cracks or other damage.
1. Retaining nuts
A WARNING 3. Remove storage compartment cover.

must be strictly adhered to. Storage Compartment Cover
Locking devices when removed (e.g.: locking Disassembly
cotter pins, etc.) must be replaced with new Storage Compartment Cover Inner Shell
one. 1. Remove inner shell retaining screws.
W1JlliJj Hoses, cables or locking ties re

PROCEDURES
GELCOAT
For information and repair, refer to BODY
(RXT/GTX/VVAKE PRO) subsection.
DECALS
For information and repair, refer to BODY
(RXT!GTX/VVAKE PRO) subsection. smr201 1 -039-00 2_a
INNER SHELL RETAINING SCREWS

CARPETS
2. Unlatch both retaining tabs at the rear using a
For information and
repair, refer to BODY screwdriver.
(RXT/GTX/VV AKE PRO) subsection.
STORAGE COMPARTMENT
COVER
Storage Compartment Cover Removal
1 . Open storage compartment cover.
2. Remove nuts and bolts securing storage com
partment cover to hinge.
610 smr2011-039
Storage Compartment Cover

Assembly
The assembly is the reverse of the disassembly
procedure. However, pay attention to the follow
ing.
Tighten inner shell retaining screws to specifica
1 mr20 1 1-039-00 3_•
RETAINING TABS
3. Unlatch retaining tabs on both sides using a

screwdriver.
smr2 01 1·039-004
4. Disassemble inner shell from storage compart-

ment cover.
Storage Compartment Cover Latch

1. Ensure that inner shell is removed.
2. Remove latch by slightly pushing both retaining
holes toward the inside.
smr201 l-039 611

TORQUE STORAGE COMPARTMENT

COVER HINGE
Inner shel l retaining I 2.0 N• m (1 S lbf•in)
screws Storage Compartment Cover Hinge
Removal
1. Proceed with STORAGE COMPARTMENT
COVER REMOVAL.
2. Remove screws securing storage compart
ment cover hinge to deck.
sm r20 t l -03iHlOS_a
TIGHTENING SEQUENCE
Storage Compartment Cover

Installation
smr201 1 -039 -00 8 _a
The installation is the reverse of the removal pro HINGE RETAINING SCREWS
lighten storage compartment cover retaining nuts Storage Compartment Cover Hinge
to specification as per the following sequence. Installation
TORQUE The installation is the reverse of the removal pro
Storage compartment I S.O N•m (?1 lbf•in)
cover retaining nuts Use a 0 6.5 mm (1/4 in) steel rod to make a hook
in order to lock the hinge.
sm
r 2011 -03 9-0l7_ e s m r201 1 -039-009
TIGHTENING SEQUENCE TYPICAL
Insert the steel hook on the lateral tab of hinge in

order to slightly load the spring.
612 sm12011·039
Subsection 03 (BODY {GTS/GTl/WAKE))
1 n u2011-039-0 1 O..a
1. Steel hook
lighten hinge reta ining screws to specification as RETAINING SCREWS

per the following sequence.
3. Hit with a sharp blow the front part of mirror
TORQUE toward the rear to unlock it.
Storage compartment
cover hinge screws
I B.O N•m (71 lbf•in)
• •••2011·039·0 1 3 .i!
4. Remove gauge trim from mirror support.
'""2011-039-0l l_ a
Gauge Trim Installation
TIGHTENING SEQUENCE The installation is the reverse of the removal pro
GAUGE TRIM Prior to inserting gauge trim into mirror support,
ensure that all tabs are properly aligned.
Gauge Trim Removal
1. Open storage compartment cover.
2. From underneath mirror, remove retaining
screws on both sides.
smr2011 ·039
613
3. From inside storage compartment, remove

plastic rivets securing lateral trim panel to
deck.
smr2011.039 -014_ a
TOP OF GAUGE TRIM
& mr'201 t -039-018_a
PLASTIC RIVETS
\ \ \\\ \\If.Ulll111 1l
1i
BOTTOM OF GAUGE TRIM
LATERAL TRIM PANEL

Lateral Trim Panel Removal smr20 11-039-019
1 . Remove seat.
4. Remove plastic rivets securing the rear portion
2. From inside storage compartment, remove of lateral trim panel.
screws securing lateral trim panel to deck.
••
sm 1 2 C 11-039-C t20_a
s mr20 1 1-039--01 7_a PLASTIC RIVETS

RETAINING SCREWS
614 smr2011-039
5. Slide panel toward the front to unlock retaining

tabs.
1. Mirror support retaining rivets
5. Remove fuel tank cap.

6. Place a clean cloth rag onto fuel tank tube.
7. Unlatch retaining tabs on both sides using a
screwdriver.
omr2011-0�22_o
Lateral Trim Panel Installation

Install NEW plastic rivets.
MIRROR SUPPORT smr'.1011-039024.J>
1. Side retaining tabs
Mirror Support Removal

8. Unlatch retaining tabs on the top using a screw
1. Proceed with LATERAL TRIM PANEL RE driver.
MOVAL See procedure in this subsection.
2. Proceed with INFORMATION CENTER RE
MOVAL Refer to INFORMATION CENTER
{GAUGE) subsection.
3. Remove steering column, refer to STEERING
AND 0. TA.S. subsection.
4. Remove the following rivets securing mirror
support to deck.
REQUIRED TOOL
SUPERTANIUM DRILL BIT 3116' (P/N 529 031 800)
smr2011-039 615
Subsection 03 (BODY (GTS/GTl/WAKE})
2. Remove GLOVE BOXCOVER, see procedure in

this subsection.
3. Remove the following rivets securing console
to deck.
REQUIRED TOOL
SUPERTANIUM DRILL BIT 3116" (PIN 529 031 800)
s m i201 1 -0:l 9 -02S_ a
1. Top retaining tab
9. Remove mirror support by pulling it upwards.

10. Remove cloth rag and reinstall fuel tank cap.
AwARNING
Fuel vapors are flammable and explosive
under certain conditions. Unless otherwise
noted, the fuel tank cap must always be in
stalled o n watercraft.
.smr201 1 -039-02 6 _a
Mirror Support Installation
1. Console retaining rivets
Prior to inserting mirror support into console, en
sure that all tabs are properly aligned.
Install rivets upside down with washers on mirror
support top surface.
MIRRORS
Mirror Replacement
1. Proceed with GAUGE TRIM REMOVAL, see
2. From inside gauge trim, slightly heat mirror.
3. Push at the back of mirror to remove it .
smr2011-03 9 ·027...a
4. Properly clean gauge trim surface of any glue 1. Console retaining rivets
residue.
4. Remove console by pulling it upwards.
5. Install mirror using adhesive tape at the back of
mirror. Console Installation
6. Reinstall gauge trim as the reverse of removal. The installation is the reverse of the removal pro
CONSOLE
Console Removal
1. Proceed with MIRROR SUPPORT REMOVAL.
See procedure in this subsection.
616 smr2011-039
To ease installation of rivets located in glove box, RECOMMENDED PRODUCTS

proceed as follows:
XPS MULTI-PURPOSE CLEANER (P/N 219 701
AIR INTAKE
- Remove air intake silencer, refer to 1.
709)
SYSTEM (EXCEPT 1S AND aS MODELS} sub
section. 2. Dish Soap (Dawn or Ivory)
- Install rivets upside down with washers on con 3. Fantastik
sole top surface.
4. 3M Citrus Cleaner
GLOVE BOX COVER 5. 303 Protectant
Glove Box Cover Replacement Vinyl Cleaning Recommendations for Special

1. Open glove box cover. Stains
2. Pull glove box cover upwards to release it from TYPE OF STEP STEP STEP
ACTION
console hinge. STAIN 1 2 3
B allpoint ink * E B A
- A Medium-soft brush,
Chewing gum D A
warm soapy water,
Coffee. tea. - - rinse/dry .
B
chocolate
Pen D B -
- B. Vinyl Finish Cleaner.

Grease D B
rinse/dry .
Household soil A B -
Ketchup A B -
A B - C. One (1) tablespoon

Lat ex paint
of ammonia, one-fourth
Lipstick A B - ( 1/4) cup of hydrogen
peroxide, three-fourth
Mildew or wet
c B A (3/4) cup of water.
smr2011-039-028..a leaves *
rins e/dry.
Motor oil B - -
3. Reinstall glove box cover as the reverse of re
moval. Oil-based paint D B -
D. Wipe or scrape off
Perman ent
SEAT marker*
E B c excess (c hill gum with
ice befo re hand).
Seat Cleaning Spray paint B B -
For general purpose cleaning, use XPS MULTI-PUR Suntan lotion A B -
POSE CLEANER (PIN 219 701 709), Vinyl Finish Vinyl E. De natu red alcohol,
Tar/asphalt D B -
Cleaner, Fantastik or warm water with a mild dish rins e/d ry.
soap such as Dawn or Ivory. Gently scrub with a Yellow mus ta rd A B c
small soft bristle brush.
* Suntan lotion. tree pollen. wet leaves and some other
For dirt
build-up, use XPS MULTI-PURPOSE products can contain dyes that sta in perm ane ntly.
CLEANER (PIN 219 701 709), Vinyl Finish Vinyl
Cleaner or an equivalent. Let soak for approxi All cleaning methods must be followed by a thor
mately 1 O minutes, then gently scrub with a soft ough rinse with warm water.
bristle brush. For specific stain removal, refer to
Certain household cleaners, powdered abrasives,
your cleaning and care card.
steel wool and industrial cleaners can cause dam
Do not use any silicone-based protectants. They age and discoloration and are not recommended.
will extract the plasticizers, leaving the vinyl hard Dry cleaning fluids and lacquer solvents should
and brittle, and eventually cracking will occur. not be used as they will remove printed pattern
and gloss. Waxes should be used with caution
as many contain dyes or solvents that can perma
nently damage the protective coating.
smr201 1-039 617

SEAT LATCH
Seat Latch Adjustment
NOTE: Apply LOCTITE 243 (BLUE) (P/N 293 800 060)
on threads of lock pin when the adjustment is re
quired or when the lock pin is removed. If a new
lock pin is used, it is already coat with a thread
locker.
1. Loosen adjustment nut.
2. Adjust lock pin height. Do not torque yet.
3. Position the lock pin longitudinally into the rear
handle slot. smr2011.03 .Q30_1
9
1. Rear handle retaining screws
LOCK PIN POSITIONING
MEASURE A MEASURE B 3. Replace rear handle.
24.0mm ± 1. 0mm 30mm ± 1.0mm 4. lighten rear handle screws to specification.

(.945 in ± .039 in) (1.181 in ± .039 in)
TORQUE
Rear handle screws I 8.0 N•m (71 lbf•in)
BUMPER
Bumper Replacement
1. Remove screws securing front bumper.
2. Remove front bumper from deck.
smr:I01 1.03lMl29_1
A 24.0mm± 1.0mm (.945in ± .039in)

B. 30mm ± 1 .0 mm (1.181 in± .039in)
4. Hold the lock pin in this position and tighten as

per the following sequence.
SEAT LATCH TIGHTENING SEQUENCE

smt'l
O 1 1.Q3$Q3I_I
9.5N•m
STEP 1 Lock pin 1. Front bumper retaining screws
(841bf•inl
8.0N•m 3. Remove screws securing both rear corner

STEP 2 Adjustment nut bumpers.
(71 lbf•in)
4. Remove rear corner bumpers from deck.
5. Close the seat and readjust if required.
REAR HANDLE
Rear Handle Replacement
1 . Remove seat.
2. Remove screws securing rear handle to deck.
618 smc2011-039
•mf201 H3
l 9-03 4_ a
TIGHTENING SEQUENCE
sm12011-039-032... •
1. Rear corner bumper retaining screws VENTILATION DUCT

5. Slide side bumpers toward the rear to remove Ventilation Duct Replacement
them from deck.
1. Proceed with LATERAL TRIM PANEL RE
6. Slide rear bumper toward the side to remove it MOVAL. See procedure in this subsection.
from deck.
2. Remove plastic rivet securing ventilation duct
to housing.
snv2011·039-033 -•
7. Install new bumpers as the reverse of removal. smr2 0 1 1·039.035a

_
NOTE: Use soapy water to ease bumper installa

tion.
3. Remove the following rivets securing ventila
tion duct housing to deck.
8. Tighten front bumper lower retaining screws to
specification. REQUIRED TOOL
TORQUE SUPERTANIUM DRILL BIT 3/16" (P/N 529 031 800)
Front bumper lower

8.0 N•m (71 lbfein)
screws
9. Tighten bumper retaining screws to specifica

TORQUE
Bumper retain ing screws I 4.5 N•m (40 lbf•in)
smr2011·039
619
omr 2 0 1 0-0411-00 7 .,a
1. Wake pylon bottom bolts
emt'l01 1 ·009-035_o
Remove bolts securing the wake pylon support to
4. If applicable, remove locking tie securing wiring body.
harness to ventilation duct.
5. Remove ventilation duct and its housing from
watercraft.
6. Reinstall parts as the reverse of removal.
WAKE PYLON (WAKE)

Wake Pylon Removal
Open the seat.
Remove both lateral arms.
1. Wake pylon support bolts
Lift the wake pylon to disengage its bottom from

the body.
Slide the bottom of the wake pylon rearward to
remove the wake pylon from vehicle.
&mr20 1 �S-•
1. Lateral arms screws
Remove bolts at the bottom of wake pylon.
Wake Pylon Disassembly

Extend the handle completely.
Turn the wake pylon upside down.
620 smr2011-039
Move both ends of locking strap to disengage the

inner lock and free the handle.
A. 75mm to 90mm (3in to 3-112 in}
om r 2008-035-0 1 4_
a
Insert two thin feeler gauges between handle
7. Locking strap end
2. Handle stem stem and extension tube.
Locking Strap
Using a screwdriver or any other suitable tool, de
tach a side of the locking strap from retaining pin.
smr 2008-035-0 1 7_a
1. Handle stem
2. Feeler gauges
3. Extension tube
Place a rag around the joint to catch balls and

spring.
• mr200 8-0l35-01 5_a
Hold feeler gauges and pull the handle.
1. Locking strap
Wake Pylon Assembly

Remove locking strap and the inner lock.
Handle
Handle
Install a loose locking tie on handle stem.
Extend handle approximately 75 mm to 90 mm
(3 in to 3-1/2 in). Apply XPS SYNTHETIC GREASE (P/N 293 550 010) on
each ends of spring.
Insert the spring in the handle stem hole.
Position a ball on each ends of spring.
Install a feeler gauge over each balls.
Tighten the locking tie in order to retain feeler
gauges and balls.
smf.2011-039 621
u
nr208
0 .03S.0 2 1 _t
1. Feeler gauges
2. Ball 1. Retaining pin
2. Locking strap
Apply XPS SYNTHETIC GREASE (P/N 293 550 010) in

Using a suitable tool, position the locking strap in
both recesses of the extension tube.
its groove.
1 2
1. Locking strap
2. Locking strap groove
1. Extension tube
2 Recesses Reinstall the wake pylon trim.
Slide the handle stem into the extension tube. Do not install the handle into wake pylon yet.
Remove feeler gauges and locking tie. Wake Pylon Installation

Locking Strap Position the wake pylon on deck.
Remove the wake pylon trim. Install and secure wake pylon and lateral arms us
ing previously removed fasteners and new elastic
stop nuts.
1 1
1 1
1. Wake pylon trim screws 1. Bottom of wake pylon

2. Rubber washers
3. Flat washers
Install lock and insert the end of the locking strap 4. New elastic stop nuts
over the retaining pin.
622 sm<2011-039
smr201 0-046-011_ a
1. Flat washers
2. New elastic stop nuts
Tighten all bolts by hand.

Ensure base of wake pylon is well leaned against
body.
Tighten all bolts as per the following sequence.
TIGHTENING SEQUENCE
Insert the handle into the wake pylon.

Move both ends of the locking strap forward to
fully insert handle.
smr2011-039 623
624
Subsection 04 (BODY (RXT/GTX/WAKE PRO))
BODY (RXT/GTXJWAKE PRO)

SERVICE TOOLS
SUPERTANIUM DRILL BIT 3/16' ... . . ..... . ... .. .. .. .. . ..... .. . 529 031 800 ......................................... 650
.. . .. .. .. . . . .. . . . .. .
SERVICE PRODUCTS
LOCTITE 243 (BLUE) .................................................................... . 293 800 060 ......................................... 644
LOCTITE 414 ..... . . . . . . . . . . . . . . .............................................................. 413 705 800 ................................. 642, 660
LOCTITE 5150 (SILICONE SEALANT) .......................................... . 296 000 309 ................................. 655-656
XPS MULTI-PURPOSE CLEANER ................................................ . 219 701 709 .................. . . . . . . .. . .... 644
. . .. .. . . . .
XPS SYNTHETIC GREASE............................................................ . 293 550 010 ......................................... 673
smr201 l-040 625

------------=-
Section 07 BO
Subsection
D HULL
:�=R O=-))
(�OyDYAN(RXT/GTX/WAKE
04 p
BODY (iS AND aS MODELS)
626 smr201 l·040

8 N•m
(71 lbf•in)
smr2011-040 627
0.4 N•m
(4 lbfoin)
4.5 N•m
(40 lbMnl
smr20t 0-0<6- 1 03_•
628 smr2011-040
Subsection 04 (BODY (RXT/GTXJWAKE PRO))
BODY (MODELS WITHOUT iS OR aS)
smr2011-040 629
BODY (MODELS WITHOUT iS OR aS)
4.5 N•m
(40 lbfoin)
Loctite
243
&
v
8 N•m
f®�
(71 lbfoin)
s mr?Ol Q.046..1 05..a
630 smr2011-040
STORAGE COMPARTMENT OS AND aS MODELS)
0.9 N•m
(8 lbf.in)
3 N•m
(27 !bf.in) ��
�
,/"
0.4N•m . � 8 N•m
(4 lbfoin) !M �'7 ;}N•m
l �.i'l .( , (22 !bf.in)
. �.
I
1. 1 N•m • l 1! /
5 N•m
(44 lbfoin)
smr2011-040 631
Section 07 BO AND HULL
(�OyDY (RXT/GTXJWAKE RO))
Subsection 04 p
�:_o
STORAGE COMPARTMENT (MODELS WITHOUT '·s � 1R aS)
-----
632 smr2011·040
VENTILATION (iS AND aS MODELS)
1.2 N•m
(11 lbfoin)
'
\ \
smr201HJ.40 633
VENTILATION (MODELS WITHOUT iS OR aS)
s rnr201 0.040 · 100
634 smr2011-040
FRONT COVER
'
\ \ \ XPS
'\ \ \ synthetic
\,
\ \' \•/'>..1''..,.._..,. grease
•
'
.\ \.
'
\ \.
: f>
\ '
2 N•m
-.._;.---7(18 lbMn)
! m c 2 0 10-046-106_ 0
smr2011-040 635
Subsection 04 (BODY (RXT/GTX/WAKE PRO)}
SEAT
, GXTseries
I
I_ - - - - - - - - - - - - - - - - - - - - - - - - - I
I
I
�- i
;s models
: - ---?<- '
'
'
I I
I
I
: 6.5 N•m :
I (58 lbfoin} I
I
-
I - - - - - - - _
s-.v1Q" ().046- 109..>l
636 smr2011·040
WAKEBOARD RACK AND WAKE PYLON

Wake Pro
6N•m
(53 lbf.in)
Loctite
5150
(silicone
sealant)
&
XPS
synthetic
grease
5m!"2011..Q40..l00_i
smr2011-040 637
GENERAL You can order on the web site and get confirm a
tion of your order within hours. Quick, reliable ser
Verify hinges condition and la tch ing mechanisms
vice is what is offered to all BRP dea lers around
condition and operation. Replace any damaged
the world.
components .
There are many services on this web site to

Clean threads before applying a threadlocker. Re make your ordering quick and informative. Or
fer to SELF-LOCKING FASTENERS and LOCTITE you can call Gelcote I n ternational directly with
APPLICATION at the beginning of this manual for any question per taining to gelcoat. Service, value
complete procedure.
and knowledge is what you can expect when you
call Gelcote International.
IM1Ji[IJj When applying threadlocker prod
ucts (anaerobic products), pay attention so Gelcote International Ltd
that it does not come in contact with ABS plas 174 Colonnade Road Suite 29
tic parts (painted parts). It could lead to plastic Ottawa, Ontario
cracks or other d amage . Canada, K2E 7J5
Phone: (613) 225-2177

A WARNING Phone: (877) 435-2683 (Toll Free)
Torque wrench tightening specifications Fax: (613) 225-5297
Web Site: www.gelcoat.ca
E-mail: info@gelcote.com
cotter pins, etc.) must be replaced with new
one .
A WARNING
Protect skin, wear gloves when in contact
with resin, hardeners and gelcoat. A barrier
W1Jil1Jj Hoses, cables or locking ties re skin cream may also be used. Do not expose
moved during a procedure must be reinstalled area to open flame or lit cigarette. Some of
the materials are flammable. Protect eyes,
wear safety g l asses when grinding, sanding
PROCEDURES or spraying. Use a dust mask when sanding
or grinding. When spraying wear a respirator
GELCOAT or paint mask. Always read warning labels
on pr oducts .
The deck is constructed of chopped fiberglass,

saturated with resin. It is sprayed on the layer of
TOOLS
gelcoat along with pieces of fiberglass mat, cloth
Air mask Power sander
and woven roving which are added at required
are as . Buffing pda Putty knife
For the hull, a d iff eren t material is used and a stan Cover sheets Safety glasses
dard polyester based fiberglass repair kit will not Heavy-duty polisher Sanding block
work. Refer to HULL su bsection for proper mate Paint bruhs Sci ssor s
rial and proc edures .
Plastic container (mixing) Spray gun
Gelcoat Repair Information Plastic fil m Stirring stick
All liquid gelcoat and repair kits can be purchased Plastic squeegee White cloths
directly from Gelcote International Ltd. BRP does

not d istri bute these products.
NOTE: Fiberglass re pair kit is also available
through automotive or marine suppliers.
Gelcote International Ltd web site has all the Sea
Doo personal watercraft and sport boat gelcoat
colors.
638 smr2011-040
MATERIALS buffing with a white medium compound. Finish

off using a fine compound. While buffing, pay
Acetone Epoxy filler
close attention to avoid overheating the surface.
Cabosii Masking tape
Cardboard Liquid gelcoat Blisters Repair

Fine compound Medium compound Possible causes:
(white) (white)
- Insert catalyst
Fiberglass cloth Polyester resin
- lmrrorer catalyst/gelcoat ratio.
Fiberglass mat 24-grit sanding disks
A blister is a visible bump on the watercraft sur
Gelcoat putty Wax face that may not necessarily come right through
Sandpaper (100-grit, 220-grit, 320-grit, 400-grit, the gelcoat layer. In the case of only a few blis
600-grit, 1000-grit) I ters, follow the same repair procedure as for air
bubbles. If they are numerous and in close con
Air Bubbles Repair centration, spray liquid gelcoat to achieve proper
repair. This procedure is covered in MINOR GEL
Possible cause:
COAT FRACTURES.
- Air pocket trapped between layers of laminate
and gelcoat. Minor Gelcoat Fractures Repair
Preparation of Surface Possible causes:
Remove all of the damaged gelcoat surrounding - Flexing of fiberglass laminate
the air bubble with a putty knife or preferably a - Gelcoat thickness
carbide grinding tip. Make sure all loose and weak - Direct result of impact.
areas are completely removed. Sand a small area
In case of fractures which have not penetrated
of the gelcoat surface with 220-grit sandpaper. If
past the gelcoat layer, the repair concerns the gel
needed, sand the cavity itself. These areas must
coat only. If flex cracking or impact are evident,
have a rough surface to allow the gelcoat putty to
then additional reinforcement may be necessary.
bond properly.
This subject will be covered in COMPOUND
Filling the Cavity FRACTURES.
The prepared surface must be cleaned with ace Preparing the Surface
tone on a cloth. Use a gelcoat repair kit. Follow
Small Fractures: Open the cracks up with a
the mixing instructions in the kit when preparing
sharp triangular can opener or preferably a car
the gelcoat putty.
bide tipped die grinder. The V groove will provide
Carefully mix the required amount while making a good bonding area for the gelcoat. With 220-grit
sure there are no air bubbles in the mixture. With sandpaper, sand the sides of the notched out ar
a putty knife, fill the repair area and cover with eas.
plastic film. Curing time may depend on tempera
Numerous Fractures: Using a grinder with a
ture, amount of putty and percentage of catalyst.
24-grit disk, remove the gelcoat. Sand the area
After 2 hours. press lightly on the surface with
edge with 220-grit sandpaper.
fingers to test the hardness. When the area be
comes hard, remove the plastic film. Filling the Repair Area
San d i ng Small Fractures: Refer to the same procedure as

in the AIR BUBBLES.
Begin block sanding the patch with 320-grit sand
paper until you come close to the original surface. Numerous Fractures Over Large Surface: Pre
Remove dust with a water soaked cloth and con pare the area for spray application of liquid gel
tinue sanding with a 400-grit wet paper. Finish coat. Wipe down the surface with acetone. Mask
wet sanding with a 600-grit to remove deeper the area off to protect the watercraft from over
scratches. If needed you can wet sand with finer spray.
grit paper such as 1000-grit. Mix the needed quantity of gelcoat and catalyst
Buffing and Wa xing according to suppliers recommendations. The
gelcoat can be thinned with acetone up to 10%.
Buff the surface using a heavy duty polisher with
If it needs more consistency you can add cabosil.
a buffing pad. Make sure the pad is free of dirt
or you may damage the gelcoat. Carefully begin
smr2011-040 639
Subsection 04 (BODY (RXT/GTX;WAKE PRO))
Make sure that the air supply is free of oil. dirt and fiberglass cloth. If the fracture is small enough all
water. you may have to do is fill the area with an epoxy
filler.
Test spray the gelcoat mixture on paper to verify
its consistency and pattern. You may have to ap Inside: For the interior repair, you can grind more.
ply 5 or 6 coats to cover the area properly. Over This will allow for more fiberglass material which
lap each coat further than the last, leaving at least will strengthen the area. If the fracture opening is
30 seconds between passes. Avoid trying to coat too large after surface preparation, you may need
the surface with only a few heavy coats. this will a backing support to cover the opening. Cut Alter
not allow the gelcoat to dry properly. nating pieces of fiberglass mat and cloth in over
lapping sizes.
Apply a coat of polyvinyl alcohol (PVA) to seal off
the air and protect the gelcoat surface from dust. Patching the Repair Area
PVA speeds up the curing process because gel
Outside: The outside should be done first. Wipe
coat will not cure properly when exposed to air.
clean the area with acetone on a cloth, then mask
Sanding off area. For a small crack use an epoxy filler in
the same way you would use gelcoat repair putty.
Wash the polyvinyl alcohol off with water. De
When laying up a larger area you will use mat,
pending on the size of the area repaired, you
can either block sand as per previous procedure cloth and fiberglass resin and catalyst. Use a clean
container to mix the resin, mix only what you will
or you may use an air sander. Sand the surface
down with progressively finer grits of sandpaper need. Follow the recommended catalyst ratio.
until the desired finish is achieved. Using a clean paintbrush, brush the mixed resin
on the surface. Place the smallest piece of mat
Buffing and Waxing
over the fracture and then wet out the mat. Fol
Buff the surface using a heavy duty polisher with low with the remaining pieces of mat and final
a buffing pad. Make sure the pad is free of dirt layer of cloth. While wetting the pieces make sure
or you may damage the gelcoat. Carefully begin you work the air bubbles out and saturate all the
buffing with a white medium compound. Finish pieces evenly. Try to work quickly, you may only
off using a fine compound. While buffing, pay have 15 or 20 minutes. You may clean the brush
close attention to avoid overheating the surface. with acetone.
Wait until the repair has hardened before moving
Compound Fractures Repair
on to the interior repair. If the size of the opening
Possible causes: is too large for the pieces to maintain the proper
- Thickness of fiberglass laminate shape, you will have to use a backing support. It
- Direct result of impact. is a shaped piece of cardboard that fits flush to the
interior surface and has a plastic layer on the repair
Compound fractures are those that have gone
side. It is held in place by tape or a support.
past the gelcoated surface and in through the lay
ers of fiberglass laminate. Two types of repairs Inside: Wipe down the area with acetone on a
have to be performed. The first is to restore the cloth. Apply the same procedure as for outside
structural integrity of the damaged area. Fracture repair when laminating the alternating pieces
types can vary from a simple crack to a large of fiberglass material. If a backing support was
hole. Usually, fiberglass reinforcement becomes used, remove it before starting the repair. After
necessary, especially if the fracture can be at the area has hardened, remove sharp edges of
tributed to weakness. The final part of the repair material from surface. If required paint the sur
is the gelcoating, which cannot be done until the face.
interior and exterior laminate surfaces have been
Sanding
repaired.
Outside: This surface will have to be prepared for
Outside: Remove the damaged gelcoat and fiber
application of gelcoat. The size of the area will
glass with a 24-grit disk using a power sander.
determine the gelcoating procedure to be used.
Grind outward at least 2 inches from the fracture
Refer to the MINOR GELCOAT FRACTURES RE
to allow the patch to bond to strong material.
PAIR.
Cut enough pieces of fiberglass mat necessary
to build up the area. The pieces should be cut Buffing a n d Waxing
so they overlap each other by at least a half inch. Refer to the BUFFING AND WAXING in MINOR
For a smoother finish, the last layer should be GELCOAT FRACTURES REPAIR.
640 smr2011·040
Subsection 04 (BODY (RXT/GTX/WAKE PRO}}
DECALS Remove front protective film once decal has ad

hered to hull.
Decal Removal
Installation on Plastic Surface (Storage Cover)
Using a heat gun warm up one end of decal for a
few seconds until decal can roll off when rubbing Clean surface with isopropyl alcohol and dry thor
with your finger. oughly.
NOTE: When heating near light surfaces, duct Using a pencil and the decal as a template, mark
tape should be applied to protect the surface. the area where decal will be located.
Otherwise the light color could become a yellow
ish color.
@Z1Jiti1Jj Do not use soapy water to locate de
cal on plastic parts.
Pull decal slowly and when necessary apply more
heat to ease removal on the area that has to be Remove back protective film from decal and care
peeled off. fully align decal with marks. When well aligned
squeegee decal beginning at center and working
If decal tears while pulling off, it has to be heated
outward using firm, short, overlapping strokes.
for a few seconds longer. If decal tends to stretch
while pulling off, stop heating and wait a few sec Remove front protective film once decal has ad
onds to let it cool, then peel it off. hered.
Decal Installation (with a Protective CARPETS

Film on Back Side)
Carpet Cleaning
These decals usually contain written information
(e.g.: warning) and are used on gelcoat or metal. To clean the carpets, use 3M™ Citrus Base
Cleaner or the equivalent. See the manufac
Using isopropyl alcohol, clean the surface and dry
turer's instructions.
thoroughly.
Using a pencil and the decal as a template, mark Carpet Removal
the area where decal will be located.
Unstick a carpet corner.
Remove half of the decal back protective film and
Pull carpet vigorously to remove the carpet and its
align decal with marks. Start sticking it from cen
glue from body .
ter and remove the other half of the film to stick

it completely. Carefully squeegee decal beginning To remove the remaining glue from body, use a
at center and working outward using, firm, short, plastic or rubber spatula. Scrape remaining glue
overlapping strokes. with spatula.
NOTE: Do not use any products (alcohol, ace
Decal Installation (with a Protective tone, thinner, etc.) or heat the remaining carpet
Film on Both Sides) glue. Chemical reactions make glue very hard to
These decals usually contain graphics and are remove.
used on gelcoat or plastic.
Carpet Installation
Installation on Gelcoat
Clean body surface with isopropyl alcohol and dry
Using isopropyl alcohol, clean the surface and dry thoroughly.
thoroughly.
Install new carpet.
Using a pencil and the decal as a template mark
the area where decal will be located.
For better adhesion a dry application is recom
mended, however, to ease decal installation a
mild solution of soapy water can be sprayed over
surface where decal will be installed.
Remove back protective film from decal and align
decal with marks. When well aligned squeegee
decal beginning at center and working outward us
ing firm, short, overlapping strokes.
smr2011-040 641
Subsection 04 (BODY (RXT/GTX/WAKE PRO})
STORAGE COMPARTMENT
COVER
smr2009-042 -029_
•
1. Cover hinge key

2. Front body module slot
sml'2000-042-074_a
TYPICAL - iS MODEL SHOWN Storage Compartment Cover

1. Storage compartment cover Installation
Storage Compartment Cover Removal
1 . Open cover.
Remove gas shock attachment from cover.
2. Cut locking tie retaining the bellows of gas
Apply LOCTITE 414 (P/N 413 705 800) on threads of
shock.
shock absorber body.
lighten manually the attachment on gas shock.
Install the bellows and secure it using a locking tie.
Install the gas shock on cover.
NOTE: The corrugated section of bellows must
point downward.
s mr2009-04 2-028_a
3. Move bellows downward.

4. Unscrew gas shock from its upper attachment.
5. Remove gas shock from vehicle.
6. Open cover completely.
7. Align cover hinge keys with front body module
slots. 1. Corrugated sectt0n
8. Pull up cover to remove it. Install cover on vehicle.
W1Ji(ij Make sure to insert cover hinges

completely. A click must be heard to indicate
complete insertion.
Position the gas shock lower attachment on cavity

opening.
IN•)i(ij To avoid breaking the attachment,

do not force to insert it in cavity.
642 smr2011-040
SEAT
Seat Removal
1 . Open seat.
2. Attach the seat to support it during removal.
3. Remove Allen socket screw retaining the lateral
arm to moving deck (one each side).
smt2009-04-2-()3 1 _a
1. Lower attachment in its cavity
Close cover to lock the bottom of the gas shock.
GLOVE BOX COVER
s m2009-042
r · 026_a
1. Allen socket screw

2. RH lateral arm
4. Remove bolts securing the central arm to seat.

$mr2009-042-055_a
TYPICAL - iS MODEL SHOWN

1. Glove box cover
Glove Box Cover Removal

1. Move steering in its upper position.
2. Open glove box cover until cover hinges are
aligned with front body module openings.
s m t 2009-042-027_
a
1. Central arm
2. Retaining bolts
5. Remove seat from vehicle.
Seat Installation
smr2000-042-025_a
Install seat to central arm.
1. Glove box cover hinge
2. Front body module opening lighten seat retaining bolts to specification.
3. Pull the bottom of cover gently to release SEAT RETAINING BOLTS TORQUE
hinges.
Glove Box Cover Installation Secure lateral arms to moving deck. Install parts
Reverse the removal procedure. as shown.
smr2011·040 643
Vinyl Cleaning Recommendations for Special

Stains
TYPE OF STEP STEP STEP

ACTION
STAIN 1 2 3
Ballpoint ink" E B A
- A. Medium-soh brush.
Chewing gum D A
warm soapy water.
Coffee, tea, rinse/dry.
- -
B
chocolate
-
Pen D B
- B. Vinyl Finish Cleane r,
•mr2D09-042-032.• Grease D B
rinse/dry.
1. Allen socket screw -
Household soil A B
2. Stamless steel flat washers
3. Sleeve -
4. RH lateral arm Ketchup A B
5. Rubber grommet in moving deck C. One (1) tablespoon
-
Latex paint A B
of ammonia, one-fourth
Tighten lateral arm screws to specification. -
Lipstick A B (1/4) cup of hydrogen
LATERAL ARM SCREWS TORQUE peroxide, three-fourth
Mildew or wet
c B A (3/4) cup of water,
1.5 N•m (13 lbf•in) leaves•
rinse/dry.
- -
Motor oil B
Qlui@j Do not tighten screws over this
Oi l-b ased paint D 8 -
recommended torque. Otherwise, the rubber
D. Wipe or scrape off
grommet could turns and screw will be hard Perma nent
E 8 c excess !chill gum with
to remove. marker*
ice before hand).
-
Spray paint B B
Seat Cleaning
-
Su ntan lotion A B
For general purpose cleaning, use XPS MULTI-PUR
- E. Denatured alcohol.
POSE CLEANER (P/N 219 701 709), Vinyl Finish Vinyl Tar/asphalt D B
rinse/d ry.
Cleaner, Fantastik or warm water with a mild dish
. Yellow mustard A B c
soap such as Dawn or Ivory. Gently scrub with a
small soft bristle brush. •suntan lotion. tree pollen, wet leaves and some other products
can contain dyes that stain permanently.
For dirt build-up, use XPS MULTI-PURPOSE
CLEANER (P/N 219 701 709), Vinyl Finish Vinyl
All cleaning methods must be followed by a thor
Cleaner or an equivalent. Let soak for approxi
ough rinse with warm water.
mately 10 minutes, then gently scrub with a soft
bristle brush. For specific stain removal, refer to Certain household cleaners, powdered abrasives,
your cleaning and care card. steel wool and industrial cleaners can cause dam
age and discoloration and are not recommended.
Do not use any silicone-based protectants. They
Dry cleaning fluids and lacquer solvents should
will extract the plasticizers, leaving the vinyl hard
not be used as they will remove printed pattern
and brittle, and eventually cracking will occur.
and gloss. Waxes should be used with caution
RECOMMENDED PRODUCTS as many contain dyes or solvents that can perma
nently damage the protective coating.
1 XPS MULTI-PURPOSE CLEANER
(P/N 219 701 709)
SEAT LATCH
·
2. Dish Soap (Dawn or Ivory)

Seat Latch Adjustment
3. Fantastik
NOTE: Apply LOCTITE 243 (BLUE) (P/N 293 800 060)
4. 3M Citrus Cleaner
on threads of lock pin when the adjustment is re
5. 303 Protectant quired or when the lock pin is removed. If a new
lock pin is used, it is already coat with a thread
locker.
1. Loosen adjustment nut.
644 smr2011-040
2. Adjust lock pin height. Do not torque yet.

3. Position the lock pin longitudinally into the rear
handle slot.
4. Hold the lock pin in this position and tighten ad
justment nut to specification.
SEAT LATCH ADJUSTMENT NUT TORQUE
5. Close the seat and readjust as required.
•mr200�2-042_•
1. Front retaining tabs

2. Side retaining tabs
3. Locating tabs
2. Remove nut and spring securing mirror.
smf201C>
. -046-01 4_e
1. Lock pin
2. Adjustment nut
MODEL MEASURE A MEASURE B
iS and as 32.4mm ± 1.0mm

Models (1.276 in ± .039in) smr2011-040-00 1 ..a
34.4mm ± 1.0mm 1. Nut

Models (1.354 in ± .039in) 2. Spring
36.4mm ± 1.0mm
without
(1.433in ± .039in) 3. Install the new mirror and tighten nut to speci
iS or as
fication.
MIRRORS MIRROR SPRING LENGTH SPECIFICATION
10mm to 12mm (13/32in to 15/32in)

Mirror Replacement
1. Remove mirror trim as follows.
1.1 Using a small screwdriver, unlock both
front tabs securing the front of mirror
.r
trim.
1.2 Tilt the trim forward and remove it.
s m 120 1 1-040-002_ a
A. 10mm to 72mm (13!32in to 15!32inJ
smr2011·040 645
4. Install mirror trim as follows. 2. Remove side screws securing front bumper to
body.
4.1 Install the front locating tabs.
11'11l 2009-04 2-048_ a

smr2()()9.()d 2 .()43_1
FROM RH SIDE OF VEHICLE
1. Front locating tabs 1. Fronr bumper
2. Retaining screw
3. Side bumper
4.2 Lower rear part of trim.
4.3 Lift up the rear edge and press the center 3. Remove screws located under front bumper.
of trim to position retainers over front re
taining tabs.
UNDERNEATH FRONT OF VEHICLE

1. Retaining screws
4. Remove front bumper from vehicle.

1. Trim rerainers Rear Bumper
2. Retaining tabs
1 . Remove both protective caps (one on each
side).
BUMPERS
Bumper Removal
Front Bumper
1. Remove both protective caps.
TYPICAL iS MODEL SHOWN

-
7. Rear bumper
2. Protective cap
2. Remove side screws securing rear bumper to

smf.1009-042-045_1 body.
TYPICAL - iS MODEL SHOWN
1. Front bumper
2. Protective caps
648 smr201 l-040

s m r'2009·
042-049 _a
FROM RH SIDE OF VEHICLE

1. Rear bumper
2. Retaining screw
3. Side bumper Bumper Installation
3. Remove screws located under rear bumpe r. Front and Rear Bumper
cedure.
Tighten bumper screws to s pecificati on .
BUMPER SCREWS TORQUE

Side Bumpers
• mr2009-042-05 0_•
j 1. Remove all remaining residues of the mounting
tape.
2. Clean bumper area using i so pr o pyl alcohol.
1. Retaining screws
3. Remove the protecti ve skin on mou ntin g tape.
4. Remove rear bumper from ve hicle .
Side Bumpers
1 . Remove front and rear bumpers.
2. Using a marker, trace a line at b umper end.
NOTE: These marks will be used during ins tal la

tion.
sm 12 009 · 042- 053_

a
1. Protective skin
4. I nse rt bumper over body lip.

4.1 Insert lower section first.
4.2 Insert upper section last.
smr21)()9.() 42· 051 _a
1. Trace a line here
3. P ull the to p of bumper to unclip it from body.

NOTE: A heat gun can be used to soften si de
b umpe r.
smr2011-040 647
4. Move both upper trims rearward and remove

them.
smr2 000-04 2 -0 52..b
1. Make sure bumper is posirioned correcrly
NOTE: A heat gun can be used to soften side LH SIDE SHOWN

1. LH upper trim
bumper.
5. Remove the plastic push-in clips retain ing the
BODY COVER LH and RH trims.
smf.1009-042-057,fl
TYPICAL - IS MODEL SHOWN LH SIDE SHOWN

1. Body covers 1. Remove this plastic push-in clip
Body Cover Removal 6. Open seat and using a 3/16" drill bit, drill the
rivets securing the seat trims.
1. Remove the STORAGE COMPARTMENT
COVER. see procedure in this subsection.
2. Remove the FRONT GRILLE. see procedure in
this subsection.
3. Remove the plastic push-in clip securing the up
per trim.
LH SIDE SHOWN
1. Remove these nvets
7. Remove seat trim and drill the front rivet secur

ing the body cover.
• •i2009*13 - 002.;I
8. At t he front of front body module, remove
LH SIDE SHOWN screws or rivets retaining both body cover.
1. Remove this plastic push-in clip
9. Unlock rear and center retaining tabs.
648 smr2011·040
FRONT BODY MODULE
RH SIDE SHOWN smr2009·042-0 65_a

1. Rear retainmg rabs TYPICAL iS MODEL SHOWN
-
1. Front body module
Front Body Module Removal

1. Refer to appropriate procedures and remove
the following parts:
- Storage compartment cover
- Storage bin
- Glove box cover
- Body covers and front grille
- Steering and steering lock
- Speed-Tie unit (if equipped).
2. Remove both screws and washers located be
RH SIDE SHOWN tween seat and glove box.
1. Center retaining tab
10. Unlock the four retaining tabs securing the

front of body cover.
s mr2009-04 2-06 1_
a
sfl\J2009-042·060_a 1. Rear retaining screws
RH SIDE SHOWN
1. Front retaining tab 3. On each side of front body module, remove
both retaining screws.
11. Remove body covers.
Body Cover Installation

cedure.
smr2011-040 649
.s mr200!M>A2.o::; 2_ 1
1. LH side retaining screws

4. At the front of body module, remove screws. 3. Move upper trim rearward and remove it.
1. Upper trim
I Front retaining screws

4. Remove the plastic push-in clip retaining the LH
trim.
5. Unlock retaining tabs.
I. Front body module reUJining tabs

6. Remove front body module. 5. Open seat.
Front Body Module Installation 6. Drill rivet securing the LH body cover and the
seat trim.
cedure. REQUIRED TOOL
SUPERTANIUM DRILL BIT 3/16' (P/N 529 031 800)

SPEED-TIE UNIT
Front Speed-Tie Unit Removal
1 . Open the glove box.
2. Remove the plastic push-in clip securing the LH
upper trim.
650 Smf2011-040
7. LH body cover
2. Remove rhis rivet ssi. 20G9-0
03-009_a
3. Seat trim 1. Front locking tab
7. Remove front trim by releasing both retaining 13. Unlatch the rear tab.
tabs.
smr200CJ.()42· 034_a
ssi 2009--0 �3-01 o_ �
1. Retaining tabs
1. Rear locking tab
8. Using a small screwdriver, release both retain

14. Slightly pull the top of LH trim and remove the
ing hooks securing the cam trim on locking
reel of the Speed-Tie unit from its location as
mechanism.
shown.
1. Retaining hooks
s s 12009-003 · 0 1 l _ a
9. Remove screws retaining the Speed-Tie unit. 1. Speed-Tie unit reel
1 O. Position the reel of Speed-Tie unit to the bot 14![,Ji@j During Speed-Tie unit removal, be
tom of its cavity. careful not to damage the LH trim.
11. Remove the locking mechanism from vehicle.
12. Open storage cover and unlock the front tab

securing the LH trim.
smr2011-040 651
Rear Speed-Tie Unit Removal

iS and aS Models
1. Remove screws securing the Speed-Tie unit to
the boarding platform.
2. Remove rear trim by releasing retaining tabs.
1. Double cage nul

2. Positioning tab
2. Insert the Speed-Tie unit in vehicle.

2.1 Unlock the front tab securing the LH trim.
1. Retaining tabs
3. Remove screws securing the locking mecha

nism to the boarding platform.
1 Fronr locking tab
2.2 Unlatch the rear tab.

1. Retaining screws
4. Remove the Speed-Tie unit from vehicle.
1 . Remove both access covers.
2. From underneath deck, remove screws retain
ing the Speed-Tie cover.
3. Remove bolts securing the Speed-Tie unit to
deck.
Front Speed-Tie Unit Installation

1. Ensure both double cage nuts are correctly in
SOl200 9·003-0 1 0_B
serted into Speed-Tie unit cavities.
1. Rear locking tab
2.3 S lightly pull the top of LH trim and insert

the reel of the Speed-Tie unit in its location
as shown.
NOTE: Insert the unit with the marking out
side.
652 S'TV2011.()40
LOCKING MECHANISM RETAINING

SCREWS TORQUE
ssi2009-003-0 l 1 _a
1. Speed·Tie unit reel
1ifZ1Jifi1j During Speed-Tie unit insertion,

be careful not to damage the LH trim.
NOTE: To facilitate the locking mechanism inser 1. Locking mechanism retaining screws (M6 x 45)
tion, temporarily pull approximately 200 mm (8 in)
7. Install the cam trim.
of rope between reel and locking mechanism.
7.1 Insert both cam trim retaining hooks into
3. Position the reel to the bottom of its cavity.
locking mechanism openings.
s si2009..003-0l 5_a
1. Push in the reel
1. Retaining hooks
4. Lift the lever and insert the locking mechanism

7.2 Press down the cam trim until it snaps into
so that the lever is pointing toward the front of
place.
vehicle.
8. Install the front trim.
8.1 Insert top tabs and align lower tabs with
openings.
1. Lo cking lever
2. Rope
5. Align the reel with the locking mechanism.

SS i2009·003-01 6 _a
6. Tighten locking mechanism retaining screws to 7. Tabs
specification.
8.2 Press trim in place.
smr2011-040 653
Subsection 04 (BODY (RXT/GTX;WAKE PRO))
9. Test Speed-Tie operation.

10. Reinstall all removed parts.
Rear Speed-Tie Unit Installation

iS and as Models
1. Lift up the boarding platform.
NOTE: To facilitate the locking mechanism inser
tion, temporarily pull approximately 200 mm (8 in)
of rope.
1. Double cage nut
4. Secure it using retaining screws.
1. Locking mochanism � 104 _ 1
A. 200 mm (8 in) 1. Retaining screws (M6 x 45)
2. Insert the locking mechanism in boarding plat 5. Install the se.cond double cage nut.
form opening. Position the locking lever toward
6. Secure the reel of the Speed-Tie unit on board
the slot.
ing platform.
7. Tighten Speed-Tie retaining screws to specifica
tion.
SPEED-TIE RETAINING SCREWS TORQUE

1. Locking lever
2. Boarding platform slot
3. Position a double cage nut on the locking mech

anism.
· 1 05_•
S5i2 009-003
1. Speed-Tse unit
8. Close boarding platform.

9. Tighten locking mechanism retaining screws to
specification.
654 smr2011·040
Subsection 04 (BODY (RXT/GTX/VVAKE PRO))
LOCKING MECHANISM SCREWS TORQUE 2. Apply LOCTITE 5150 (SILICONE SEALANT)

(P/N 296 ooo 309) i n the Speed-Tie unit holes.
2.5 N•m (22 lbf•in)
!!&2009-003-106.•
2. Locking m<Jchanism
10. Install the cam trim. ssi 2 0 1 0.0 1 1-0i7
10.1 Insert both cam tr im retaining hooks into

3. Align Speed-Tie unit holes with body holes.
locking mechanism openings.
4. Secure the Speed-lie unit.
ssi2009-003-l 07_ a
1. Retaining hooks
10.2 Press down the cam trim against board

ing platform.
11. Install the rear trim. 1. M6 x 30 Allen socket screw
2. M6 flat washers
11.1 Align tabs and alignment pin with corre 3. Speed-7ie unit
sponding openings.
5. lighten Speed-lie unit retaining screws to
specification.
SPEED-TIE UNIT RETAINING SCREWS TORQUE
6. Pull the locking lever to allow cover installation.
1. Tabs
2. Alignment pin
11.2 Press trim in place.

12. Test Speed-Tie operation.
1. Clean all residues of silicone from deck and
Speed-Tie cover.
smr2011-040
655
... 201c;o11-019..,1
1. Locking lever
...2010-011.on_.
7. To facilitate new cover installation and avoid 1. Cover

2. Locking lever
cross threading, install both Plastite screws in 3. Mooring rope stopper
cover posts (approximately 3-4 turns). Then,
remove screws. 9.2 Insert cover posts into cover holes.
NOTE: Due to the drilling precision, it may be
necessary to pry slightly the cover to insert
cover posts into cover holes.
9.3 From underneath deck, secure the cover
with Plastite screws and flat washers. To
avoid damaging the cover, stop tightening
as soon as the washers are against the
deck.
IW'tJilflJj
Do not tighten screws more than
necessary to avoid damaging the cover.
<1: i2G10-01 I .020.o 10. Test Speed-lie operation.

1. Cover 11. Reinstall access covers.
2. Cover posts
3. Plaslite screws K40 x 13
Speed-Tie Unit Cleaning
8. Apply LOCTITE 5150 (SILICONE SEALANTI
A minimum of maintenance is required to keep
(P/N 296 ooo 309} all around both cover holes.
the Speed-lie unit and the rope in seNiceable con
dition.
Clean the locking mechanism and rope with fresh
water to remove salt, sand or other deposits.
*•!l'1i@j Do not use a high pressure washer

to clean the Speed-Tie unit.
Let dry.
Speed-Tie Rope Replacement

1. Remove the Speed-lie unit from the vehicle.
2. Using a small tool, remove the rope cap.
9. Install the cover.

9.1 Insert cover opening over the mooring
rope stopper and the locking lever.
656 smr2011-040
1. Cap 1. Rewind unit

2. Small screwdriver
7. Turn the unit upside down and remove the re
3. U nti e the knot and remove the b u tton. taining screw.
1. Untie this knot

2. Button 1. Retaining screw
4. Remove the locking mechanism and let the 8. Split the rewind unit and remove damaged
rope retracts into housing. rope.
5. Remove the back cover.
1. Back cover
2. Retaining screws 9. Before discarding rope, remove and keep the
inner stopper.
6. Remove the rewind unit.
smt201l-040 657
·subsection 04 (BODY (RXT/GTX/WAKE PRO))
SSt 2009-003-0 2 3_ a
1. Inner stopper
10. Insert the inner stopper on new rope and tie ss1 200 9-003-01 7_ •
a knot near the end of the line. Position the 1. Short tongue
inner stopper in order to its flat side leans

13. Install the rewind unit cover.
against the knot.
13.1 Align the cover notch and the rope.
002009-003-02 5_.
I. Inner stopper
A. 106mm ± 6mm (4-1/Bin ± 15/64 in} 1. Cover notch
11. On rewind unit base, identify the short tongue. 13.2 Press in the cover until both parts are
completely pressed together.
I. Short tongue
12. Install the rope end (with the knot) over the
short tongue as shown.
13.3 Install and tighten retaining screw to
specification.
REWIND UNIT COVER RETAINING

SCREW TORQUE
658 smr2011-040
1. Rewind unit cover retaining screw 1. Spring in notch
14. Turn rope clockwise. Check indications on in NOTE: Ensure spring is properly inserted in
ner side of rewind unit. notch.
17. Using a screwdriver, crank rewind spring ex
actly 7 turns {clockwise).
15. Lock the end of rope as shown.
18. Unlock the end of the rope and pull it out by

the housing opening.
NOTE: Be careful not to release the rope and the
spring. Otherwise you will need to remove drum
and repeat the cranking operation.
19. Install locking mechanism and rope.
19.1 Pull out rope end.
19.2 Insert end of rope through locking mech
ssi 200�.03 1
anism.
16. Install rewind unit into housing.

16.1 Install the rewind unit with the retaining
screw downward. The end of rope must
be placed in front of the housing opening.
16.2 Insert spring in shaft notch.
ssi2009.000. 0 34 _a
1. Locking mechanism
19.3 Pass rope end through the rope button

and tie a knot on the rope end, see pic
ture.
smr2011-040 659
1 Rope
A. 18 mm ± 6 mm (23/32 in ± 15/64 m)
SrT'r21J !J9-042-0
J/ .•
1. Boarding platform hinge

19.4 Pull knot in the button and install the
2. Fixed hmge
button cap. Make sure cap is properly
snapped. 8. Remove boarding platform.
20. Install and tighten Speed-Tie cover retaining
Boarding Platform Installation
screws to specification.
1 . Remove gas shock attachment from boarding
SPEED-TIE COVER RETAINING SCREWS
platform.
TORQUE
2. Apply LOCTITE 414 (P/N 413 705 800) on threads
of shock absorber body.
21. Check Speed-Tie operation. 3. Manually tighten the attachment on gas shock.
22. Reinstall the Speed-Tie unit on vehicle. 4. Install the bellows and secure it using a locking
tie.
BOARDING PLATFORM 5. Install the gas shock on cover.

{iS AND aS MODELS) NOTE: The corrugated section of bellows must
point downward.
Boarding Platform Removal
6. Align boarding platform hinge openings with flat
1. Unlatch the boarding platform. sides of fixed hinges.
2. Open boarding platform completely. 7. Push in the boarding platform to assemble
3. Cut locking tie retaining the bellows of gas hinges.
shock. 8. Position the bottom of the gas shock on cavity
opening .
IM1Ji@j To avoid breaking the attachment,

do not force to insert it in ca v i ty .
$0V 2 009-042-078J
7. Cut this /ockmg tie
4. Move bellows downward. $'?¥2009 -042-038g
1. Lower attachment on cavtty opening

5. Unscrew gas shock from its upper attachment.
6. Remove gas shock from vehicle. NOTE: Make sure upper attachment is properly
inserted in its slots.
7. Align boarding platform hinge openings with flat
sides of fixed hinges.
660 smr2011-040
3. Remove screws securing air inlet to deck ex

tension.
1. Upper attachment
9. Close boarding platform to lock the bottom of

the gas shock. s.mr200 � 4 2-020..a
1. Air inle t retaining screws

10. Lock boarding platform.
4. Remove coolant reservoir screws.
DECK EXTENSION
(iS AND aS MODELS)
smr2-009-042-02 1 _•
1. Coolant reservoir screws
5. Remove all screws retaining deck extension to

omr 2009-042 009_a fixed deck.
7. Deck extension 6. Close seat.
7. Tilt the MOVING DECK, see procedure in this
Deck Extension Removal
subsection.
1 . Open seat.
8. Remove the deck extension.
2. Remove the rear ventilation box.
Deck Extension Installation
1. Position the deck extension.
2. Install screws retaining deck extension and air
inlet.
3. Tighten deck extension retaining screws to
specification.
DECK EXTENSION RETAINING SCREWS

TORQUE
1.2 N•m (11 lbf•in)
tl![tli(IJI
Do not tighten screws over this
recommended torque. Otherwise, the rubber
&rm2009-0l �Ol_a
grommet could turns and screw will be hard
1. Rear ventilation box
2. Retaining latches to remove.
smr2011·040 661
4. Install and tighten coolant reservoir screws to

specification.
COOLANT RESERVOIR SCREWS TORQUE
5. Reposition moving deck. Refer to MOVING

DECKin this subsection.
MOVING DECK
(iS AND aS MODELS)

arm covers.
1. Moving deck
The moving deck is comprised of:

- Front storage cover
- Front body module
- Steering
smr20C$042-0 1 0.ll
- Seat
1. Cover screws
- Foot wells.
3. Mark position of rear suspension arm brackets
The moving deck is attached to the intelligent sus
for proper reinstallation.
pension and moves as a single unit.
4. Remove and discard screws securing rear sus
The moving deck does not comprise the boarding
platform and the rear storage bins.
It is possible to tilt the moving deck for servicing
the watercraft, such as:
- Deck extension removal
- Working on air intake system
- Suspension position sensor replacement
- Suspension hydraulic pump replacement.
The moving deck removal is also required for ma
jor repairs, such as:
- Engine removal
- Suspension component removal (except sus-
pension position sensor) 1. Rear suspension arm
- Fuel tank removal. 2. Reinstsllstion marks
3. Screws (discard)
Tilting Moving Deck for Servicing 5. Lift the rear suspension arm against seat handle
Watercraft and attach it with locking tie or strap.
1 . Remove the BOARDING PLATFORM, see pro
662 smr2011-040
snv2009-0 42-012_ i!I
1. Seat handle
2. Ski/Wakeboard attachment
3. Locking tie aS MODEL
1. Remote reservotr retaining screws (2x)
2. Hose bellows
6. Install two pieces of wood (4 x 4) under mov
ing deck front area as shown to avoid potential
9. Using suitable lifting devices, raise the rear of
damage when lifting the moving deck.
moving deck to 340 mm (13-1/2 in).
1. Hoist
2. Lifling strop
1. Pieces of wood
7. Place stee ring in its lower position .
8. On aS models, ensure that remote re servoir

hose has enough free length before tilting the
moving deck.
- If hose is too tight, remove remote reser
voir retaining screws then move hose inside
deck.
s m r 2 009-042.023. a
1. Use this rivet as reference point

A 340mm (13-1/2in)
IWomJj Lifting the rear of moving deck more

than the recommended height can damage the
steering cable and the remote reservoir hose.
smr2011-040 663
Lowering Back Moving Deck

1. Carefully lower and secure the rear suspension
1
arm to the fixed deck.
1.1 Position the rear suspension arm brackets
in accordance with the reference marks
previously drew on fixed deck.
10.JillJIIf no mark was trace, refer to IS

SUSPENSION subsection for proper pro
cedure to install and align the rear suspen
sion arm.
1.2 Install NEW screws to secure rear suspen 1. Boarding platform

sion arm brackets.
1 .3 lighten screws to specification. 4. Remove bolts securing both rear suspension
arm covers.
REAR SUSPENSION ARM RETAINING
SCREWS TORQUE
25 N•m (18 lbf•ft)
2. Detach lifting device.

3. Remove pieces of wood located under the front
of moving deck.
Removing the Moving Deck for

Servicing Watercraft
1. Open the front storage cover and remove the
front basket. em'.1009-042 010.t
2. On aS models, remove remote reservoir from 1. Cover screws

moving deck as follows:
5. Mark position of rear suspension arm brackets
2.1 Remove both retaining screws. for proper reinstallation.
2.2 Detach hose bellows from moving deck. 6. Remove and discard screws securing rear sus
2.3 Insert remote reservoir into moving deck pension arm to fixed deck.
hole.
smr2 0C-S.C>42� 1 1 11

2. Rei11stall<1cion marks
3. Screws (discard)
snv2011-04().()()4_a
7. Lift and attach the rear suspension arm against
aS MODEL
1. Remore reservoir retaining screws (2x)
seat handle.
2. Hose bellows
3. Remove the BOARDING PLATFORM. see pro

664 smr2011·040
Subsection 04 (BODY (RXT/GTX/WAKE PRO})
s m •200 9-042-0 1 S_•
RH SIDE SHOWN
1. Seat handle 1. Retaining screws (discard}
2. Ski/wakeboard attachment
3. Locking tie 10. Open seat.
8. Manually tip up the front of moving deck and 11. Remove and discard MS screws securing the
install a piece of wood (2 x 4) between fixed suspension mounting plate and moving deck.
deck and each lateral supports.
�M
smr200 l4 2-01 6_a
1. Moving deck central screws (to discard)

FROM THE FRONT OF VEHICLE
1. RH lateral support
2. Piece of wood 12. Close seat.
13. Remove the gauge support. Refer to INFOR
9. Detach moving deck from lateral supports.
MATION CENTER (GAUGE) subsection.
9.1 Remove front carpet of foot wells and pro
tective caps on both sides of the moving
deck. Discard the front carpets.
!= 11'1 r 2 0 1 1 -040· 003_8

$tn r 2 009-042·G1 4 _
t'I
1. Gauge support
RH SIDE SHOWN
1. Front carpet (discard)
2. Protective cap 14. Disconnect both connectors under moving
deck.
9.2 Remove and discard screws securing
moving deck to lateral supports.
smr2011·040 665
15.5 Free steering cable from fixed clamp.

16. Install lifting straps.
16.1 Using both mooring cleats under steer
ing, install two lifting straps.
mr2 01().-0$.01 S._t

s
1 Sreering connector
2. 0. T.A. S. connecror
15. Detach steering cable from steering column. • mr2009·042-079.

•
15.1 Remove bolt securing ball joint to steer 1. Front lifting srrap hooks into sceering mooring cleats
ing column.
16.2 Install another liftin g strap on seat handle.
17. Attach all lifting straps to an lifting device to lift
the moving deck.
A CAUTION M ake sure lifting device is lo

cated at the center of the vehicle to rise moving
deck horizontally.
18. Raise moving deck slowly and drive steering
cable out of steering column.
19. Place the moving deck on a level surface.
Moving Deck Installation

s m'2009-042 -00G_ o 1. Install 2 pieces of wood un der lateral supports.
I. Steering cable ball joint
2. Steering column
15.2 Remove bolts retaining steering cable

clamp.
15.3 Un latch steering cable clamp.
smr 2009-04 2 071
•rv200!>042 -0i>7_• 2. Slowly, lower the moving deck just enough to

1. Steering column be able to insert the end of steering cable in
2. Sreering column clamp bolts
steering column.
3. Steenng column clamp
W'1ill1j M ake sure not to pinch electrical har
15.4 Place steering in its lower position. ness while lowering the moving deck.
666 smr2011-040
3. Install steering cable clamp and its bolts. Do 6. Remove pieces of wood located under lateral
not tighten bolts yet. supports and reposition one under moving deck
front area.
smr2009 -06 2·00?_a
1. Sreermg column
2. Steering column clamp bolts
smr2009·042-090_•
4. Connect both electrical connectors under mov 1. Install piece of wood here
ing deck.
7. Remove the front lifting straps.
8. Open seat.
9. Raise rear of moving deck until suspension is
clear of moving deck.
ltoililJj Do not raise the rear of moving deck

more than 340mm (13-1/2in).
s m 1 2 0 1 0-046-0l 5_ a
1. Steering connector
2. 0. T.A.S. connector
5. Lower the front of moving deck and secure it

on both lateral supports using NEW screws.
smr 2009-042-023 ...a
1. Use this river as reference point

A. 340mm (13-1/2in)
10. Install two homemade alignment pins on sus

pension mounting plate.
10.1 Take two MS x 50 bolts and cut their
heads.
10.2 Grind down the cut ends to make a
rounded shape.
5 m r2009·042-01 $_a
RH SIDE SHOWN
1. Retaining screws (new)
smr20i 1-040 667

Subsection 04 (BODY (RXT/GTXM'AKE PRO))
IW1)il1Jj
If no mark was trace, refer to iS
SUSPENSION subsection for proper pro
cedure to install and align the rear sus
pension arm.
16.2 Install NEW screws to secure rear sus

pension arm brackets.
16.3 lighten screws to specification.
REAR SUSPENSION ARM RETAINING

SCREWS TORQUE
•mr200!r-042-073_a
25 N•m (18 lbf•tt)
10.3 Install alignment pins into the 2 rear out

17. Remove rear lifting strap.
side positions of suspension mounting
plate. 18. Attach steering cable to steering column.
19. Install gauge support.
Refer to INFORMA
TION CENTER (GAUGE) subsection.
20. On aS models, install remote reseNoir on
moving deck.
21. Install NEW front carpets on foot wells and
protective caps on moving deck.
22. Check steering alignment then tighten steer
ing clamp bolts. Refer to STEERING subsec
tion.
FRONT GRILLE
(iS AND aS MODELS)
1. Alignment pins
11. Position the moving deck so that alignment

pins are aligned with suspension reinforce
ment plate holes.
12. Lower the moving deck over alignment pins.
13. Install NEW M8 screws to secure the moving
deck to suspension mounting plate.
NOTE: Remove the alignment pins only when 2
screws are engaged in mounting plate.
14. Tighten screws to specification.
MOVING DECK RETAINING SCREWS

TORQUE (M8) LOCATED UNDER STORAGE COMPARTMENT COVER
1. Front grille
25 N•m (18 lbf•ft)
Front Grille Removal
15. Close seat.
1. Remove the STORAGE COMPARTMENT
16. Carefully lower and secure the rear suspen COVER, see procedure in this subsection.
sion arm to the fixed deck.
2. Press on both tabs securing front grille to front
16.1 Position the rear suspension arm brack body module.
ets in accordance with the reference
marks previously drew on fixed deck.
668 smr2011-040
REAR VENTILATION BOX

(iS AND aS MODELS)
Rear Ventilation Box Removal
1 . Open seat.
2. Release all retaining latches.
1. Front grille
2. Retaining tabs
3. Remove grille.
Front Grille Installation

The installation is the reverse of the removal pro ;;::--_ --
cedure. s m r 2 009-017-01 0_ a
1. Ventilation box
2. Retaining latches
SPLASH DEFLECTOR
3. Remove the ventilation box.
(iS AND aS MODELS)
Splash Deflector Removal Rear Ventilation Box Installation
Before installing the ventilation box, check the
condition of its seal.
If the seal is damaged, replace the ventilation box
as an assembly.
FRONT VENTILATION BOX

(iS AND aS MODELS)
Front Ventilation Box Removal
1. Open the front storage cover and remove the
sdd20 0 S-00 1-0SZ_ a
storage basket.
1. To remove the splash deflector, drill out the 4 2. Remove screws securing the ventilation box to
rivets securing the splash deflector to the fixed fixed deck.
deck.
2. Pull the deflector from the fixed deck.
l•!['1illJI A molded location pin at each end

of the deflector are each inserted into the fixed
deck. Be careful not to break them when re
moving the deflector.
Splash Deflector Installation

1 . Position the splash deflector over the forward
end of the fixed deck and press the guide pins
into the holes provided in the deck. snv2om-0 1 7-003_ a
1. Front ventilation box

2. Install four new rivets to secure the deflector to 2. Retaining screws
the deck.
smr2011-040 669
3. Remove the ventilation box. REAR ACCESS PANELS (MODELS

WITHOUT iS OR aS)
Front Ventilation Box Installation
Before installing the ventilation box, check the
condition of its seal.
If the seal is damaged, replace the ventilation box.
lighten ventilation box screws to specification.
VENTILATION BOX SCREWS TORQUE
1.2 N•m (11 lbf•in)
AIR INTAKE DUCT

1. Rear access panels
(iS AND aS MODELS)
Rear Access Panel Removal
Air Intake Duct Removal
Turn the lock handle to select the UNLOCK posi
Remove engine. Refer to ENGINE REMOVAL
tion.
AND INSTALLATION subsection.
- LH access panel: turn lock handle counterclock
Remove the suspension base. Refer to 1S SUS
wise.
PENSION subsection.
- RH access panel: turn lock handle clockwise.
Remove air intake duck from vehicle.
Air Intake Duct Installation

Install suspension base. Refer to iS SUSPENSION
for complete procedure.
Install engine. Refer to ENGINE REMOVAL AND
INSTALLATION
After deck extension installation, tighten screws
retaining the air intake duct to deck extension to
specification.
AIR INTAKE DUCT RETAINING SCREWS TORQUE
1.2 N•m (11 lbf•in)
smr201 0-04600
3_a
LOCK HANDLE OF THE LH ACCESS PANEL

7. Lock handle
2. UNLOCK position
3. LOCK position
RXTX
Open and remove the panel.
GTX 155, RXT 215 and WAKE Pro 215

Open the panel completely.
Move the bottom of the panel outwards to re
3l"l"W2009-04 2..Q20_a
move it.
1. Air inlet retaining screws
670 smr2011-040
sm'2010-046-004_•
sm'201(>-0
4 6-00 2_•
Step 1: Open the panel
Step 2: Move the panel outside LOCK HANDLE OF THE RH ACCESS PANEL
1. Lock handle in LOCK position
Rear Access Panel Installation

WAKE PYLON (WAKE PRO 215)
cedure. However, pay attention to the following. Wake Pylon Removal
GTX 155, RXT 215 and WAKE Pro 215 Open the seat.
Insert rubber stoppers under the deck. Remove both lateral arms.
smr2010· 046·005_•
s m'20 1 0-046-006 _•
1. Rubber stoppers
1. Lateral arms screws
Close the panel partially and center it into the deck

Remove bolts at the bottom of wake pylon.
cavity.
Press the corner, near the lock handle, against the
deck and turn the lock handle in the LOCK posi
tion.
sm'2010-046-007 _e
1. Wake pylon bottom bolts
Remove bolts securing the wake pylon support to

body.
smr2011·040 671
Locking Strap
Using a screwdriver or any other suitable tool. de
tach a side of the locking strap from retaining pin.
c nv 20 1 0 4! 6 -0(IS
..a
1. Wake pylon support bolts
Lift the wake pylon to disengage its bottom from

the body.
Slide the bottom of the wake pylon rearward to
remove the wake pylon from vehicle. UT'l r2008-03Ml1 5_a
1. Locking strap
Remove locking strap and the inner lock.
Handle
Extend handle approximately 75 mm to 90 mm
(3 in to 3-1/2 in}.
Wake Pylon Disassembly

Extend the handle completely.
Turn the wake pylon upside down.
Move both ends of locking strap to disengage the &m12008-035-016_a
inner lock and free the handle. A. 75 mm to 90 mm (3 in to 3-112 in)
Insert two thin feeler gauges between handle

stem and extension tube.
sm•2008-035.0 1 4..a
1. Locking strap end

2. Handle stem
672 srru2011-040
5mr2006-035.01 7-•
1. Handle stem
7. Extension tube
2. Feeler r;auges
2. Recesses
3. extension tube
Place a rag around the joint to catch balls and Slide the handle stem into the extension tube.
spring. Remove feeler gauges and locking tie.
Hold feeler gauges and pull the handle. Locking Strap
Remove the wake pylon trim.
Wake Pylon Assembly
Handle
Install a loose locking tie on handle stem.
Apply XPS SYNTHETIC GREASE (P/N 293 550 010) on

each ends of spring. 1 1
Insert the spring in the handle stem hole.
Position a ball on each ends of spring.
Install a feeler gauge over each balls. 1
1
lighten the locking tie in order to retain feeler
gauges and balls.
•n>'200B.035-020_•
1. Wake pylon trim screws
Install lock and insert the end of the locking strap

over the retaining pin.
smr2008-035-0 i e_e
1. Feeler gauges
2. Ball
Apply XPS SYNTHETIC GREASE (P/N 293 550 010) in

both recesses of the extension tube.
1
om r 2008·03!>0Zl _o
1. Retaining pin
2. Locking strap
Using a suitable tool, position the locking strap in

its groove.
smr201 H>40 673

Tighten all bolts as per the following sequence.
1. Locking strap
2. Locking strap groove
"""2011·039-016 ...
Reinstall the wake pylon trim. TIGHTENING SEQUENCE
Do not install the handle into wake pylon yet.

Insert the handle into the wake pylon.
Wake Pylon Installation Move both ends of the locking strap forward to
Position the wake pylon on vehicle. fully insert the handle.
Install and secure wake pylon and lateral arms us

ing previously removed fasteners and new elastic
stop nuts.
o m · 2 010· 0 • &010_0
1. Botrom of wake pylon

2. Rubber wasliers
3. Flat washers
tTH"201 0 -04 6·0 1 1JJ

S
1. Flat washers
Tighten all bolts by hand.

Ensure base of wake pylon is well leaned against
body.
674 smr2011-040
Subsection 05 (HULL (GTS/GTl,IWAKE))
HULL (GTS/GTl/WAKE)
SERVICE PRODUCTS
BRP HEAVY DUTY CLEANER....................................................... 293 110 001 ................................. 680-682
LOCTITE 5150 (SILICONE SEALANT) ........................................... 296 000 309 ................................. 683, 685
LOCTITE 5900 293 800 066 ................................. 680-682
..................... . . . . . . . . . . . . . ...................... . . . . . . . . . . . . . . . . . . . . . . .
smr2011·047 675
Subsection 05 (HULL (GTS/GTl/WAKE))
IEi!lJ IEi!lJ
8 N•m 14.5 N•m
(71 lbf•in) (128 lbfoin)
14.5N·m
(128 lbfoinl
/
Loctite 5150
&(silicone sealant)
8 N•m IEi!lJ
(71 lbf•in) 16 N•m
(142 lbf-in)
')� .·�
----�-'l'-1>1
'-l�� .
�/' IEi!lJ
8.5 N•m
(75 lbf•in) 8 N•m
(71 lbfein)
-,
-��
�
<(/" .
4.5N•m
28 lbf•in)
8.5 N•mJ?/'
(75 lbfein)
mi!lJ = Component must be replaced when removed.

smf2011.()47-004_a
676 smr2011·047
mm
25 N•m
(18 lbMt)
0
I
'
mm
9 N•m
(80 lbfoin)
aim = Component must be replaced when removed.

�1 H)O-oo:l_o
smr2011·047 677
Subs e cti o n 05 (HULL (GTS/GTl/WAKE))
GENERAL also be used as a barrier coat before refinishing

with gelcoat. Epoxy adheres to S3 hull material,
Verify condition and operation of hinges and latch and gelcoat adheres to epoxy.
ing mechanisms. Replace any damaged compo
nents. An epoxy repair kit can b e purchased directly from
WEST SYSTEM.
and service products as specified in the exploded Go to ht tp://www.westsystem.com.
views. On this site you will find complete repair instruc
tions, click on HOW TO USE.
fer to SELF-LOCKING FASTENERS and LOCTITE Also training videos, tools and several products
APPLICATION at the beginning of this manual for are available on the web site.
complete procedure.
Consumer Assistance
l![tJittJI When applying threadlocker prod
ucts (anaerobic prod ucts), pay attention to North and South America
prevent the product from comi n g into contact
WEST SYSTEM
with ABS plastic parts (painted parts). 102 Patterson Ave.
P.O. Box 665 Bay City, Ml 48707-0665
A WARNING
To rque w r e nch tighte n ing specifications Phone: 989 684-7286
must be strictly adhered to. Toll free: 866 937-8797
Fax: 989 684-1374
stop n u ts, self-locking fasteners, cotter pins, Europe, Middle East, Africa and Asia
etc.) must be replaced with new ones .
WESSEX RESINS AND ADHESIVES LIMITED

Cupernham House, Cupernham Lane, Ro msey
England S051 7LF
dards. Phone: 44-1-794-521-111
Fax: 44-1-794-517-779
PROCEDURES E-mail: info@wessex-resins.com
Australia, South Pacific and Asia

HULL
ATL COMPOSITES
Hull Repair P.O. Box 2349/Southport 4215
The repair procedures of the S3 hull is not the Queensland, Australia
same as a fiberglass composite hull and deck.
Tel.: +61 7-5563-1222,
The standard polyester based fiberglass repair
Fax: +61 7-5563-1585
kits will not work with this type of hull. The
E-mail: info@atlcomposites.com
polyester will not adhere to the S3 hull material.
Only two-part epoxy repair material should be New Zealand, South Pacific and Asia
used.
ADHESIVE TECHNOLOGIES LTD.
To repair a S3 hull, the use of an Epoxy repair sys 17 Corbans Ave./Box 21-169, Henderson
tem, such as the WEST SYSTEM® or equivalent Auckland, New Zealand
epoxy, is mandatory.
Phone: 64-9-838-6961
However, the finish on the S3 hull is a polyester
Fax: 64-9-836-4849
based gelcoat with a bonding layer between the
E-mail: enquiries@adhesivetechnologies.co.nz
hull and the gelcoat. Standard gelcoat refinishing
can be performed if the damage is limited to the
color surface. If damage requires the removal or
the r epair to structure material, the epoxy may
WEST SYSTEM is a registered trademark of Gougeon Brother, Inc
678 smr2011-047
Subsection 05 (HULL (GTS/GTl;WAKE))
INLET GRATE
Inlet Grate Removal
1. Remove inlet grate retaining screws using an
impact tool.
stm201 l - 04 l-001 _I>
TIGHTENING TORQUE SEQUENCE
RIDE PLATE
A Ride Plate Removal
�
sm 120 t l-04 t .00l_a 1. Remove inlet grate, see procedure in this sub
GTS, GT/ AND WAKE 155 section.
1. Inlet grate
2. Inlet grate screws 2. Remove jet pump. Refer to JET PUMP.
3. Drain cooling system. Refer to COOLING SYS
2. Remove inlet grate.
TEM
Inlet Grate Installation 4. From inside the hull, disconnect coolant hoses
from the ride plate.
1. Install NEW at the proper location.
5. Remove coolant hose fittings from the ride
plate.
1
L'l•litfJI If possible, remove the hose fittings
from the ride p late before removing the ride
plate. If fittings cannot be removed, proceed
with care when removing the ride plate .
6. Heat retaining screws using a heat gun.

7. Remove ride plate retaining screws using an
impact tool.
s m 2. 0 1 t-041 · 001 _e
r
SCREW LOCATION
7. MB x 40 screw
2. MB x 16 screws
2. Tighten screws to the specified torque and se

quence.
TORQUE
First step Hand tighten
INLET
Second step 25 N•m (18 lbf•ft)
GRATE
SCREWS Recheck tightening
Final step
torque of screw 1
s mr2Cl 1-0d1-0 02_a
1. Ride plate retaining screws
smr2011·047 679
Subsection 05 (HULL (GTS/GTIM'AKE))
8. Install a low height hydraulic bottle jack and 2

steel plates between ride plate and hull as per
following illustration.
smr2011·047·00 1 _ o
SEALANT APPLICATION
2. Install both hose fittings on the ride plate.

Tighten to the specified torque.
TYPICAL TORQUE
1. Hydraulic bottle jack
2. Steel plates Hose fittings I 9 N•m (80 lbf•in)
9. Heat the edge of the ride plate with a heat gun 3. Position ride plate on hull and thread NEW
to soften the sealant before prying the ride plate screws 5 turns by hand.
and pump support off the watercraft.
4. Position inlet grate and thread NEW screws 5
10. Start pumping the hydraulic jack slowly. turns by hand. Refer to INLET GRATE in this
11. Using a sharp knife. carefully cut the sealant subsection.
around the ride plate edges. 5. Tighten screws to the specified torque and se
12. Pump the hydraulic jack slowly to pry the ride quence.
plate from the hull. TORQUE
I
Ride Plate Cleaning Ride plate retaining
25 N•m (18 lbf•ft)
screws
1. Carefully scrape off all excess sealant from ride
plate and hull.
2. Clean hull surface with BRP HEAW DUTY
CLEANER (P/N 293 11 O 001) to eliminate grease,
dust and sealant residue. Clean fitting threads.
Ride Plate Installation

1. Apply LOCTITE 5900 (P/N 293 800 066) sealant as
illustrated.
smr2011-047-002 _1
RIDE PLATE TIGHTENING SEQUENCE (FIRST STEP)
680 smr2011-047
'"""1011-04 7-00 7 .•
s m r2011-047-002. b
INSIDE THE HULL
RIDE PLATE TIGHTENING SEQUENCE (FINAL STEP)
1. Jet pump support retaining nuts
6. Tighten inlet grate screws to the specified 4. Heat the jet pump support using a heat gun in
torque and sequence, refer to INLET GRATE order to soften the sealant.
INSTALLATION in this subsection.
5. Pull jet pump support off the hull.
7. Reinstall coolant hoses on ride plate fittings.
6. Note the alignment shims location.
lffe'.lifij
Make sure the coo lant hose clamp
screws do not rub on any component. fiUoifij Alignment shims have to be rein
stalled at the same location.
8. Fill and bleed cooling system and carry out a
leak test. Refer to COOLING SYSTEM subsec Jet Pump Support Cleaning
tion. 1. Scrape off all excess sealant from jet pump sup
9. Install all remaining parts. Refer to the applica port, ride plate, and hull.
ble procedures. 2. Inspect pump support for cracks or other dam
age.
JET PUMP SUPPORT 3. Clean jet pump support and hull surface with
BRP HEAVY DUTY CLEANER (PIN 293 110 001) to
Jet Pump Support Removal
eliminate grease, dust, and sealant residue.
1 . Remove drive shaft (and jet pump). Refer to
DRIVE SHAFTsubsection. Jet Pump Support Installation
2. Disconnect exhaust water supply hose and 1. Make sure sealant contact areas are clean and
bailer hoses from jet pump support. dry.
2. Apply LOCTITE 5900 (PIN 293 800 066) on the jet
pump support as shown (thick black line).
smr2011- 047-006.•
INSIDE THE HULL

1. Exhaust water supply hose
2. Bailer hoses
3. Remove jet pump support retaining nuts and smr2011-047 008o
washers. SEALANT APPLICATION
smr2011·047 681
3. Insert the studs in the jet pump support square

holes.
4. Slide the alignment shims on the studs.
5. Position the jet pump support against the hull.
6. Inside the hull, thread all 4 retaining nuts.
7. lighten retaining nuts to the specified torque
and sequence.
TORQUE
I
Jet pump support
25 N•m (18 lbf•ft)
retaining nuts
smr 20 1 t -041·009_&
1 Reraining screws
2. Thru-hull fitting
3. Heat the thru-hull fitting with a heat gun to

soften the sealer.
4. Pull thru-hull fitting off the hull.
Thru-Hull Fitting Area Cleaning

1 . Scrape off all excess sealant from the hull.
2. Clean hull surface with BRP HEAVY DUTY
CLEANER (P/N 293 11 O 001) to eliminate grease.
dust. and sealant residue.
NOTE: Use only a clean, dry, oil free filtered air
JET PUMP SUPPORT TIGHTENING SEQUENCE (FIRST STEP) supply for dusting and drying parts or hull.
Thru-Hull Fitting Installation

1. Make sure thru-hull fitting sealing surface is
free of sealant residue, clean and dry before
installation.
2. Apply LOCTITE 5900 (P/N 293 800 066) sealant as
illustrated.
Stn'2011-0IH
l07 _c
JET PUMP SUPPORT TIGHTENING SEQUENCE (FINAL STEP)
8. Remove excess sealant.

9. Reinstall other removed parts. Refer to appro
priate subsections for procedures.
THRU-HULL FITTING
.,,, .
2 011-047-010 •
Thru-Hull Fitting Removal SEALANT APPLICATION
1. Remove drive shaft, refer to DRIVE SHAFTsub 3. Tighten screws to the specified torque and se
section. quence.
2. Remove the thru-hull fitting reta ini n g screws.
682 smr2011-047
TORQUE
Thru-hull fitting
retaining screws
smr2010-047-00 4_a
1. Apply silicone sealant here
3. Apply a small amount of LOCTITE 5150 (SILI

CONE SEALANT) (P/N 296 000 309) into each hull
hole.
•mr201 J.047-Cl09_b
THRU-HULL FITTING TIGHTENING SEQUENCE
4. Install other removed parts, refer to the appro

priate subsections.
SPONSONS smr2010-047-005
_a
1. Apply silicone sealant in these holes

NOTE: Removal and installation procedure for RH
and LH sponson is similar. 4. Insert a bolt with washer through each hole and
install the sponson against the hull.
Sponson Removal
5. From inside hull, secure each bolt with a
On starboard (RH) side, remove the resonator. washer and a NEW elastic stop nut.
Refer to the EXHAUST SYSTEM subsection.
6. lighten nuts as specified in the exploded view.
From inside hull, hold sponson nuts while remov
7. Reinstall resonator. Refer to EXHAUST SYS
ing sponson retaining bolts and washers.
TEM for the procedure.
BAILE RS
Two bailer pick ups (one each side), draw water
from the bilge when watercraft is in operation.
The bailer pick ups are connected to syphon tubes
mounted in the jet pump venturi that use the jet
pump thrust to create a vacuum. The bailers are
also connected to the bilge drain plugs in the
stern.
TYPICAL - RH SPONSON SHOWN
1. Sponson Bailer Pick-Up Location
2. Retaining bolts
Port side (LH): underneath the iBR actuator (if
Sponson Installation equipped).
Starboard side (RH): underneath the rear exhaust
1. Clean any residues of silicone sealant on hull
and sponsons. hose.
2. Apply LOCTITE 5150 (SILICONE SEALANT)

(P/N 296 ooo 309) on back side of sponson
spacers.
smr2011-047 683
smr2 Q11-04 7·01 U
RH SIDE SHOWN
TYPICAL - LEFT SIDE SHOWN (iBR ACTUATOR REMOVED} 1. Drain plug neck
1. Bailer pick-up 2. Rear exhaust hose
Bailer Pick-Up Inspection Drain Plug Neck Removal

1. Check holes in the bailer pick-ups to see if they 1. Cut locking tie securing bailer hose to the drain
are obstructed. Clean if necessary. plug assembly.
2. Check if the hole on each bailer hose elbow fit
ting is obstructed. Clean elbow fittings if nec
essary.
smr20 11-047-01 l _ b
RH SHOWN
1. Drain plug neck
2. Locking tie
2. Unscrew the drain plug from the drain neck and

pull the drain plug out of the neck.
smr2<lOS-OJ S-OO l_a
1. Elbow fitting holes
NOTE: When repositioning the bailer hose el

bows, attach them at the highest available point
on the exhaust hose.
DRAIN PLUGS
NOTE: Each drain plug on the stern are each con
nected to a bailer. When watercraft is off the wa
ter, the drain plugs can be removed to manually
drain the bilge.
I'
Drain Plug Neck Location

Port side (LH): behind the iBR actuator (if DRAIN PLUG REMOVAL
1. Drain plug
equipped).
2. Drain neck
Starboard side (RH): behind the rear exhaust hose.
684 smr2011·047
3. Inside the hull. hold drain neck nut using ad

justable pliers.
4. Insert a ratchet extension in the square hole,
then unscrew the drain neck from the hull.
smr201 1-047-0 • 2..•
TYPICAL INSIDE THE HULL

-
1. Threaded portion of the eyelet

2. Rubber washer
3. Large stainless steel washer
4. Elastic stop nut
smr2009-04 3-033
DRAIN NECK REMOVAL 2. Pull eyelet off the hull.

3. Clean any silicone sealant residue.
Drain Plug Neck Installation
1. Install drain neck and torque to 9 N•m Eyelet Installation
(80 lbf•in). 1. Inside the hull, apply LOCTITE 5150 (SILICONE
2. Secure bailer hose to drain neck using a NEW SEALANT) (P/N 296 000 309) around eyelet
locking tie. mounting holes.
3. Reinstall all removed parts in the reverse order 2. Position eyelet and hardware as illustrated. Use
of removal. NEW elastic stop nuts.
NOTE: Bow and stern eyelets have the same
BOW AND STERN EYELETS hardware layout.
Bow Eyelet Access

Open the front storage cover.
Stern Eyelet Access

Remove seat.
Eyelet Removal
1. Unscrew and discard both bow eyelet retaining
nuts.
NOTE: Keep all washers for installation. Bow and
stern eyelets have the same hardware layout. smf2007·Q34.. l 12_a
TYPICAL
1. Eyelet
2. Small stainless steel washer
3. Nylon washer
4. Loctite 5150 (silicone sealant) here
5. Rubber washer
6. Large stainless steel washer
7. Elastic stop nut
3. Tighten nuts to the specified torque.
TORQUE
Eyelet retaining nuts I 14.5 N•m (128 lbf•in)
smr2011·047
685
HULL INSERTS 2. Remove any excess glue from around the head
of the insert that would prevent proper insertion
Metal inserts (brass) of various types and sizes of the socket used to remove the insert.
are screwed into the hull at various locations. A
threaded hole in the insert is used for fastening
various parts and equipment onto the hull.
Some inserts pass completely th rough the hull,
while others do not (blind hole inserts).
BLIND HOLE INSERT

1. Excess glue on head
3. Use a six-point socket of appropriate size and a

ratchet wrench to unscrew the insert from the
hull.
TYPICAL
7. Pass through insen NOTE: An impact tool may be used to facilitate
removal of the insert.
Insert Installation
1. Clean the insert hole in the hull to remove any
dirt or loose glue using clean, dry, oil free fil
tered air.
ll!l•Jitl1jDo not use a metal tool to clean or

remove the glue inside the hull insert hole to
prevent damaging the threads in the hull ma
terial. The glue that is properly bonded to the
hull does not need to be removed.
2. If the insert passes completely through the hull,

snv2009-0'3-01 6_• screw a stud of appropriate size into the insert
TYPICAL (M6 or M8) to prevent any glue from seeping
1. Blind hole insen
into the fastener threads in the insert. Apply
All type inserts may be replaced if the inner screw the SIX10 glue from West System (see HULL
threads are damaged. REPAIR at the beginning of this subsection for
more information) or an equivalent to the outer
NOTE: Inserts should only be replaced as a last
threads of the insert.
resort. First try passing a tap, cleaning the hole,
and using a NEW self-locking screw. If fastener NOTE: Apply a sufficient amount of glue through
can be tightened to the specified torque, do not the full length of the insert threads to ensure ex
change insert. If torque cannot be applied, drill cess glue will come out of the hole as the insert
and tap insert one size larger before trying to is screwed into the hull.
change an insert. 3. If the insert screws into a blind hole, apply the
SIX10 glue or an equivalent to the threads in the
Insert Removal hull.
1. Heat the insert using a heat gun to soften the
glue securing the insert into the hull.
686 smr2011-047
Subsection 05 (HULL {GTS/GTl/WAKE))
4. Screw the insert in the hull boss and torque to

25 N•m (18 lbf•ft). Ensure the flanged portion
of the insert makes contact with the boss it is
being screwed into.
smr2011-047 687
688
Subsection 06 (HULL (GTX/RXT/WAKE PRO})
HULL (GTXJRXT/WAKE PRO)

SERVICE PRODUCTS
BRP HEAW DUTY CLEANER....................................................... 293 110 001 ......................... 694, 696, 698
LOCTITE 5150 (SILICONE SEALANT) ....... .................. ........... .... 296 000 309 ......................... 699, 702-703
. . .
LOCTITE 5900....... ....... .......................................................... ......

. 293 800 066 ......................... 695-696, 698
smr2D11·D41 689
Subsection 06 (HULL (GTX/RXT/WAKE PRO))
15 N•m
Loctite 5150
(silicone sealant)
&
'"'
"'
9 N•m
,"'
(80 lbfoin)
"
' --
mm
14.5 N•m
(128 lbfoin)
8 N•m
(71 lbfoin)
o n112010-04?·001 _.
690 smr2011-041
Subsection 06 (HULL (GTX/RXTJWAKE PRO))
mm
5 N•m
t-1
(44 lbfein) mm
5 N•m
(44 lbfoin)
'
I
'
I
'
I i ;
.
7 N•m
.
I (62 !bf.in)
I I
I '
smr20 1 0-047-00 2 _a
smr201Hl41 691
GENERAL the repair to structure material, the epoxy may

also be used as a barrier coat before refinishing
Verify condition and operation of hinges and latch
with gelcoat. Epoxy adheres to S3 hull material,
ing mechanisms. Replace any damaged compo
and gelcoat adheres to epoxy.
nents.
An epoxy repair kit can be purchased directly from
During assembly/installation. use torque values WEST SYSTEM.
and service products as specified in the exploded
views. Go to http://www.westsystem.com.
Clean threads before applying a threadlocker. Re On this site you will find complete repair instruc
fer to SELF-LOCKING FASTENERS and LOCTITE tions, click on HOW TO USE.
APPLICATION at the beginning of this manual for Also training videos, tools and several products
complete procedure. are available on the web site.
IM1Ji@I When applying threadlocker prod Consumer Assistance

ucts (anaerobic products), pay attention to
North and South America
prevent t he product from coming into contact
with ABS plastic parts (painted parts). Plastic WEST SYSTEM
parts may develop cracks or other damages, 102 Patterson Ave.
and fin is h ed or painted surfaces may become P.O. Box 665 Bay City, Ml 48707-0665
damaged.
Ph one: 989 684-7286
Toll fr ee: 866 937-8797
Fax: 989 684-1374
A WARNING
Torque wrench t i g hten i ng specifications Europe, Middle East, Africa and As ia
must be strictly adhered to .
Wessex Resins and Adhesives Limited,
L ocking devices (e.g.: lockin g tabs, elastic Cupernham House, Cupernham Lane, Romsey ,
stop nuts, self-locking fasteners, cotter pins, England S051 7LF

etc.) must be replaced with new ones. Phone: 44-1-794-521-111
Fax: 44-1-794-517-779
E-mail: info@wessex-resins.com
procedure must be reinstalled as per factory stan Australia, South Pacific and Asia
dards.
ATL Composites.
P.O. Box 2349/Southport 4215,
PROCEDURES Queensland. Australia,
Tel.: +61 7-5563-1222,
Fax: +61 7-5563-1585
HULL E-mail: info@atlcomposites.com
Hull Repair New Zealand, South Pacific and Asia
The repair procedures of the SJ hull is not the
Adhesive Technologies Ltd.,
same as a fiberglass composite hull and deck. 17 Corbans Ave./Box 21-169, Henderson,
The standard polyester based fiberglass repair Auckland, New Zealand,
kits will not work with this type of hull. The Phone: 64-9-838-6961 '
polyester will not adhere to the S3 hull material. Fax : 64-9-836-4849

Only two-part epoxy repair material should be E-mail: enquiries@adhesivetechnologies.co.nz
used.
To repair a SJ hull, the use of an Epoxy repair INLET GRATE
system. such as the WEST SYSTEM® or an other
equivalent epoxy system. is mandatory. Inlet Grate Removal
However, the finish on the S3 hull is a polyester 1. Remove inlet grate retaining screws using an
based gelcoat with s a bonding layer between the impact tool and remove inlet grate. Discard the
hull and the gelcoat. Standard gelcoat refinishing retaining screws.
can be performed if the damage is limited to the
color surface. If damage requires the removal or
WEST SYSTEM is a registered trademark of Gougeon Broth er, Inc
692 smr2011-041
RIDE PLATE
Ride Plate Removal
NOTE: The jet pump support and ride plate must
be removed as an assembly. The pump support
is fastened to the ride plate and the forward pump
support mounting screws cannot be accessed
when the ride plate is installed.
l.Y.Ji@j If the ride plate is replaced, or

removed and installed, the engine/drive
shaft/pump alignment must be checked. Refer
$mr2 009·003-01 3_
a
to ENGINE REMOVAL AND INSTALLATION
1. Infer grate screws subsection.
2. Inlet grate
1. Remove iBR gate and VTS trim ring, refer to 1BR
Inlet Grate Installation AND VTS subsection.
2. Remove jet pump and nozzle, refer to JET
PUMP subsection.
3. Drain cooling system, refer to COOLING SYS
TEM subsection.
4. Remove the battery from the watercraft, refer
to CHARGING SYSTEM subsection.
5. On iS models, move the electrical accessories
support and electrical harness above and to the
right of the resonator for improved access to
the ride plate coolant hoses and fittings.
6. Reach in between the exhaust system res
onator and hull to loosen the gear clamps and
smr200 9--0 43-01 3_ b
disconnect both coolant hoses from the ride
SCREW LOCATION
1. MB x 40 screw plate.
2. MB x 20 screws
1. Hand tighten NEW screws.

2. Tighten screws to the specified torque and se
quence.
INLET G RATE SCREWS TIGHTENING TORQUE
First step 35 N•m (26 lbf•ft)
Recheck tightening torque

Second step
of screw 1
s mr20 09·043-0 1 6 _ a
1. Exhaust system resonator

2. Gear clamps
3. Coolant hoses
7. Remove excess sealant from around the

coolant hose fittings.
8. Unscrew both hose fittings from the ride plate.
- - -�:
s mr2009 - 043.0i5,.. a
TIGHTENING TORQUE SEQUENCE
smr2011-041 693
snv2009.043-014_o
1. Hose fittings
'4il'tJltitjIf possible, remove the hose fittings l11 t2009043

S 036-4
from the ride plate before removing the ride TYPICAL
1. Hydraulic bottle jack
plate. If fittings cannot be removed, proceed 2. Steel plates
with care when removing the ride plate.
14. Heat the edge of the ride plate and the in
9. Remove INLET GRATE, see procedure in this side diameter of the pump support with a heat
subsection. gun to soften the sealer before prying the ride
10. Inside hull, remove nuts securing the 4 front plate and pump support off the watercraft.
screws of the ride plate.
11 . Heat retaining screws using a heat gun.
12. U sing an impact tool, remove and discard ride
plate retaining screws.
APPLY HEAT HERE
15. Start pumping the hydraulic jack slowly.

16. Using a sharp knife, carefully cut the sealant
TYPICAL
1. Ride plate screws around the ride plate edges.
17. Pump the hydraulic jack slowly to pry the ride
13. Install a low height hydraulic bottle jack and 2
plate from the hull.
steel plates between ride plate and hull as per
Ride Plate Cleaning
1. Carefully scrape off all excess sealant from ride
plate and hull.
2. Clean hull surface with BRP HEAVY DUTY
CLEANER (P/N 293 11 o 001 l to eliminate grease,
dust and sealant residue. Clean fitting threads.
Ride Plate Installation

1. Install the jet pump support on the ride plate,
see procedure in this subsection.
694 srnr2011-041
NOTE: The jet pump support must be installed on

the ride plate before installation of the ride plate
on the watercraft.
2. Reinstall hose fittings on ride plate and torque
to 7 N• m (62 lbf•in).
3. Apply LOCTITE 5900 (PIN 293 800 066) on ride
plate and jet pump support circumference as
seen in the following illustration.
srr.f 20 1 0-04 ?·0 10 _a
1. Hoses
1 O. Reinstall coolant hoses on ride plate fittings,

pay attention to gear clamp positioning. See
smt20 1 1).()47-0'.l3
LOCTITE 5900 SEALANT APPLICATION
4. Position ride plate on hull and engage NEW MS

self-locking screws 5 turns by hand.
5. Position inlet grate and engage NEW retaining
screws 5 turns by hand. Refer to INLET GRATE sm< 200 !)-043 -0 1 5...b
in this subsection. 1. Gear clamp positioning
6. Push ride plate completely forward and torque

11. Install jet pump, refer to the JET PUMP sub
ride plate screws to 35 N•m (26 lbf•ft) as per
section.
following torque sequence.
12. Install iBR gate and VTS trim ring, refer to the
!BR AND VTS subsection.
13. Install battery and electrical accessories sup
port, refer to CHARGING SYSTEM subsec
tion.
14. Refill cooling system and carry out a leak test.
15. Install all remaining parts in the reverse order
of removal.
smr2009-04:>-01 S_b JET PUMP SUPPORT

TYPICAL
Jet Pump Support Removal
7. Torque inlet grate screws. See INLET GRATE 1. Remove the inlet grate and ride plate, see pro
INSTALLATIONin this subsection. cedures in this subsection.
8. Inside hull, install nuts on the 4 front screws 2. Remove the four screws retaining the pump
and tighten them to 20 N•m (15 lbf•ft). support to the ride plate.
9. Install a piece of hose over the threaded end of
the front ride plate screws.
srnr2011-041 695
Subsection 06 (HULL (GTX/RXTJWAKE PRO))
1
1
TYPICAL TOP VIEW RIDE PLATE AND PUMP SUPPORT

•
1. Pump support retaining screws
3. Using a heat gun, heat the base of the pump

RIDE PLATE
support to soften the sealant and carefully pry 1. Apply Loctite 5900 here
the pump support off the ride plate.
UNDERSIDE OF JET PUMP SUPPORT

1. Apply Loctite 5900 here
APPLY HEAT HERE

3. Torque jet pump support screws as specified in
exploded view.
Jet Pump Support Cleaning
1. Scrape off all excess sealant from jet pump sup
port, ride plate. and hull.
2. Inspect pump support for cracks and other 1
1
damages. Replace as necessary.
3. Clean jet pump support and hull surface with
BRP HEAVY DUTY CLEANER (P/N 293 110 001) to
eliminate grease, dust, and sealant residue.
Jet Pump Support Installation

1. Ensure sealant contact areas are clean and dry.
2. Apply LOCTITE 5900 (P/N 293 800 066) on the ride s m r2009 .()43.() 1 9_a
plate and pump support as seen in the following 1. Jet pump support screws
illustrations.
4. Remove any excess sealant from the right hand
forward ride plate mounting hole.
5. Reinstall all removed parts in the reverse order
of removal. Refer to appropriate subsections
for procedures.
696 smr2011-041
THAU-HULL FITIING
The thru-hull fitting is composed of 2 pieces, an
outer fitting, and an inner fitting that screws onto
the outer fitting after the outer fitting is inserted
in the hull.
..,..-ioo 9-043-031 _.
1. Inner thru-hull fitting (overlapping glue removed)
4. Unscrew the inner fitting from the outer fitting

sml'2009-043-02 4 _a using a 65 mm (2.56 in) socket.
1. Outer fitting
2. Inner fitting Outer Fitting Removal
1. Carefully cut sealant around the edge of the
Thru-Hull Fitting Removal outer fitting (jet pump side).
Inner Fitting Removal
1. Remove drive shaft, refer to DRIVE SHAFTsub
section.
2. Using a heat gun, heat the glue at the joint be
tween the hull and the inner thru-hull fitting to
soften the glue applied.
TYPICAL
7. Cut sealant around outer fitting here
2. Heat the inside of the outer fitting to soften the

sealant and help break the bond between the
hull and fitting.
3. Using a rubber mallet (or a hammer and a
wooden block), hammer the outer fitting from
1. Heat here the inside of the hull towards the outside, until
it is flush with the hull.
3. Carefully remove overlapping glue from around
the inner fitting. 4. Reach in through the pump support and pull the
fitting out of the hull.
Hull Cleaning for Thru-Hull Fitting Installation

1 . Scrape off all excess sealant from the hull on
the outer fitting side.
2. Remove excess glue from the hull on the inner
fitting side.
sm<1011-041 697
3. Clean hull surface with BRP HEAVY DUTY 3. Using a stirring stick (or a tongue depressor),
CLEANER (PIN 293 11o 001) to eliminate grease, smooth out glue over the hull and inner fitting
dust, and sealant residue. joint.
NOTE: Use only a clean, dry, oil free filtered air
supply for dusting and drying parts or hull.
Outer Fitting Installation

1. Apply a wide bead of LOCTITE 5900 (PIN 293
800 066) sealant completely around the outer
edge of the fitting (pointed end), and two beads
across the top of the fitting.
1. Smooch out glue here over edge of mner fming
4. If the outer fitting was replaced, ensure it is

properly seated against the hull in the jet pump
area. Remove excess sealant at the joint be
tween the outer fitting and hull.
5. Apply a bead of LOCTITE 5900 (P/N 293 800 066)
sealant completely around the outer edge of
1. Apply Loctite 5900 here the outer fitting to complete the sealing proce
dure.
2. Insert the outer fitting into the hull from the jet
pump side of the hull towards the inside. En
sure fitting is pushed in against the hull.
3. Continue with INNER FITTING INSTALLATION
procedure.
Inner Fitting Installation

1. Apply the SIX10 glue from West System {see
HULL REPAIR at the beginning of this subsec
tion for more information) or an equivalent com
pletely around the third thread of the fitting.
smr2009043 023
_0
TYPICAL
1. Bead of Loctite 5900 all around the outer firring
SPONSONS
NOTE: Removal and installation procedure for RH
and LH sponson is the same.
Sponson Removal
Remove the muffler or the resonator. Refer to the
smaQI 0-047-01 2J EXHAUST SYSTEM subsection.
1. Apply glue here
From inside hull, hold sponson nuts while remov
2. Screw the inner fitting onto the outer fitting and ing sponson retaining bolts and washers.
torque a s specified in the exploded view.
698 sm12011-041
BAILE RS
Two bailer pick ups (one each side), serve to drain
the bilge of the watercraft when it is in operation.
The bailer pick ups are connected through a hose
system to two syphon tubes mounted in the jet
pump venturi that draw the water out of the bilge
through the bailer pick ups. The bailers are also
connected to the bilge drain plugs in the stern.
smr2(X)6-02' -0 14_
a
TYPICAL - RH SPONSON SHOWN Bailer Pick-Up Inspection

1. Sponson
2. Retaining bolts 1. On iS models, open boarding platform and re
move the storage bins. On models without iS,
Sponson Installation remove the rear access panels.
1. Clean any residues of silicone sealant on hull 2. Inside hull, check holes in the bailer pick-ups to
and sponsons. see if they are obstructed. Clean if necessary.
2. Apply LOCTITE 5150 !SILICONE SEALANT) NOTE: On the port side (LH), the bailer is located
(P/N 296 000 309) on back side of sponson below the i BR actuator.
spacers.
smr2G10-0t7-004 ... a
1. Apply silicone sealant here
3. Apply a small amount of LOCTITE 5150 (SILI

CONE SEALANT) (P/N 296 000 309) into each hull
hole. smr2 009-043
-0fU
0 :
TYPICAL LEFT SIDE SHOWN (iBR ACTUATOR REMOVED)

•
1. Bailer assembly
NOTE: On the starboard side (RH), the bailer is

located between the battery support base and the
hull (jet pump tunnel).
smao1 ().()41-00 s
_a
1. Apply silicone sealant in these holes
4. Insert a bolt with washer through each hole and

install the sponson against the hull.
5. From inside hull, secure each bolt with a
washer and a NEW elastic stop nut. 1. Starboard bailer
6. Tighten nuts as specified in the exploded view.

3. Check if the hole on each bailer hose elbow fit
7. Reinstall muffler or resonator. Refer to EX ting is obstructed. Clean both elbow fittings if
HAUST SYSTEM for the procedure. necessary.
snv2011-041 699
DRAIN PLUG REMOVAL

1. Drain plug
2. Drain neck
1. Elbow fitting holes
4. Inside hull, hold the drain neck nut using ad

NOTE: When repositioning the bailer hose el
justable pliers.
bows, attach them at the highest position that
you can on the exhaust hose. 5. Using a ratchet handle and extension of appro
priate size, unscrew the drain neck from the
hull.
DRAIN PLUGS
NOTE: The two drain plugs on the stern are each
connected to a bailer. When watercraft is on dry
land, the drain plugs can be removed to manually
drain the bilge.
Drain Plug Neck Removal

1. On iS models, open the boarding platform and
remove the rear storage bins (one each side).
On models without iS, remove the appropriate
access panel.
2. Cut locking tie securing bailer hose to the drain
plug assembly.
DRAIN NECK REMOVAL
Drain Plug Neck Installation

1. Install drain neck and torque to 9 N•m
(80 lbf•in).
2. Secure bailer hose to drain neck using a NEW
locking tie.
3. Reinstall all removed parts in the reverse order
of removal.
BOW EYELET
LEFT SIDE SHOWN (iBR ACTUATOR REMOVED)

Bow Eyelet Removal
1. Cur this locking tie
1S Models
3. Unscrew the drain plug from the drain neck and To remove the retaining nuts on the bow moor
pull the drain plug out of the neck. ing eyelet, an access hole must be cut in the neo
prene sealing pad. Carry out the following steps.
1. Remove splash deflector.
1 .1 Drill all rivets holding the splash deflector.
700 smr201 Hl41

1. Neoprene sealing pad
�2 0 1 0-01 6-003_8
3. Make 3 cuts according to the following picture.
1. Splash deflector
2. Rivet
lift1Ji[IJj Do not cut neoprene sealing pad too
1.2 Remove splash deflector from vehicle. close to its edges to prevent tearing it off when
folding and ensure proper sealing.
$$t20 10-016-00S_a
CUTTING PATTERN
4. Gently fold all flaps of the neoprene sealing pad

towards the inside of the hull.
1.3 Clean aluminum residues.
2. Using a cutting knife, make opening in the neo
prene sealing pad.
smr2011-041 701
5. Unscrew and discard both elastic stop nuts Bow Eyelet Installation
holding the bow eyelet in place.
All Models
NOTE: The rubber washers and large washers
1. Inside hull, apply LOCTITE 5150 (SILICONE
should be kept for installation.
SEALANTI (PIN 296 ooo 309) around eyelet
mounting holes.
2. Install small washers and nylon washers on
bow eyelet and insert it through hull holes.
3. Inside hull, install rubber washers. large wash
ers and NEW elastic stop nuts.
4. Torque n u ts to 14.5 N•m (128 lbf•in).
1)y\0�,
asl2010-0 t6-01 l_a
1. Rubber washer 2
2. Large washer
3. Elastic nut
4. Screw
""'20
0 7-034-110..a
6. Pull bow eyelet to remove it from watercraft. TYPICAL
1. Bow eyelet
7. Clean any residue of silicone sealant on hull. 2. Small washer
3. Nylon washer
Models Without 1S 4. Loctite 5150 (silicone sealant) here
5. Rubber washer
1 . Open the front storage cover. 6. Large washer
7. Elastic stop nut
2. Remove the storage bin.
iS Models
3. Remove nuts and washers securing the bow
eyelet. Discard nuts. 1. The installation is the reverse of the removal
procedure. However, pay attention to the fol
lowing.
SEALANT) (P/N 296 ooo 309) around eyelet
mou nting holes.
3. Install rubber washers, large washers and NEW
elastic stop nuts.
4. Torque elastic nuts to 14.5 N•m (128 lbf•in).
5. Reinstall the splash deflector on the fixed deck
using 6 rivets.
llll•Jitlti Ensure neoprene gasket edges have

not been damaged during the installation pro
.,.-. 201 0-047-000_a cedure before reinstalling the splash deflector.
INSIDE HULL If gasket is damaged, replace by a new one.
1. Eyelet retaining nuts
4. Remove the bow eyelet from the vehicle.

5. Clean any residue of silicone sealant from the
hull.
702 smr2011·041
Subsection 06 (HULL (GTX/RXT/WAKE PRO})
STERN EYELETS
Stern Eyelet Removal
1. On iS models, open the boarding platform and
remove the applicable storage tray. On mod
els without iS, remove the applicable access
cover.
2. Inside hull, unscrew and discard elastic stop
nuts securing the stern eyelet to hull.
3. Pull stern eyelet to remove it from watercraft.
4. Clean any residue of silicone sealant from the
hull.
TYPICAL
Stern Eyelet Installation 1. Pass through insert
1. Install small washers and nylon washers to

stern eyelet and insert it through the hull.
SEALANT) (P/N 296 ooo 309) all around holes.
3. Install eyelet and other parts using NEW elastic
stop nuts as per following illustration.
smr 2009-043-0 2 G_a
TYPICAL
1. Blind hole insert
All type inserts may be replaced if the inner screw

threads are damaged beyond use.
.smr 2007-0'Jd.J 1 2_a
NOTE: Inserts should only be replaced as a last
TYPICAL resort. First try passing a tap, cleaning the hole,
1. Stern eyelet
2. Small washer and using a NEW self-locking screw. If fastener
3. Nylon washer can be tightened to the specified torque, do not
4. Loctite 5150 {silicone sealant) here
5. Rubber washer change insert. If torque cannot be applied, drill
6. Large washer and tap insert one size larger before trying to
7. Elastic stop nut
change an insert.
4. Torque retaining nuts to 14.5 N•m (128 lbf•in).
Insert Removal
HULL INSERTS 1. Heat the insert using a heat gun to soften the
glue securing the insert into the hull.
Metal inserts (brass) of various types and sizes
are screwed into the hull at various locations. A 2. Remove any excess glue from around the head
of the insert that would prevent proper insertion
threaded hole in the insert is used for fastening
of the socket used to remove the insert.
various parts and equipment onto the hull.
Some inserts pass completely through the hull,
while others do not (blind hole inserts).
smr2011-041 703
smr2009 .()43-026_ b
BLIND HOLE INSERT

1. Excess glue on head
3. Use a six-point socket of appropriate size and a

ratchet wrench to unscrew the insert from the
hull.
NOTE: An impact tool may be used to facilitate
removal of the insert.
Insert Installation
1. Clean the insert hole in the hull to remove any
dirt or loose glue using clean. dry, oil free fil
tered air.
IN•>ili/I Do not use a metal tool to clean or

remove the glue inside the hull insert hole to
prevent damaging the threads in the hull ma
terial. The glue that is properly bonded to the
hull does not need to be removed.
2. If the insert passes completely through the hull.

screw a stud of appropriate size into the insert
(M6 or M8) to prevent any glue from seeping
into the fastener threads in the insert. Apply
the SIX10 glue from West System (see HULL
REPAIR at the beginning of this subsection for
more information) or an equivalent to the outer
threads of the insert.
NOTE: Apply a sufficient amount of glue thru the
full length of the insert threads to ensure excess
glue will come out of the hole as the insert is
screwed into the hull.
3. If the insert screws into a blind hole, apply the
SIX1 O glue or an equivalent to the threads in the
hull.
4. Screw the insert in the hull boss and torque to
25 N•m (18 lbf•ft). Ensure the flanged portion
of the insert makes contact with the boss it i s
being screwed into.
704 smr2011-041
Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (GTS 130 AND GTI 130)
GTS 130 AND GTI 130

Q
MODEL
� . GTS 130 I GTI 130
ENGINE .
� .
·
-
, -�
ROTAX® 1503 4-TEC™, 4-stroke. Single Over
Engine type
Head Camshaft (SOHC)
Induction Naturally-aspirated
Number of cylinders 3
Number of valves 12 valves with hydraulic lifters (no adjustment)
Standard 100 mm (3.9 in)
Bore
1st Oversize 100.25 mm (3.95 in)
Stroke 63.4 mm (2 5in)
Displacement 1 493.8 cm3 (91 in3)
Compression ratio 10.6:1
Maximum RPM 7300 RPM

Dry sump (2 oil pumps).
Type Replaceable oil filter.
Water-cooled oil cooler
Lubrication XPS synthetic blend oil {summer grade) (P/N 293 600
Oil type
121 ). Refer to LUBRICATION SYSTEM subsection
3 L (3.2 qt (U.S. liq.)) oil change w/filter
Capacity
4.5 L {4.8 qt (U.S. liq.)) total
Intake valve opening 10° ATDC
Intake valve closing 50° ABDC
Exhaust valve opening 50° BBDC
Exhaust valve closing 10° BTDC
New 5.961 mm to 5.975 mm (.2347 in to .2352 in)
Intake
Wear limit 5.930 mm (.233 in)
Valve stem diameter
Exhaust
Valve guide diameter
Wear limit 6.060 mm {.2386 in)
New 41.02 mm {1.615 in)
Inner
Valve spring free Wear limit 38.80 mm (1.528 in)
length New 45.45 mm (1.789 in)
Outer
Wear limit 43.00 mm (1.693 in)
New 1.10 mm to 1.30 mm {.043 in to .051 in)
Intake
Valve seat contact Wear limit 1.60 mm (.063 in)
width New 1.25mm to 1.55 mm (.049 in to .061 in)
Exhaust
Rocker arm inner diameter
Rocker arm shaft diameter
Cylinder head maximum warpage Service limit 0.15mm (.006in)
smr2010-048 705
MODEL GTS 130

I GTI 130
ENGINE (cont'd)
•,•
1st Upper compression ring, rectangular
Piston ring type 2nd Lower compression ring, ta pered face

3d
r Oi I scraper ring
Rectangular New 0.30 mm to 0.50mm (.012 in to .02in)
Taper-face New 0.35 mm to 0.55 mm (.014 in to .022 in)
Ring end gap
Oil scraper ring New 0.35mm to 0.50 mm (.014in to .02 in)
All Wear limit 1.50 mm (.059 in)
Rectangular New 0.025mm to 0.070mm (.001 in to .003 in)
Ring/piston groove Taper-face New 0.015mm to 0.06 mm (.0006 in to .0024 in)

clearance Oil scraper ring New 0.020 mm to 0 .05 5mm ( .00 1in to .002 in)
All Wear limit 0.15mm (.006 in)
New 0.024mm to 0.056mm (.0009in to .0022i n)
Piston/cylinder wall clearance
Wear limit 0.100mm (.0039 in)
Cylinder taper Wear limit 0.100 mm (.0039 in)
Cylinder out of round (maximum) 0.015 mm (.0006 in)
New 24.939 mm to 24.960 mm (.9819 in to .9827 i n)
Front
Camshaft bearing Wear limit 24.910 mm (.9807in)
journal diameter New 39.892mm to 39.905mm (1.5706 in to 1.5711 in)
PTO and center
Wear limit 39.880 mm (1.57 01 in)
New 25.000mm to 25 .013mm (.9843 in to .9848 in)
Front
Camshaft bearing Wear limit 25.050mm (.9862 in)
inner diameter N ew 40.000m m to 40.020 mm (1.5748 in to 1.5756 in)
PTO and center
Wear limit 40.050mm (1.5768 in)
New 31.540mm to 31.740mm (1.2417in to 1.2496in)
Intake
Wear limit 31.50mm (1.2402in)
Cam lobe height
New 31.430 mm to 31.630mm (1.2374 in to 1.2453in)
Exhaust
Wear limit 31.380 mm (1.2354in)
Crankshaft deflection Maximum 0.05mm (.002 in)
New 0.080mm to 0.220mm ( . 0031 in to .0087 in)
Crankshaft axial clearance
Wear limit 0.35 mm (.014i n)
New 49.991mm to 50.000mm (1.9681 in to 1.9685 in)
Crankshaft bearing journal diameter
Crankshaft rad ia I c I ea ranee Wear limit 0.07 mm (.0028in)
Connectin g rod big end diameter Service limit 45.080 mm (1.7748 in)
Conn ecting rod big end radial play Service limit 0.090 mm (.0035 in)
New 0.100mm to 0.35 2mm (.004in to .014in)
Connecting rod big end ax ial play
Wear limit 0.500mm (.0197i n)
New 23.010 mm to 23.020mm (.9059in to .9063in)
Connecting rod small end diameter
Wear limit 23.070 mm ( .9083 in)
Connecting rod small end radial play Wear limit 0.080mm (.0031 in)
706 smr2010-048
MODEL
-
GTS 130
I-
GTI 130
ENGLNE (Cont'd)
Piston pin diameter
New 31.984 mm to 32.000 mm (1.2592 in to 1.2598 in)
Bal a nc e shaft journal diameter
Balance shaft radial clearance Wear limit 0.070 mm (.0028 in)
Balance shaft axial clearance New 0.020 mm to 0.250 mm (.0008 in to .0098 in)
New N.A.
Supercharger shaft driven plate journal depth
Wear limit N.A.
Ne w N.A.
Supercharger drive gear th ic kness
Wear limit N.A.
New N.A.
Supercharger lock washer thickness
Wear limit N.A.
Supercharger spring washer package height New N.A.

{not comp ressed) Wear limit N.A.
AIR INTAKE SYSTEM
Intake spark arrester Tubular, wire screen
COOUNG SYSTEM ·�
Type Closed loop cooling system

Ethylene-glycol and distilled water (50%/50%). Use
Cool an t premix coolant from BRP or a coolant specially
formulated for aluminum engines
Cooling system capacity 5.5 L (5.8 qt (US. liq.I) total
Thermostat 87°C {189°F)
Monitoring beeper setting 100°c {212°F)
EXHAUST' SYSTEM '
0-Sea-Bel sound reduction system. Water cooled/water

Type
injected (open loop). Direct flow from jet pump
3 x 3.5 mm (.138 in) on exhaust pipe and 1 x 3.5 mm
Water injection in muffler
(.138in) on muffler
FUEi! SYSTEM
Multipoint fuel injection with iTC (intelligent Throttle
Fuel injection type
Control). Single throttle body (62 mm) with an actuator
Fuel pressure 386 kPa to 414 kPa (56 PSI to 60 PSI)

Fuel injector Quantity 3
Inside North America {(RON + MON)/2) 87 or higher
Fuel type
Outside North America (RON) 92 or higher
Fuel tank {including reserve) 60 L (15.9 U.S. gal.)
Fuel tank reserve {from low level signal) approx. 12 L (3.2 U.S. gal.)
Idle speed 1750 ± 50 RPM (not adjustable)
smr2010-048 707
MODEL GTS 130 I GTI 130

ELECTRICAL SYSTEM
Magneto generator output 360 W@ 6000 RPM
Stator 0.1 to 1.0 n
Battery 12 V. 30 A•h
D.E.S.S. (Digitally Encoded Security System) with
Anti-start system selectable maximum vehicle speed settings tor RK
!rental key) and LK (learning key)
Ignition system type IOI (Inductive Discharge Ignition)
Ignition timing Variable (electronically controlled)
Make and type NGK DCPRBE
Spark plug
Gap 0.7 mm to 0.8 mm (.028 in to .031 in)
Primary 0.85 to 1.15 n
Ignition coil
Secondary 9.5 to 13.5 Kn
Engine speed limiter setting 7650 RPM

#1: i8R control 5 A
#2: Diagnostic connector 15 A
#3: START/STOP 3 A
#4: Gauge constant power 3 A
#5: power 30 A
#6: Vultaye rectifier/regulator 30 A
#8: Relay, fuses 2, 3 and 4 30 A
Fuse box
#12: O.T. A.S.. gauge start up and CAPS 3 A
#1 3: lnj/lgn cyl 1 10 A
#14: lnj/lgn cyl 2 10 A

#16: Starter solenoid 5 A
#18: Fuel pump 10 A
#19: ECM power 15 A
STEERING ANO PROPULSION
Steering Fixed column
Steering nozzle pivoting angle 20°
O.T.A.S. (Off-Throttle Assisted Steering) Electronically-controlled
Type Axial flow single stage
Jet pump
Grease type Jet pump bearing grease (P/N 293 550 032)
Rotation (seen from rear) Counterclockwise
Impeller Pitch 11°/18°
Outside diameter 155.5 mm ± 0.06 mm (6.122 in ± .002 in)
New 0 mm to 0.23 mm (0 in to .009 in)
Impeller/wear ring clearance
End play (new) 0
Impeller shaft
Side play 0
Coupling type Crowned splines, direct drive
Drive shaft
Deflection !max.) 0.5 mm (.02 in)
Minimum required water level for propulsion system 90 cm (3 ft) underneath the lowest rear portion of hull
708 Smt2010-048
MODEL GTS 130 GTI 130

iBR and VTS
Intelligent Brake and Reverse
activated by a LH lever.
Description N.A. Electronically-controlled iBR
gate to provide brake, reverse,
neutral and forward position
Forward Approx. from +8° to -4°

Neutral Approx. -52°
Gate angle (from horizontal line of watercraft) N.A.
Braking Approx. -70°
Reverse Approx. from -52° to -70°
VTS system N.A.
VTS range angle N.A.
Actuator N.A.
WEIGHT AND WADING CAPACITY

Ory weight 333 kg (734 lb) 338 kg {745 lb)
Number of passenger (driver incl.) 3
Load limit (passenger and 10 kg (22 lb) luggage) 273 kg (602 lb)
DIMENSIONS
Overall length 336.Scm (132.6in)
Overall width 123.1 cm (48.5 in)
Overall height 111.8 cm (44 in)
MATER IALS
'
Hull Composite fiberglass
Inlet grate Aluminum
Steering cover Thermoplastic
Impeller material Stainless steel
Impeller housing/stator Aluminum/aluminum
Venturi Aluminum
Nozzle Alum inum
Fuel tank Polyethylene
Seat Polyurethane/foam
N.A.: Not Available
smf201(}.048 709
710
Subsection 02 (GTI 155 AND WAKE 155)
GTI 155 AND WAKE 155

MODEL GTI 155 I WAKE 155
ENGINE
-
ROTAX® 1503 4-TEC™. 4-stroke. Single Over
Engine type
Head Camshaft (SOHCJ
Induction Naturally-aspirated
Standard 100mm (3.9in)
Bore
Stroke 63.4 mm {2.5 in)

Compression ratio 1 0.6 : 1

Lubrication XPS synthetic blend oil (summer grade) (P/N 293 600
Oil type
121 ). Refer to LUBRICATION SYSTEM subsection
3 L (3.2 qt (U.S. liq.)I oil change w/filter
Capacity
4.5 L (4.8 qt (U.S. liq.)) total
Intake valve opening 0° BTDC
Exhaust valve closing 0° ATDC
New 5.961 mm to 5.975 mm !.2347 in to .2352 in)
Intake
Valve stem diameter
Exhaust
New 41.02 mm (1.615in)
Inner
Valve spring free Wear limit 38.80 mm (1 .528 in)
length New 45.45 mm (1.789 in)
Outer
Intake
width New 1.25 mm to 1.55 mm (.049 in to .061 in)
Exhaust
Wear limit 1.80 mm (071 in)
Cylinder head maximum warpage Service limit 0.15 mm (.006 in)
smr2010·D48 711
MODEL GTI 155

I WAKE 155
ENGINE (cont'd)
- -
1st Upper compressio n rin g r ectangular
,
P i ston ring type znd Lower compression ring tapered face

,
3rd Oil scraper ring
Rectangular Ne w 0.30 mm to 0.50 mm (.012 in to .02 in)

Tap er-f ace New 0.35 mm to 0.55 mm (.014 in to .02/ in)
Ring end gap
Oil scraper ring New 0.35 mm to 0.50 m m (.014 in to .02 in)
Rectangular New 0.025 mm to 0.070 mm (.001 in to .003 i n)
Ring/piston groove Taper-face New 0.015 mm to 0.0 6 mm (.0006 in to .0024 in)

clearance Oil scraper ring New 0.020 mm to 0.055 mm (.001 in to .002 in}
All Wear limit 0.15 mm (.006 in}
New 0.024 mm to 0.056 mm (.0009 in to .0022 in}
Front
Camshaft bearing We ar l imit 24.910 mm (.9807 in)
jou rna l di ame ter New 39.892 mm to 39.905 mm (1.5706 in to 1.5711 in)
PTO and center
New 25.000 mm to 25.013 mm (.9843 in to .9848in)
Front
Camshaft b eari ng Wear limit 25.050 mm (.9862 in)
inner diameter New 40.000 mm to 40.020 mm (1.5748 in to 1.5756 in)
PTO and center
Int ake
Cam lobe height
Exhaust
Crankshaft deflection Maximum 0.05 mm (.002 in)
Wear l imit 0.35 mm (.014 in)
Crankshaft b earing journal diameter
Crankshaft radia l clearance Wear limit 0.07 mm (.0028 in)
Connecting rod big end diameter Service lim it 45.080 mm (1.7748 in)
Connecting rod big end radial play Service limit 0.090 mm (. 0 03 5 in)
New 0.100 mm to 0.3 52 mm (.004 in to .014 in)
Connecting rod big end axial play
New 23.010 mm to 23.020 mm (.9059 in to .9063 in )
Connecting rod small end radial play Wear limit 0.080 mm (.0031 in)
712 smt2010-048
MODEL GTI 155

I WAKE 155
ENGINE (cont'd)
New 22.996 mm to 23.000 mm {.9054 in to .9055 in)
Piston pin diameter
New 31.984 mm to 32.000 mm {1.2592 in to 1.2598 in)
Balance shaft journal diameter
Balance shaft axial clearance New 0.020 mm to 0.250 mm {.0008 in to .0098 in)
New N.A.
Supercharger shaft driven plate jo urnal depth
Wear limit N.A.
New N.A.
Supercharger drive gear thickness
Wear limit N.A.
New N.A.
Wear limit N.A.
Supercharger spring washer package height New N.A.

(not compressed) Wear limit N.A.
AIR INTAKE SYSTEM - '"
Intake spark arrester Tubular. wire screen

..
' '
COOLING SYSTEM
Ethylene-glycol and distilled water (50%/50%). Use
Coolant premix coolant from BRP or a coolant specially
formulated for aluminum engines
Cooling system capacity 5.5 L (5.8 qt (U.S. liq.)) total
Thermostat 87°C {189°F)
Monitoring beeper setting 100°C (212°F)
'
EXHAUST SYSTEM
D-Sea-Bel sound reduction system. Water cooled/water
Type
injected {open loop). Direct flow from jet pump
3 x 3.5 mm {.138 in) on exhaust pipe and 1 x 3.5 m m
Water injection in muffler
{.138 in) on muffler
FUEL SYSTEM .. - "
Multipoint fuel injection with iTC (intelligent Throttle

Fuel injection type
Control). Single throttle body {62 mm) with an actuator
Fuel pressure 386kPa to 414kPa {56PSI to 60PSI)
Fuel injector Quan tity 3
Inside North America ({RON + MON)/2) 87 or higher
Fuel type
Outside North America (RON) 92 or higher
Fuel tank (including reserve) 60 L {15.9 U.S. gal.)
Fuel tank reserve (from low level signal) approx. 12 L (3.2 U.S. gal.)
smr2010-048 713
MODEL GTI 155

I WAKE 155
ELECTRICAL SYSTEM
Magneto generator output 360 W @ 6000 RPM
Stator 0.1 to 1.0 n
Battery 12 V, 30 A•h
D.E.S.S. (Digitally Encoded Security System) with
Anti-start system selectable maximum vehicle speed settings for RK
(rental key) and LK (learning key)

Make and type NGK DCPR8E
Spark plug
Ignition coil
Secondary 9.5 to 13.5rn

11: iBR control 5A
#3: START/STOP 3 A
#4: Gauge constant power 3 A
#5: power 30 A
#6: Voltage rectifier/regulator 30 A
#8: Relay, fuses 2, 3 and 4 30 A

Fuse box
112: O.TAS., gauge start up and CAPS 3 A
113: lnj/lgn cyl 1 10 A

#16: Starter solenoid 5 A
#18: Fuel pump 10 A
#19: ECM power 15 A
.
STEERING AND PROPULSION
Steering Fixed column
O.T.A.S. (Off-Throttle Assisted Steerin g) Electronically-controlled
Jet pump
Rotation (seen from rear) Counterclockwise
Impeller Pitch 11°/18()
Outside diameter 155.5 mm ± 0.06 mm (6.122 in ± .002 in)
End play (new) 0
Impeller shaft
Side play 0
Drive shaft
Deflection (max.) 0.5 mm (.02 in)
714 smr2()1�8
MODEL GTI 155

I WAKE 155
iHR and VTS
Intelligent Brake and Reverse activated by a LH lever.
Description Electronically-controlled iBR gate to provide brake,
reverse, neutral and forward position
Forward Approx. from +S0 to -4°
Neutral Approx. -52°
G::ite anglR (from hnrimnt::il linA of wAtArr.raft)
Braking Approx. - 70°
Reverse Approx. from -52° to 70 - °
VTS system Yes

VTS range angle Approx. from +S0 to 4° -
12 V, SO A max. capacity. Reversible PWM

Actuator
(pulse-width modulation) motor
.
.
WEIGHT ANO LOADING CAPAotTY "·
Dry weight 338 kg (745 lb} I 339 kg (747 lb)

Load limit (passenger and 10 kg (22 lb) luggage) 273 kg (60 2lb)
-
DIMENSIONS
Overall length 336S
. cm (132.6in)
Overall width 123.1cm (4S.5 in)
Overall height 111.Bcm (44in)
MATERIALS ....
Venturi Aluminum
Nozzle Aluminum

NA: Not Available
smr2010-048 715
716
Subsection 03 (GTX 155/215/260)
GTX 155/215/260
MODEL GTX 155 GTX 215 I GTX iS 215 I GTX LTD iS 260
ENGINE
Engine type ROTAX® 1503 4-TEC™, 4-stroke, Single Over Head Camshaft (SOHC)
Induction Naturally-aspirated Supercharged intercooled
Bore
Stroke 63.4 mm (2.5 in)
Compression ratio 10.6:1 8.4:1
Maximum RPM 7300 RPM 8000 RPM
Type Dry sump (2 oil pumps). Replaceable oil filter. Water-cooled oil cooler
XPS synthetic blend oil (summer grade) (P/N 293 600 121).
Oil type
Lubrication Refer to LUBRICATION SYSTEM subsection
3 l (3.2 qt (U.S. liq.)) oil change w/filter
Capacity
4.5 l (4 8 qt (U.S. liq.)) total
Intake
Valve stem Wear limit 5.930 mm (.233 in)
diameter New 5.946 mm to 5.960 mm (.2341 in to .2346 in)
Exhaust
New 41.02 mm (1.615 in)
Inner
Valve spring Wear limit 38.80 mm (1.528 in)
free length New 45.45 mm (1.789 in)
Outer
Intake
Valve seat Wear limit 1.60 mm (.063 in)
contact width New 1.25 mm to 1.55 mm (.049 in to .061 in)
Exhaust
smrZ010-048 717
MODEL GTX 155

"
I GTX 215 I GTX iS 215 I GTX LTD iS 260
ENGINE (cont'd)
·'
'
.· u
1st Upper compression ring, rectangular

Piston ring type 2nd Lower compression ring, tapered face
3 rd Oil scraper ring
Rectangular New 0.30mm to 0.50mm (.012in to .02in)
Toper foce New 0.35 mm to 0.55 mm (.014 in to .022in)
Ring end gap
Oil scraper ring New 0.35 mm to 0.50mm (014in to .02 in)
All Wear limit 1.50mm (.059in)
Rectangular New 0.025mm to 0.070 mm (.001 in to .003 in)
Ring/piston Taper-face New 0.015 mm to 0.06 m m [.0006 in to .0024 in)
groove
clearance Oil scraper ring New 0.020 mm to 0.055mm (.001 in to .002in)
I
0.024mm to 0.056mm
New 0.04mm to 0.08 mm !.0016in to .0031 in)
Piston/cylinder wall clearance (.0009 in to .0022in)
Cylinder taper Wear limit 0.100mm (.0039 in)
Cylinder out of round (maximum) 0.015mm (.0 006 in)
New 24.939mm to 24.960mm (.9819 in to .9827 in)
Front
Camshaft Wear limit 24.910 mm (.98 07 in)
bearing journal
d iameter New 39.892mm to 39.905mm (1.5706 in to 1.5711 in)
PTO and center
New 25.000mm to 25.013mm (.9843in to .9848 in)
Front
Camshaft Wear limit 25.050mm (.9862in)
bearing inner
diameter New 40.000mm to 40.020mm (1.5748 in to 1.5756 in)
PTO and center
Intake
Cam lobe Wear limit 31.50mm (1.2402 in)
height New 31.430 mm to 31 .63 0mm (1.2374in to 1.2453in)
Exhaust
Crankshaft deflection Maximum 0.05mm (.002in)
New 0.080mm to 0 .22 0mm (.0031 in to .0087in)
Wear limit 0.35 mm (.01 4in)
Crankshaft bearing journal New 49.991 mm to 5 0.0 00mm (1.9681 in to 1.9685 in}
diameter W ear lim it 49.950mm (t .9665 in)
Crankshaft radial clearance Wear limit 0.07 mm (.0028in)
Connecting rod big end diameter Service limit 45.0BOmm (1.7748in)
Connecting rod big end radial
Service limit 0.090mm (.0035in)
play
718 smr20le>o4a
MODEL GTX 155 GTX 215

I GTX iS 215 I GTX LTD iS 260
ENGINE (cont'd)
� ..
Connecting rod big end axial New 0.100 mm to 0.352 mm (.004 in to .014 in)
play Wear lim it 0.500mm (.0197 in)
Connecting rod sm all end New 23.010mm to 23.020 mm (.9059 in to .9063 in)
diameter Wear limit 23.070mm (.9083 in)
Connecting rod small end radial
Wear limit 0.080mm l.0031 in)
play
New 22.996mm to 23.000mm (.9054 in to .9055 in)
Piston pin diameter
New 31.984mm to 32.000 mm (1.2592 in to 1.2598 in)
Balance shaft radial clearance Wea r lim it 0.070 mm (.0028 in)
Balance shaft axial clearance New 0.020mm to 0.250mm (.0008 in to .0098 in)
Supercharger shaft driven plate New N.A. 14.460 mm to 14.500mm (.5693 in to .5709 in)
journal d ep th Wear limit N.A. 14.600mm (.5748in)
Supercharger drive gear New N.A. 11.000 mm to 11.050mm (.4331 in to .435 in)
th ickness Wear lim it N .A. 10.900mm {.4291 in)
Supercharger lock washer New N.A. 4.050 mm to 4.1 50 mm (.1594 in to .1634 in)
th ic knes s Wear limit N.A. 3.950 mm (.1555 in)
Supercharger spring washer New N.A. 10.900 mm to 10.700 mm (.4291 in to .4213 in)
package height (not compressed) Wear limit N.A. 10.200mm (.4016 in)
AIR INTAKE SYSTEM
Intake spark arrester Tubular. wire screen
COOLING SYSTEM
Type Closed loop coo ling system

Ethylene-glycol and disti lled water (50%/50%). Use premix coolant from BRP
Coolant
or a coolant specially formulated for aluminum en gines
Cooling system capacity 5.5 L {5.8 qt (U.S. liq.)) total
Thermostat 87°C ( 189°F)
Monitoring beeper setting 100°c 1212°F)
EXHAUST SYSTEM
0-Sea-Bel sound reduction system. Water cooled/water injected
Type
(open loop). Direct flow from jet pum p
Water injection in muffler 3 x 3.5mm (.138 in) on exhaust pipe and 1 x 3.5 mm (.138 in) on muffler
smi2010-048 719
MODEL GTX 155 GTX 215 GTX iS 215 I GTX LTD iS 260
FUEL SYSTEM
Multipoint fuel injection with iTC (intelligent Throttle Control).
Fuel injection type
Single throttle body (62 mm) with an actuator
Fuel pressure 386 kPa to 414 kPa {56 PSI to 60 PSI)
Inside NorthAmerica
87 or higher 91 or higher
((RON + MON)/2)
Fuel type
Outside NorthAmerica (RON) 92 or higher 95 or higher
Fuel tank (including reserve) 60L (16U.S. gal.) 70 L (18 U.S. gal.)
Fuel tank reserve (from low level signal) approx. 12 L (3.2 U.S. gal.) approx. 14 L (3.7 U.S. g al .)

ELECTRICAL SYSTEM
Stator 0.1 to 1.0 n
Battery 12 V, 30A•h
D.E.S.S. (Digitally Encoded Security System) with selectable maximum vehicle
Anti-start system
speed settings for RK (rental key) and LK ( learning key)
Ignition system type IOI (Inductive Discharge Ig nit ion)

Spark plug
Gap 0.7 mm to O.B mm (.028 in to .031 in)
Ignition coil
Secondary 9.5 to 13.5 rn
Engine speed limiter setting 7750 RPM 8300 RPM
#1: iBR control 5A
#2: Diagnostic connector 15A
#3: START/STOP 3A
#4: Gauge constant power 3A
#5: i BR power 30A
#6: Voltage rectifier/regulator 30 A
#7: iS power 30A
Fuse box
#8: IFuses 2, 3, 4 and relay 30A
#11: Depth s ound er 3A
#12 O..T A.S., Gauge start up, CAPS 3A
#13: lnj/lg n cyl 1 10A
#14: lnj/lgn cyl 2 10A
#16: Starter solenoid 5A
720 smr2010-048
MODEL GTX 155

I GTX 215 GTX iS 215 I GTX LTD iS 260
ELECTRICAL SYSTEM (cont'd)
#17: iBR control 5 A
Fuse box
#18: Fuel pump 10 A
(cont'd)
#19: ECM power 15 A
STEERING ANO PROPULSION
Steering Adjustable 4 positions
O.T.A.S. (Off-Throttle Assisted Steering) Electronically-controlled
Jet pump
Rotation (seen
Counterclockwise
from rear)
Impeller
Pitch 10°/21°
I 14°/25°
Outside diameter 159 mm ± 0.06 mm (6.26 in ± .002 in)
End play (new) 0
Impeller shaft
Side play 0
Drive shaft
Deflection (max.) 0.5 mm (.02 in)
Minimum required water level for propulsion
90 cm (3 ft) underneath the lowest rear portion of hull
system
iBR and VTS
Intelligent Brake and Reverse activated by a LH lever. Electronically-controlled
Description
iBR gate to provide brake, reverse. neutral and forward position
Forward Approx. from +8° Lo -4°
Gate angle {from horizontal line Neutral Approx. -52°
of watercraft) Braking Approx. -70°
VTS system Yes
VTS range angle 8° up, -4° down
Actuator 12 V. 80 A max. capacity. Reversible PWM (pulse-width modulation) motor
WEIGHT AND LOADING CAPACITY
Dry weight 374 kg (825 lb) I 388 kg 1855 lbl 435 kg !96o lbl I 446 kg !98o lbl
Load limit (passenger and 10 kg (22 lb) luggage) 272 kg 1600 lb) 226 kg (500 lb)
DIMENSIONS
Overall length 354 cm (139 in)
Overall width 122 cm (48 in)
Overall height 116.6 cm (45.91 in) 111.4 cm (43.9 in)
Overall height with keel horizontal. suspension
N.A. 128 cm (50 in)
extended
Overall height with keel horizontal. suspension
N.A. 115.8 cm (45.6 in)
collapsed
smr2010-048 721
MODEL GTX 155

I GTX 215
I GTX iS 215 IGTX LTD iS 260
MATERIALS
Venturi Aluminum
Nozzle Aluminum
-
Fuel tank Polye thylene
S eat Polyurethane/foam
NA: Not Available
722 smr201().()48
Subsection 04 (RXT 260)
RXT 260
I I
RXT-X 260 aS/
MODEL RXT 260 RXT-X 260
RXT iS 260
ENGINE
Engine type ROTAX® 1503 4-TEC™, 4-stroke. Single Over Head Camshaft (SOHC)
Induction Supercharged intercooled
Standard 100mm (3.9in)

Bore
1st Oversize 100.25 mm (3.95in)
Stroke 63.4mm (2.5in)
Displacement 1 493.8cm3 (91 in3)

Lubrication XPS synthetic blend oil (summer grade ) {P/N 293 600 121) .
Oil type
Refer to LUBRICATION SYSTEM subsection
3 l (3.2qt (U.S . liq.)) oil change w/filter
Capacity
4.5 L (4.8qt (U.S . liq.)) total
Intake valve open ing 0° BTDC
New 5.961mm to 5.975 mm (.2347in to .2352in)

Intake
Valve stem Wear limit 5.930mm (.233i n)
diameter New 5.946mm to 5.960mm (.2341in to .2346in)
Exhaust
New 5.994mm to 6.018mm (.236in to .2369 in)

New 41.02mm (1.615 in)

Inner
Valve spring free Wear limit 38.80mm (1.528 in)
length New 45.45mm (1.789in)
Outer
New 1.10mm to 1.30mm (.043in to .051in)

Intake
Valve seat contact Wear limit 1.60mm (.063in)
width New 1.25mm to 1.55 mm (.049in to .061 in)
Exhaust
New 20.007 mm to 20.020mm (.7877 in to .7882in)

Wear limit 20.050mm (.7894in)
New 19.980mm to 19.993mm (.7866in to .7871in)

Cylinder head maximum warpage Service limit 0.15mm (.006in)
smr2010-048 723
I I
RXT-X 260 aS/
RXT iS 260
ENGINE (cont'd)
1st Upper compressi on ring, rectangular
Rectangular New o.:m mm to 0 50 mm (.012 in to .02 in)

Ring end gap Oil scraper
ring
Recta ngular New 0.025 mm to 0.070 mm (.001 in to .003 in)
Ring/piston
groove clearance Oil scraper
ring
All Wear limit 0.15mm (.006 in)
New 24.939 mm to 24.960 mm (.9819 in to .9827in)
Front
Camshaft bearing Wear limit 24.910 mm (.9807 in)
journal di ameter PTO and New 39.892 mm to 39.905 mm (1.5706 in to 1.5711 in)
center Wear limit 39.880 mm (1.5701 in)
Front
inner diameter New 40.000 mm to 40.020 mm (1.5748 in to 1.5756 in)
PTO and
center Wear limit 40.050 mm (1.5768i n)
New 31.540mm to 31.740mm (1. 241 7in to 1.2496in)
Intake
Wear li mit 31.50 mm (1.2402 in)
Cam lobe height
Exhaust
Crankshaft beari ng j ournal New 49.991 mm to 50.000 mm (1.9681 in to 1.9685 in)

diameter Wear limit 49.950 mm (1.9665 in)
Crankshaft radial clearance Wear limit 0.07 mm (.0028 in)
Connecting rod big end di am eter Service limit 45.080 mm (1.7748 in)
Connecting rod big end radial play Service lm
i it 0.090 mm (.0035 i n)
724 smr2010-048
I
RXT-X 260 aS/
RXT iS 260
ENGINE (cont'd)
..
Connecting rod small end New 23.010mm to 23.020 mm (.9059in to .9063 in)
diameter Wear limit 23.070 mm (.9083in)
Connecting rod small end radial

play
New 22.996mm to 23.000mm (. 9054in to .9055 in)
Pi ston pin diameter
Wea r limit 22.990mm (.9051in)
New 31.984 mm to 32.000mm (1.2592in to 1.2598in)
Wea r limit 31.950 mm (1.2579in)
Balance shaft radial clearance Wear limit 0.070 mm (.0028in)
Balance shaft axial clearance New 0.020mm to 0.250mm (.0008in to .0098in)
Supercharger shaft driven plate New 14.460mm to 14.500mm (.5693in to .5709in)

jou rnal depth Wear limit 14.600mm (.5748in)
New 11.000 mm to 11 .050mm (.4331in to .4 35in)

Supercharger lock washer New 4.050mm to 4.150mm {.1594in to .1634in)

thickness Wear limit 3.950mm (.1555in)
Supercharger spring washer New 10.900mm to 10.700mm (.4291in to .4213 in)

package height (not compressed ) Wear limit 10.200 mm (.4016in)
AIR INTAKE SYSTEM
COOLING SYSTEM
Ethylene-glycol and distilled water (50%/ 50%). Use premix coolant from
Coolant
BRP or a coolant specially formulated for aluminum engines
Cooling system capacity 5.5 L (5.8qt (U.S. liq.)) total
Thermostat 87°C (189°F)
Monitoring beepe r setting -
100°C (212°F)
--
EXHAUST SYSTEM
0-Sea-Bel sound reduction system. Water cooled/water injected
Type (open loop). Direct flow from jet pump
Water injection in muffler 3 x 3.5mm (.138in) on exhaust pipe and 1 x 3.5 mm (.138in) on muffler
FUEL S:YSTEM
Multipoint fuel injection with iTC (i ntell igen t Throttle Control).
Fuel injection type
Single throttle body (62 mm ) with an actuator
Fuel pre ssure 386kPa to 414kPa (56 PSI to 60PSI )

Inside North Ame rica
91 or higher
Fuel type ({RON + MON)/2)
Outside North America {RON) 95 or higher
Fuel tank (including reserve) 60 L (16 U.S. gal .) 70L (1 8U.S gal.)
app rox . 14 L
Fuel ta nk reserve (from low level signal) approx . 12 L (3.2 U.S. gal.)
(3.7 US. gal.)
smr2010·048 725
I I
RXT-X 260 aS/
RXT iS 260
ELECTRICAL SYSTEM
Stator 0.1 to 1.0 n
Batte ry 12 V. 30A•h
O.E.S.S. (Digita ll y Encoded Security System) with selectable m axi mum vehicle
Anti-start system
speed settings for AK (rental key) and LK (learning key)
Ignition timing Variable (electronically controlledl
Spark plu g
Ignition coil
Secondary 9.5 to 13.5 Kn
Engine speed limiter sening 8300 RPM
ELECTRICAL SYSTEM
#1: iBR control 5A
113: ST
ART/
STOP 3A
#4: Gauge constant power 3A
#5: iBR power 30 A
#£: Voltage rectifier/regulator 30 A
117: iS power 30 A
#8: !Fuses 2, 3, 4 and relay 30A
Fuse box 111: Depth sounder 3A
#12 O.T.A.S., Gauge start up, CAPS 3A
#14: l nj/lg n cyl 2 10A
#16: Starter solenoid 5A
#17: iBR control SA
#18: Fuel pump 10A
#19: ECM power 15 A
726 smr201G-048
RXT-X 260 aS/

RXT iS 260
aS: Steering:
Steering: Adjustable
Adjustable 4 positions.
4 positions
Steering Adjustable 4 positions Handlebar: -0.0
Handlebar: -0.0 mm
mm to +25 mm.
to +25 mm
iS: Adjustable 4 positions
0.T.A.S. (Off-Throttle Assisted Steering) Electronically-controlled. Achieved with the iBR gate and engine speed
Jet pump
Rotation (seen from
Counterclockwise
rear)
Impeller
Pitch RXT: 10°/21° 14°/25°
Outside diameter 159 mm ± 0.06 mm (6.26in ± .00 2in)
New 0 mm to 0.23mm (0 in to .009 in)
End play (new) 0
Impeller shaft
Side play 0
Drive shaft
Deflection (max.) 0.5mm (.02 in)
iBR and VTS
Intelligent Brake and Reverse activated by a LH lever. Electronically-controlled
Description
iBR gate to provide brake. reverse. neutral and forward position
Forward Approx. from +8° to - 4 °
Gate angle (from horizontal line Neutral Approx. -52°

of watercraft) Braking Approx. -70°
VTS system Electronically-controlled through the VTS control button with 2 preset positions
Actuator 12 V, 80 A max. capacity. Reversible PWM (pulse-width modulation) motor

aS: 436 kg (961 lb)

Dry weight 383 kg (845 l b ) RXT-X: 388k g (855 lb)
iS: 441 kg (970 lb)
Load limit (passenger and 10 kg (22 lb) luggage) 272 kg (600 lb) 226 kg (500lb)
DIMENSIONS
Overall height 116.6cm (45.91in) 118 cm (46.5 in) 111.4cm (43.9 in)
Overall height with keel horizontal, suspension
N.A. 128cm (50in)
extended
Overall height with keel horizontal, suspension
NA 1 1 5.8cm (45.6 in)
collapsed
smr2010-048 727
I I
RXT-X 260 aS/
RXT iS 260
MATERIALS
Hull Compos ite fiberg lass

lmpP.llP.r material Stainless steel

Venturi Aluminum
Nozzle Aluminum
N.A.: Not Available
728 smr2010-048
Subsection 05 (WAKE PRO 215)
WAKE PR0215
MODEL WAKE PRO 215
ENGINE
Engine type ROTAX® 1503 4-TEC™, 4-stroke, Single Over Head Camshaft (SOHC)
Induction Supercharged intercooled
Bore
Stroke 63.4 mm (2.5 in)
Lubrication XPS synthetic blend oil (summer grade) (P/N 293 600 121).
Oil type
Refer to LUBRICATION SYSTEM subsection
3 L (3.2 qt (U.S. liq.II oil change w/filter
Capacity
4.5 L (4.8 qt (U.S. liq.)) total
Exhaust valve opening 50° BBOC
Intake
Valve stem diameter
Exhaust
Wear limit 5.930 mm 1.233 inl
Ne w 5.994 mm to 6.018 mm (.236 in to .2369 in)
New 41.02mm (1.615in)
I nner
Valve spring free length
New 45.45 mm (1.789 in)
Outer
Intake
width New 1.25 mm to 1.55 mm (.049 in to .061 in}
Exhaust
smr2010-048 729
MODEL WAKE PRO 215

. >
ENGINE (c ont'd)
lSl Upper compression ring, rectangular
Rectangular New 0.30 mm to 0.50 mm (.012 in to .02 in)
Taper-face New 0.35 mm to 0.55 mm (.014 in to .un in)
Ring end gap
Oil scraper ring New 0.35 mm to 0.50 mm (.014 in to .02 in)
Rectangular New 0.025mm to 0.070 mm (.001 in to .003in)
Ring/piston groove Taper-face New 0.015 mm to 0.06 mm (.0006 in to .0024 in)

clearance Oil scraper ring New 0.020 mm to 0.055 mm (.001 in to .002 in)
All Wear limit O.l5mm (.006in)
N ew 0.04 mm to 0.08 mm (.0016 in to .0031 in)
New 24.939m m to 24.960 mm (.9819 in to .9827 in)
Front
journal diameter New 39.892 mm to 39.905 mm (1.5706 in to 1.5711 in)
PTO and center
Wear limit 39.880 mm {1.5701 in)
Front
Camshaft bearing inner Wear limit 25.050 mm (.9862 in)
diamete r New 40.000 mm to 40.020 mm (1.5748 in to l .5756 in)
PTO and c enter
Wear limit 40.050 mm (l .5768 in)
New 31.540 mm to 31.740 mm (12417 in to 1.2496 in)
Intake
Wear limit 31.50 mm 11.2402 in)
Cam lobe height
Exhaust
Wear limit 31.380mm (1.2354in)
New 0.080 mm to 0.220 mm (.00 31 in to .0087 in)
New 49.991 mm to 50.000 mm {1.9681 in to 1.9685in)
Crankshaft bearing journal d ia meter
Crankshaft radial clearance Wear limit 0.07 mm {.0028 in)
Connecting rod big end diameter Service limit 45.080 mm (1.7748 in)
Connecting rod big end radial play Service limit 0.090 mm (.0035 in)
New 0.100 mm 0.352 mm (.004 in
· · .014 in)
Wear limit 0.500m m (.0197 in)
730 smr20t0·04S
MODEL WAKE PRO 215

ENGINE (cont'd)
Connecting rod small end radial play Wear limit 0.080 mm (.0031 in)

Piston pin diameter

Balance shaft axial clearance New 0.020 mm to 0.250 mm (.0008 in to .0098 in)
Supercharger shaft driven plate journal New 14.460 mm to 14.500 mm (.5693 in to .5709 in)
depth Wear limit 14.600 mm (.5748 in)
Supercharger spring washer package height New 10.900 mm to 10.700 mm (.4291 in to .4213 in)
(not compressed) Wear limit 10.200 mm (.4016 in)
AIR INTAKE SYSTEM

COOLING SYSTEM
Ethylene-glycol and distilled water (50%/50%). Use premix coolant
Coolant
from BRP or a coolant specially formulated for aluminum engines
Cooling system capacity 5.5 L (5.8 Qt (U.S. liq.)) total

Thermostat 87°C (189°F)
Monitoring beeper setting 1 00 °C (212°FJ
EXHAUST SYSTEM
D-Sea-Bel sound reduction system. Water cooled/water injected
Type
(open loop). Direct flow from jet pump
Water injection in muffler 3 x 3.5 mm (.138 in) on exhaust pipe and I x 3.5 mm (.138 in) on muffler
FUEL SYSTEM
Multipoint fuel injection with iTC (intelligent Throttle Control).
Fuel injection type
Single throttle body (62 mm) with an actuator
Fuel pressure 386 kPa to 414 kPa (56 PSI to 60 PSI)
Inside North America (IRON + MON)/2) 91 or higher

Fuel type
Outside North America (RON} 95 or higher
Fuel tank (including reserve} 70 L (18 U.S. gal.)
Fuel tank reserve (from low level signal) approx. 14 L (3.7 U.S. gal.I
smr2010-048 731
MODEL WAKE PRO 215
ELECTRICAL SYSTEM
Stator 0.1 to 1.0 n

Battery 12 V. 30 A•h
D.E.S.S. (Digitally Encoded Security System) with selectable maximum
Anti-start system
vehicle speed settings for RK (rental key) and LK (learning key)

Make and type NGK OCPR8E
Spark plug
Ignition coil
Secondary 9.5 to 13.5 rn
#1: Gauge 3 A
#2: CAPS 3 A
#3: Depth sounder 3 A
114: Starter solenoid 5 A
#5: iBR control 5 A
Fuse box #1 16: Fuel pump 10 A

#10: O.T.A.S. switch 3 A

#11: iS control Empty
Relay 30 A
#15: Charging system 30 A
#16: iS power Empty
#17: Batt power 30 A
Fuse box #2 #18: iBR power 30 A
#20: ECM 15 A
#21: START/STOP switch 3 A
#22: Diag connector 15 A
#23: GPS 3 A
Steering Adjustable 4 positions

Electronically-controlled. Achieved with the iBR gate
O.T.A.S. (Off-Throttle Assisted Steering)
and engine speed
Jet pump
Rotation (seen from
Counterclockwise
rear)
I m peller
Pitch 10°/21°
Outside diameter 159 mm ± 0.06 mm {6.26 in ± .002 in)
732 smr2010.048
MODEL WAKE PRO 215

STEERING AND PROPULSION (cont'd)
New 0 mm to 0.23 mm (O in to .009 in)
End play (new) 0
Impeller shaft
Side play 0
Couplino typA Crowned splines. direct drive
Drive shaft
Deflection (max.) 0.5 mm ( 02 in)
.
iBR and VTS
Intelligent Brake and Reverse activated by a LH lever.
Description Electronically-controlled iBR gate to provide brake, reverse.
neutral and forward position
Forward Approx. from +8° to -4°
Gate angle (from horizontal line of Neutral Approx. -52°

watercraft) Braking Approx. -70°
VTS system Electronically-controlled through the VTS control button

12 V, 80 A max. capacity. Reversible PWM
Actuator
(pulse-width modulation) motor
Ory weight 388 kg (855 lb)

Load limit (passenger and 10 kg (22 lb) luggage) 272 kg (600 lb)
DIMENSIONS
Overall height 116.6 cm (45.91 in)
MATERlALS


Ven turi Aluminum
Nozzle Aluminum
smr2010-048 733
734
WIRING DIAGRAM
Section 09
Subsection 01 (WIRING DIAGRAM INFORMATION)
WIRING DIAGRAM INFORMATION

__
GENERAL
L
PK- BK- _Q_l.-;..- ..- -F -U-EL - L-EV E L ...
- PK-_Q_ I--<.�""""'"
WIRING DIAGRAM LOCATION
SENSOR
-Vl-RD-i-=8'"'1��-
The wiring diagrams are in the back cover pocket.
P
WIRING DIAGRAM CODES 1 ,-A ...___. F
______ L_
uE_ r_
uM_
_
Wire Color Codes
•mr2009 -04 5-00 5_o
1. Terminal position
------ YL-BK------
1 \ On a connector, a letter or a digit is usually molded
1 2 on the connector to identify the terminal position.
1. Wire main color

2. Tracer (thin colored line)
General Wire Color Use
COLOR USE
Battery power (12 Vdc directly
RED
connected to battery)
Fused 12 Vdc power or switched

RED+ tracer
power from relay
VIOLET or Fused 12 Vdc power from

VI 0LET + tracer fuse box
Alternating current (AC)

YELLOW
from magneto
BLACK G ro und TYPICAL

1. Wire identification numbers
BLACK + tracer Switched ground (by ECM)
WHITE/RED CAN HI wires Terminal Identification on a Wiring

WHITE/BLACK CAN LO wires Diagram
In-line connectors of wiring harnesses are identi
Color Codes fied on the wiring diagram with their approximate
location and the following information.
COLOR CODES
CODE COLOR CODE COLOR
BE TAN OR ORANGE
BR BROWN PK PINK
BU BLUE RD RED
BK BLACK VI VIOLET
GN GREEN WH WHITE
GY GRAY YL YELLOW
Terminal Identification on Connector

On the wiring diagram a letter or a digit is used to
,
identify the terminal position in a connector.
smr201Q.048 735
Section 09 WIRING DIAGRAM
Subsection 01 (WIRING DIAGRAM INFORMATION)
i!i
17
s I <f2� � �
18 � � ...
m
� � i ! ;;: !C �� I
.. "'
16
� ;
� :! It
i �
i � �I
7 i
I I
I
I
I
I
I
�·
2 3 11 1 2 9 19 20 10 UI
---.J
- (II (') ... .,., co � ti. ti, � J> !: z
C'5 5
I BUS CAN HI
I I BUS CAN LOW
I
TYPICAL
1. CAN wire
2. Wire origin
2 3 3. Destination terminal (as referenced at ECMJ
smr2009--0 4�-•
TYPICAL
1. Connector location
Fuse Box Terminal Reference
2. Connector identification (reference number)
Refer to POWER DISTRIBUTION AND GROUNDS
3. Number of pins
subsection.
CAN Wire Circuit References
Component Application
On the wiring diagram, CAN linked components
If a component in the wiring diagram is not appli
use the following coding.
cable to every vehicle model, or can be installed
as an option or accessory on certain models, the
2 1 component shall be enclosed in a dash line.
I .I B·MI
riiiUJl Wi411 _t:_" o.c1
F82.cl mlK·------- 8-C2
""'2009-045-007_.
TYPICAL
1. CAN wire
2. Wire destination
FB2: Fuse box no. 2
Cl: Terminal Cl m fuse box no. 2
On the wiring diagram, corresponding CAN links

are identified at fuse box no. 2 using the following
coding.
1. Component(s) optional or applicable to certain models

2. Indicates each switch is a separate component
736 Smt2010·048
Subsection 02 (CONNECTOR INFORMATION)
CONNECTOR INFORMATION
SERVICE TOOLS
CRIMPING TOOL (HEAVY GAUGE WIRE) .............. .................... . 529 035 730 ......................................... 751
ECM ADAPTER TOOL. 529 036 166 ......................................... 74 1
..... . . . . . . . . . . . . . . . . . . . . . ........................................
ECM TERMINAL REMOVER 2.25 ................................................ 529 036 175 ......................................... 741
.
ECM TERMINAL REMOVER 3.36 ................................................. 529 036 17 4 ......................................... 741

AMP TERMINAL EXTRACTOR ..................................................... . 726503-1 ......................................... 743

DELPHI TERMINAL EXTRACTOR ................................................ . 12094429 ......................... 742, 745-748
FCI TERMINAL EXTRACTOR TOOL ............................................. 54241678 ................................. 746, 748
GM TERMINAL EXTRACTOR ...................................................... . . 12094430 ................................. 743, 750
PROCEDURES
MAGNETO AND ENGINE

CONNECTOR (DEUTSCH)
Connector Removal from its Support
1. Insert a small flat screwdriver between the sup
port and the Deutsch connector.
2. Pry the connector away from the support
slightly while sliding it out in the direction
shown.
TYPICAL - MALE CONNECTOR REMOVED FOR CLARITY

Connector Disconnect
1. To disconnect a Deutsch connector, press the
release tab and twist a small flat screwdriver
between the male and female housing to dis
engage and disconnect them.
s mr1009-045-00 9_a
MALE CONNECTOR REMOVED FOR CLARITY

smr2011·0<1.4 737
(CONNECTOR INFORMATION)
Subsection 02
2 Connector Disassembly and

Reassembly
FOOHIC A
F18ZOMA 1 2
TYPICAL - DEUTSCH CONNECTOR

TYPICAL
1. Mala connector
1. Release tab
2. Female connector
2. Deutsch connector
3. Secondary lock
4. Sealing cap
l.1•>ilH41Do not apply dielectric grease on ter

minal inside connector.
To remove terminals from connector. proceed as

follows:
1 . Using long nose pliers, pull out the plastic lock
from between the terminals.
f18ZONA 2 1
TYPICAL
2. Press release button
V O I GOO A 1
FEMALE CONNECTOR
1. Female lock
F18ZOl.A 2
TYPICAL
1. Flat screwdriver
738 smr2011-044
3. Pull back on the terminal wire to be sure the

retention fingers are holding the terminal.
4. After all required terminals have been inserted,
the lock must be installed.
V01GOPA 1
MALE CONNECTOR
1. Male Jock
NOTE: Before pin extraction. push wire forward

CONNECTOR PIN-OUT
to relieve pressure on retaining tab. 1. Terminal position identification numbers
2. Insert a 4.8 mm (.189 in) wide screwdriver

blade inside the front of the terminal cavity. ECM CONNECTOR (MOLEX}
3. Pry the retaining tab away from the terminal There are 2 connectors on the ECM.
while gently pulling the wire and terminal out
The engine wiring harness connector is con
of the back of the connector.
nected to ECM connector "A". The vehicle wiring
harness connector is connected to ECM connec
1
tor ·s·.
Each ECM connector has 48 pins.
ECM CONNECTORS
Connector Removal
V11 1 GOOA 1 1. To access the ECM, refer to ELECTRONIC
FEMALE CONNECTOR
1. Retaining tabs
2. Press and hold the locking tab on the connec
To install: tor to be disconnected.
1. For insertion of a terminal, ensure the plastic

lock is removed.
2. Insert terminal through the back of the connec
tor in the appropriate position, and push it in as
far as it will go. You should feel or hear the ter
minal lock engage.
smr2011-044 739
smr2009-04 5-0 I 3 _
b
s m r 2009-045-0l l_
a
CONNECTOR LOCKING CAM IN RELEASE POSITION
LOCKING TAB TO PRESS AND HOLD
2. Insert connector on ECM.
3. As you hold the locking tab, rotate the connec
tor locking cam until it stops. 3. As you push the connector onto the ECM, ro
tate the connector locking cam until it snaps
locked.
CONNECTOR LOCKING CAM ROTATION TO RELEASE
4. Pull connector off ECM.

1. Locked here
4. Ensure the locking tab is fully out.
smr2009·045-0 1 3 . a
Connector Installation
1. Fully open connector locking cam.
740 smr2011-044
5Z0036 1 65
1. Disconnect the ECM connector to be probed,

and reconnect it on the ECM adapter.
srnr2009-04 5-0 1 1_a

2. Probe wire terminals of the circuit to be tested
LOCKING TAB FULLY OUT
directly in the adapter holes.
Connector Inspection
Before replacing an ECM, always check electrical
connections.
1. Ensure connector locking mechanism is func
tioning properly.
2. Ensure all wire terminals (pins) are properly
locked in the connector.
3. Ensure they are very tight, make good contact
with the pins in the ECM.
4. Ensure the pins in the harness connector
and the ECM connector are clean, shiny and TYPICAL
corrosion-free. 1. ECM connector
2. ECM adapter
5. Check wiring harness for signs of scoring.
ffl1)i@j Never probe d irect l y on the ECM
NOTE: A "defective ECM module" could possi
harness connector This could change the
bly be repaired simply by disconnecting and recon
.
shape or enlarge the terminals and create in

necting it.
termittent or permanent contact problems.
lllt1)i{fij Do not apply any l ubri ca nt product
to the pins of the ECM connector. Connector Terminal Removal (Harness
Connector)
Connector Probing To remove a signal terminal from the ECM har
The most recommended and safest method to ness connector, use the ECM TERMINAL RE
probe the MOLEX (ECM) connector terminals is MOVER 2.25 (P/N 529 036 175).
to use the ECM ADAPTER TOOL (P/N 529 036 166). To remove a power terminal, use the ECM TERMI
This tool will prevent deforming or enlarging of NAL REMOVER 3.36 (P/N 529 036 174).
the terminals. which would lead to bad ECM ter
minal contact creating intermittent or permanent
problems.
smr2011·044 741
1. Remove rear protector from connector.

2. Pull out the connector lock.
1l![1)ffljj Before installing wire terminals in

the connector, ensure all terminals are prop
erly crimped on wires. After installation of
wire terminals in the connectors, ensure they
are properly locked by gently pulling on them
as if to extract them.
BRLS, TAS AND STARTER

SOLENOID CONNECTORS
(DELPHI)
Connector Terminal Removal
s m r2009-04S-025_ •
To remove a terminal (pin) from the connector, use
3. Insert tool to unlock terminal. a special tool such as the DELPHI TERMINAL EX
TRACTOR (P/N 12094429).
DELPHI TERMINAL EXTRACTOR (PIN 12094429)
NOTE: Grinding the tool end to a taper is required.

1. Carefully insert the tool in the space provided to
release the pin lock.
2. Push the pin out the front of the connector by
pushing on the wire.
1. Unlock here
4. Gently pull on the wire to extract the terminal

out the back of the connector.
742 smr2011-044
Subsection 02 {CONNECTOR INFORMATION)
s m r2009-0-i 5-0 1 6_ a
s m r20a9 -04S.01 4 _ a 1. Unlock terminal here

1. Unlock terminal here
2. G ently pull on the wire to extract the pin out the
back of the connector.
smr 2 009-0iS-01 S_a
lll1'1itf1j Before installing terminals in the

connectors, ensure all terminals are properly
crimped on the wires. After installation of the
wire terminals in the connectors, ensure they snv2009-045-017 _a
are properly locked by gently pushing on them

as if to extract them. l@t.Ji@j Before installing terminals in the
iBR AND iS POWER wire terminals in the connectors, ensure they
CONNECTORS (DELPHI) are properly locked by gently pushing on them
To remove a terminal (pin) from the connector, use SPS CONNECTORS (BOSCH)
a special tool such as the GM TERMINAL EXTRAC
TOR (P/N 12094430). Connector Terminal Removal
To remove a terminal (pin) from the connector, use
a special tool such as the AMP TERMINAL EXTRAC
TOR (P/N 726503-1).

GM TERMINAL EXTRACTOR (PIN 12094430)

smrZ011·04'1 743
sm r209
0 -045-0I S.. •
1. Pry out locking cap
1. Unlock terminal here
2. Release the pin in the front of the connector.

2. Gently pull on the wire to extract the pin out the
IN1Jil11j Before installing terminals in the

are properly locked by gently pulling on them smt\?009-045-0 2 1 _1
1. Unlock here
INFORMATION CENTER back of the connector.
CONNECTOR (DELPHI)
1. To remove a terminal from the connector, first
remove the locking cap in the front of the con
nector.
l.Y•lllilj Before installing terminals in the

744 smr2011-044
VTS, iS, MODE/SET

AND UP/DOWN SWITCH
CONNECTORS (DELPHI)
Terminal Removal
1. To remove a terminal from connector, first re
move the locking cap.
smr 2009·04S-028_a
IN•>i@j Before installing terminals in the

s m r 2 000-045- 0 2 3 a
_
1. Pry out locking cap are properly locked by gently pushing on them
2. C a refully insert the DELPHI TERMINAL EXTRAC
TOR (P/N 12094429) in the space provided to re
lease the pin lock.
24 PINSTEERING CONNECTOR
(APEX ERGOMATE)
1 2
DELPHI TERMINAL EXTRACTOR (PIN 12094429)
5
smr2010·050-004_a
APEX ERGOMATE 24-PIN CONNECTOR

1. Male connector
s. rn r2009-045-024_
a
2. Female connector
1. Unlock here 3. Safety lock
4. Locking cam
5. Connector sleeve
3. Gently pull on th e wire to extract the pin out the
Connector Disconnect
1. Pull the red safety lock out of the locking cam.
smr2011 ·044 745

529C)3
6188
2. Probe the applicable circuit using the test con-

nector on the diagnostic harness.
smr:l01 0-0Sll-OOS_a
Step '/: Pull RED safety lock back

IMoi[ljj Attempting to probe the connector
without using the diagnostic connector may
2. Press the tab on the side of the connector damage the connector pins, or even cause a
sleeve. short circuit if test in g an energized circuit.
Extracting Pins (Female Connector)

To release on e of the 16 small pins towards the
middle part of the connector, use the FCI TERMI
NAL EXTRACTOR TOOL (P/N 54241678).
FCI 54?4t678
FCI TERMINAL EXTRACTOR TOOL (P/N 54241678)
To release one of the 8 larger pins towards the

Step 2: Press tab outer part of the connector. use the DELPHI TER
MINAL EXTRACTOR (P/N ·12094429).
3. Pull the connector sleeve back. The cam will
rotate and unlock the male and female connec
tors.
DELPHI TERMINAL EXTRACTOR TOOL{P/N 12094429)
NOTE: G rinding the DELPHI TERMINAL EXTRAC

TOR (P/N 12094429) end to a taper is required to
allow insertion of the tool between the lock and
the pin.
Step 3: Pull connector sleeve back
4. Pull the connectors apart.
Connector Probing
1. Disconnect the APEX ERGO MATE connector in
the vehicle and connect it to the DIAGNOSTIC
HARNESS (P/N 529 036 188).
746 smr2011-04<1
FEMALE CONNECTOR
1. Secondary pin lock
2. Retaining tabs
1. Insert the DELPHI TERMINAL EXTRACTOR

(P/N 12094429) in one of the holes at the end of
the secondary lock (the white plastic insert in
the connector). s mr20l 0 -050.0l0_•
Steps 2 and 3: Gently pry to release secondary lock (both ends)
3. Repeat the previous step at the other end of

the secondary lock and pull it up to the detent
position. This will allow unlocking of the pins.
NOTE: It is not necessary to remove the sec
ondary lock.
4. Insert the extractor tool in the small hole adja-
cent to the pin.
NOTE: Push the extractor tool in only as far as
required to release the lock from the pin. The
tool should slide along the pin and be inserted
between the pin and the lock.
•mr2010-0;o.()()9
_a
Step 7: Insert extractor tool here
2. Gently pry the tool towards the center of the

connector to release one end of the secondary
lock, then pull it up slightly.
EXTRACTING A SMALL PIN

Step 4: Insert FCI terminal extractor tool (PIN 54241678) in round
hole
A. Pin hole
smr2011-044 747
DELPHI TERMINAL EXTRACTOR TOOL (PIN 12094429)
NOTE: Grinding the DELPHI TERMINAL EXTRAC

TOR (P/N 12094429) end to a taper is required.
1. Using a pair of thin long nose pliers, pull the
secondary lock up to the detent position (the
white plastic insert in the connector). This will
allow unlocking of the pins.
smr201 0-<l50.0 l 2.
a
EXTRACTING A LARGER PIN !Lft'1itJJI

Do not attempt to remove the sec
Step 4: Insert the DELPHI terminal extractor (PIN 12094429) in ondary lock or damage will occur. Be careful
square hole
not to bend the pins when using the pliers.
A. Pin hole
unr2010-050-<l14..a
MALE CONNECTOR
Step 1: Pull on secondary lock here
SECONDARY LOCK REMOVED FOR CLARITY

1
1. Pin stop
2. Pin lock
3. Exrractor toot inserts here
4. This pin is not locked and pushed back

Extracting Pins (Male Connector)

To release one of the 16 small pins towards the
middle part of the connector, use the FCI TERMI
NAL EXTRACTOR TOOL (P/N 54241678).
smr20I O-OS0-01 5_e
MALE CONNECTOR
1. Secondarv lock in detente position
.,,, . 20 1 0 -052. 0 02
FCI TERMINAL EXTRACTOR TOOL (PIN 54241678) 2. Insert the extractor tool in the small hole adja-
cent to the pin.
To release one of the 8 larger pins towards the
outer part of the connector. use the DELPHI TER NOTE: Push the extractor tool in only as far as
MINAL EXTRACTOR (P/N 12094429). required to release the lock from the pin. The
tool should slide along the pin and be inserted
between the pin and the lock.
748 smr2011-()44
•• ,,�010°050-01 6_•
SMALL PIN EXTRACTION

Step 2: Insert FCI Terminal extractor tool (P/N 54241678) in small
round hole
srnr20 10-050-018_e
SMALL PIN INSERTION

1. Notch
2. Stepped portion towards nocch
4. Push the pin in until the pin lock engages the

pin.
5. Gently pull on the pin to ensure it is properly
locked.
6. Repeat previous steps for each pin to be in
serted.
"""2 0 11).05().()1 7 _•
7. Push the secondary lock into the connector to
LARGE PIN EXTRACTION
the locked position.
Step 2: Insert DELPHI terminal extractor (PIN 12094429) in square
hole
Reconnecting the APEX ERGOMATE
3. Gently pull on the wire to extract the pin out the Connector
1. Insert the male connector into the female con
Inserting Pins nector so the lock pin inserts into the lock cam.
1. Ensure the terminal (pin) is properly crimped

onto the wire.
2. Ensure the secondary lock (the white plastic in
sert in the connector) is up in the detent posi
tion.
3. Insert the pin in through the back of the connec-
tor.
NOTE: When inserting a small pin, insert the
stepped portion facing the notch in the connector
pin hole. The large pin does not have a specific
orientation.
.,,,20
, 1 �00 1 9_..
Seep 1: Insert male connector in female connector

A. Lock pin
B. Lock cam
2. Push the female connector sleeve over the

male connector to rotate and fully engage the
locking cam.
smr201l-044 749
GM TERMINAL EXTRACTOR (PIN 12094430}
Step 2: Push female connecror sleeve over male connector
3. Push the red safety lock into the locking cam.
Step 2: Insert GM extractor tool (PIN 12094430)

Smr2D10-05().(X)5_b
Step 3: Push safety lock ;nro locking cam
VOLTAGE
REGULATOR/RECTIFIER
CONNECTOR (FURUKAWA)
Terminal Removal
1. Remove the secondary lock (plastic insert).
smr2 01 0-050-023.o
Step 3: Pull wire to extract pin
IW•>itflj Before installing terminals in the

BATTERY CABLES
smr201 0·050-021 _0
Battery Cable Crimping
Step 7: Remove the secondary lock Carefully strip the wire approximately to 10 mm
(3/8 in) in length, using a wire stripping tool or
2. Carefully insert the GM TERMINAL EXTRACTOR sharp blade/knife.
(P/N 12094430} between the lock and the pin to
release the pin.
750 smr'2011-044
A32E20A
A. 7 0 mm (3/8 in}
NOTE: Make sure not to cut wire strands while

stripping the wire.
Install the appropriate terminal on the wire ac A32E2SA
cording to the requirement. Refer to appropriate POSITIONING THE CRIMPING PLIERS

PARTS CATALOG. Step 1: Press
Step 2: Rotate
After positioning the crimping pliers, crimp the ter

minal already installed on wire.
A32E2AA
INSTALLATION OF TERMINAL
Follow the instructions provided with the CRIMP

ING TOOL (HEAVY GAUGE WIRE) (P/N 529 035 730)
to select the proper positi on of the tool.
A32E2TA
529035 730
CRIMPING OF WIRE
NOTE: Different wires require different crimping
pliers settings so make sure to follow the instruc
,
tion supplied with the tool.
A32E2UA
PROPERLY CRIMPED WIRE
To verify if the wire is properly crimped, apply

,
some pulling force on wire and the terminal at the

same time from both directions.
l+![oi@j Never weld the wire to the terminal.

Welding can change the property of the wire
and it can become brittle and break.
smr2011·044 751
Install the protective heat shrink rubber t ube on

the terminal. Heat the heat shrink rubber tube us
ing the h eat gun so that it grasps the wire and the
terminal.
IWumJj Make sure that the protective heat

shrink rubber tube has been properly installed
and no part of wire is exposed.
752 smr2011-044
2011 SEA-DOO COlOR.TABlE
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NOTES
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SE�DD. �
WATERCRAFT
SERVICE
Bulletin
November 2, 2010 Subject: Sea Level and High Altitude Impeller Charts No. 2011-2
2011 All All All
HIGH ALTITUDE PARTS RETURN

PARTS EXCHANGE/ Return the original UNUSED impellers. Attach
proof that replacement parts were purchased
L ABOR CREDIT from BRP (invoice or a packing slip).
PROGRAM Please return impellers using the same boxes that
This program allows dealers/distributors to return your high altitude impellers were shipped in.
new and resalable impellers and covers the labor The impellers must be returned within 30 days
time to change out the impeller. from the date the modification is performed.
The parts must be new and in resalable con
ffl.J@ljj The technical recommendations
dition. Parts will be inspected when received,
contained herein apply only to the current
and if damaged, will be returned to the dealer
model year watercraft operating between
without credit.
900 m (3,000 ft) and 2 400 m (8,000 ft) above
sea level. PROGRAM ONLY APPLIES TO WATERCRAFT
MODIFIED BY THE DEALER!
File a claim on BOSSWeb or fill out a warranty
claim form (P/N 484 070 600) with the following HIGH ALTITUDE PARTS RETURN ADDRESSES
information:
Canadian Dealers
JOB CODE 05 70
Bombardier Recreational Products Inc.,
Claim Type 03 Predelivery Centre de pieces de garantie,
Warranty Parts Center,
Flat Rate lime 0.8 hour
565, de la Montagne,
Valcourt, QC JOE 2LO
NOTE: Claim comments should read: "High Alti
tude Parts Return" and the original impeller part U.S. Dealers
number should be listed on the claim, not the Bombardier Recreational Products Inc.,
high altitude one. Filing a claim other then the 7575 Bombardier Court,
way herein described will cause the claim to be Wausau, WI
rejected. 54401
Purchase from Bombardier Recreational Products International

Inc. (BRP) the necessary parts for high altitude ap
All parts must be returned to your
plication. Anything other than a BRP part will not
distributor or BRP regional office.
be accepted.
Please contact them for complete address
and shipping information.
Printed in Canada. (sbs2011·006 en AP)

1 I 5
®™ and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates.
SEA LEVEL SPECIFICATIONS
WATERCRAFT IMPELLER
Model Impeller I Venturi

Model Engine Pitch Angle (0) Part Number
Number Diameter (mm)
GTI™ Series
GTI 238A
130 11-18 155/84 267 000 532
GTI inti 2388
GTI SE 248A, 248C

130 11-18 155/84 267 000 532
GTI SE inti 2488
GTI Limited 398A

155 11-18 155/84 267 000 532
GTI Limited inti 3988
GTI SE 308A
155 11-18 155/84 267 000 532
GTI SE inti 3088
GTS™ Series
GTS 438A
GTS inti 4388 130 11-18 155/84 267 000 532
GTS inti (Rental) 258A
GTS PRO 448A 130 11-18 155/84 267 000 431
GTXt Series
GTX 388A
155 11-18 155/83 267 000 577
GTX inti 3888
GTX 428A
215 10-21 159/83 267 000 575
GTX inti 4288
GTX iS 338A 215 10-21 159/83 267 000 575
GTX LTD iS 188A

260 14/23 159/83 267 000 567
GTX LTD iS inti 1888
RXP™ Series
RXP-X 328A 14-24 159/87 267 000 444

255
RXP-X RS inti 3288 14-25 159/87 267 000 481
RXT™ Series
RXT 178A
260 14-23 159/83 267 000 567
RXT inti 1788
RXT iS 348A
260 14-23 159/83 267 000 567
RXT iS inti 3488
t GTX is a registered trademark of Castro! Ltd, used under license.
2I 5 2011-2 SERVICE
WATERCRAFT IMPELLER

RXT™ Series (cont'd)
RXT-X 31BA
260 14-23 159/83 267 000 567
RXT-X RS inti 3188
RXT-X aS 418A
260 14-23 159/83 267 000 567
RXT-X RS as inti 4188
WAKE™ Series
WAKE 358A
155 11-18 155/84 267 000 532
WAKE inti 3588
WAKE PRO 268A

215 10-21 155/83 267 000 575
WAKE PRO inti 2688
SERVICE 2011-2 3I 5
HIGH ALTITUDE SPECIFICATIONS
Models equipped with variable trim system (VTS) must have nozzle set to 0° for optimum skiing facility.
NOTE: Test altitude: 1 676 m (5,500ft).
WATERCRAFT IMPELLER

GTI™ Series
GTI 238A
130 11-17 155/84 267 000 600
GTI inti 2388
GTI SE 248A, 248C

130 11-17 155/84 267 000 600
GTI SE inti 2488
GTI Limited 398A

155 11-17 155/84 267 000 602
GTI Limited inti 3988
GTI SE 308A
155 11-17 155/84 267 000 602
GTI SE inti 3088
GTS™ Series
GTS 438A
GTS inti 4388 130 11-17 155/84 267 000 600
GTS inti (Rental) 258A
GTS PRO 448A 130 11-15 155/84 267 000 447
GTXt Series
GTX 388A
155 11-16 155/83 267 000 594
GTX inti 3888
GTX 428A
215 10-19 159/83 267 000 596
GTX inti 4288
GTX iS 338A 215 10-19 159/83 267 000 596
GTX LTD iS 188A

260 14-22 159/83 267 000 598
GTX LTD iS inti 1888
RXP™ Series
RXP-X 328A
255 14-23 159/87 267 000 456
RXP-X RS inti 3288
AXT™ Series
AXT 178A
260 HP 14-22 159/83 267 000 598
AXT inti 1788
AXT iS 348A
260 14-22 159/83 267 000 598
AXT iS inti 3488
t GTX is a registered trademark of Castro! Ltd, used under license.
4I 5 2011-2 SERVICE
WATERCRAFT IMPELLER

AXT Series (cont'd)
RXT-X 31BA
260 14-22 159/83 267 000 598
RXT-X RS inti 3188
RXT-X aS 418A
260 14-22 159/83 267 000 598
RXT-X RS as inti 4188
WAKE™ Series
WAKE 358A
155 11-17 155/84 267 000 602
WAKE inti 3588
WAKE PRO 268A

215 10-19 155/83 267 000 596
WAKE PRO inti 2688
SERVICE 2011-2 5I 5
WATERCRAFT
� SERVICE
� Bulletin
February 10th, 2011 Subject: SEA-DQQf> Paint Codes & Gelcoat No. 2011-5

2011 All All All
PAINT CODES
These paints should be used for minor touch-ups only.
Actual finish on hulls is gelcoat, not paint. See further in this bulletin for gelcoat information.
CORRESPONDING PAINT CODES
BRP COLORS B.A.S.F., R-M PPG
5801-88-01 White 88643 DCC 98192
B-160 Deep Black 85366, RM 85366 DCC 95066 I DBC 9554
B-176 Viper Red 94820 DCC 74790
B-212 Scarlet Red 98088 N/A
B-286 Swift Silver 796948 BC-DCC 00005
B-310 Cuban Orange 881951 N/A
B-311 Dragon Red 862181 FBCH SOL 926050
B-313 Vegas White 862276 FBCH MET/MICA926051
B-320 Casino Gold 870212 N/A
B-325 Marina Blue 865718 N/A
B-329 Alpine White 881950 N/A
J-805 Pewter Metallic 625331 N/A
M-506 Bright Yellow 88245, RM88152 N/A
N/A: Information not available at time of printing.
NOTE: Unless otherwise specified, gloss level for all colors is High.
GELCOAT
This is a reminder that all liquid gelcoat and repair kits can be purchased directly from Gelcote* Interna
tional Ltd. BRP does not distribute these products.
Gelcote International Ltd web site has all the Sea-Doo personal watercraft and sport boat gelcoat colors.
:I: Gelcote is a trademark of Gelcote International Ltd
Printed in Canada. (sbs2011·002 en AB)

1 I 6
®™ and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates.
You can order on the web site and get confirmation of your order within hours. Quick, reliable service is
what is offered to all BRP dealers around the world.
There are many services on this web site to make your ordering quick and informative. Or you can call
Gelcote International directly with any question pertaining to gelcoat. Service, value and knowledge is
what you can expect when you call Gelcote International.
Gelcote International Ltd

174 Colonnade Road Suite 29
Ottawa, Ontario
Canada, K2E 7J5
Phone: (613) 225-2177

Phone: {877) 435-2683 {Toll Free)
Fax: (613) 225-5297
Web Site: www.gelcoat.ca

E-mail: info@gelcote.com
WATERCRAFT COLOR CODES

GT/ MODELS
8-160
8-176
8-325 5801-88-01 8-160
5801-88-01
8-160
8-176
8-32 � ........
8-160
smo2011-003-00 2 J>
GT/, GT/ SE AND GT/ LIMITED
2I 6 2011-5 SERVICE
GTS MODELS
B-176
B-160
5801-88-01
smo2011-003-001_c
GTS RENTAL (INT'L) AND GTS
WAKE MODEL
B-160
B-160
smo2011-003-003_c
GTX MODELS
B-212 J-805 B-212
B-160
5801-88-01
B-160
smo2010-002-001_c
GTX
SERVICE 2011-5 3I 6
B-160
B-160
smo2009-002 - 1 oo_e
GTX LIMITED iS AND GTX iS
RXT MODELS
B-160
B-160
obs2011.Q02-001_a
RXTiS
4/ 6 2011-5 SERVICE
8-160 -----====---
smo201Hl02-008_b
RXT
RXT-X
8-160
smo2011-002.002_b
RXT-X aS
SERVICE 2011-5 5I 6
WAKE PRO MODEL
8-160
smo2011-002-001_b
GTS PRO MODEL
8-160
smo2011-001-00 2_c
RXP-X MODEL
$n'I020l 1-001-001_c
6I 6 2011-5 SERVICE
ADVANCED TEC™ iCATCH™ I
Overall width
Width between walk pad1 4' 3•
Overall height (walk pad)2 32"
Overall height (iCatch)3 3•3•
Coupler 2.0·
Approx. weight 3601bs

Shown with optional accessories
Carrying capacity 1,200 lbs
With never-seen-before industry

firsts like an iCatch and release
system, a walk pad and roller bunk,
Sea-Dao Advanced TEC iCatch
iCatch and release system eliminates traditional winch Walk pad guidance system Premium rolle r bunk system
and tackle process, simplifies launching and loading. allows you to conveniently allowing for smooth and Trailer is so over and above
Works in conjunction with walk pad guidance system. walk around to access your resistance free PWC manipulation
PWC. Doubles as a guidance when launching and loading.
the competition, it clearly pays
Patentpending
system for a trouble free
mooring process. Launch
to have the best.
and load in seconds.
ADVANCED TEC I
Overall length 13' 6°
Overall width 5' 10"
Width between fenders1 4' 7'
Overall height (fender)2 23'
Overall height (winch)3 31'
Coupler 2.0"
Approx. weight 2601bs
Carrying capacity 1,300 lbs

USA I ' Maximum PWC width 1 Coupleron ground ' Coupleron hitch at 16" above theground
Marine Jack and Stand - 295 100 399
INCLUDED ADVANCED TEC iCATCH I ADVANCED TEC I

Rugged and durable
• •
hot-dipped galvanized finish
8 adjustable rollers
•
(4" left to right, 8-degree angle)
Adjustable iCatch system •
Non-marking rollers •
Blow molded walk pad •
Alloy Mag Wheel Kit - 295 100 401 2 adjustable wooden bunks with carpet
•
(sold in pairs with center cap & nuts) (4" left to right, 8-degree angle)
Adjustable winch strap •
Multi adjustable axle • •
Torsion rubber suspension • •
Tire size: 4.80 x 12 • •
Bolt pattern: 5 bolts on 4 1/z" diameter • •
Ground wired • •
Fully enclosed wiring harness • •
Submersible lights • •
Coupler stand • •
Suspended plastic fender

• •
Spare Tire Support - 295 100 400 for better splash protection
Safety cable • •
No-maintenance sealed bearing • •
RETAIL PRICE $1,399.99 $799.99

* *
WARRANTY 1/5 year 115 year
REQUIRED OPTION RETAIL PRICE

iCatch bow cup
$39.99
(295 100 403)
OPTIONAL
RETAIL PRICE
ACCESSORIES
Marine jack and stand $69.99 • •
Spare Wheel Assembly - 271 001 676 Alloy mag wheel kit $399.99 • •
Spare tire support $64.99 • •
Spare wheel assembly $89.99 • •
Walk pad carpet kit $119.99 •
*One year complete warranty and 5 years on frame and axle.
©2009 Bombardier Recreational Products Inc., (BRP). All rights reserved. ™,®and the BRP logo are trademarl<s of Bombardier Recreational
Products Inc. or its aff iliates . In the U.S.A., products are distributed by BRP US Inc. In Canada, products are distributed by Bombardier Recreational
Products Inc. Because of our ongoing commitment to product quality and innovation, BRP reserves the right at anytime to discontinue or change
specifications, price, design. features, models or equipment without incurring any obligat ion. Printed in Canada.
Walk Pad Diamond Plate Carpet Kit

295 100 398
T1£ GOOD LIFE JUST &OT BETTER"
I have removed certain pages from this technical update
book that contained dealer only contact information.
The contact information required a valid dealer number

and is useless to the general public.
If you bought this manual from any other seller, they are reselling my work.
Please leave them negative feedback & email me at saJes@green-manuaJs.com .
Our goal is to be one of the BEST sellers on eBay and the internet by providing you with
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For a Better Tomorrow www.midwestmanuals.com
2011 Technical Update Book
TECHNICAL UPDATE BOOK and the DEALER CERTIFICATION PROGRAM

(for North American dealer only):
This Technical Update Book and it's associated exam are critical components of your Dealership Certifi
cation Level and your Technicians Training Status.
To maintain or achieve Gold or Platinum status two technicians must complete the training provided by
this book by passing the exam with 75% or higher scores. Technicians must complete this training to
achieve or maintain their Technician or Certified Level training status. Master Technicians must complete
this training and pass the exam on the first attempt with a 90% or better score. Training must be com
pleted prior to the deadline.
Enjoy the Update Book and good luck on the exam. See page 36 for details on Technical training.
LEGAL DEPOSIT:
NATIONAL LIBRARY OF QUEBEC
NATIONAL LIBRARY OF CANADA 2011
All RIGHTS RESERVED. NO PARTS OF THIS MANUAL MAY BE REPRODUCED IN ANY FORM W ITHOUT
THE PRIOR WRI TIEN PERMISSION OF BOMBARDIER RECREATIONAL PRODUCTS INC. (BRP)
c BOMBARDIER RECREATIONAL PRODUCTS INC. (BRP) 2011
PRINTED IN CANADA
TECHNICAL PUBLICATIONS
BOMBARDIER RECREATIONAL PRODUCTS INC. (BRP)
VALCOURT (QUEBEC) CANADA
41TM TRADEMARKS OF BOMBARDIER RECREATIONAL PRODUCTS INC. (BRP) OR ITS AFFILIAT ES.
• TRADEMARKS OF BOMBARDIER INC., USED UNDER LICENSE.

ROTAX 41
STEP BY STEP INSTRUCTIONS ON HOW TO DO THE EXAMS ON BRPTI :
(for North American dealer only)
If you are new to BOSSWeb and BRPTI OR you have a BRPTI login but not set up as a user in
BOSSWeb:
- Ask your dealership's BOSSWeb administrator to create your profile in BOSSWeb by making sure that
all the personal information fields are completed and the Training, BRPTI role BRP Dealer Employee
BRPTI responsibility is checked off in your profile.
- If you have a BRPTI login, your BOSSWeb administrator must make sure your first name, last name,
date of birth and gender are the same in BOSSWeb as they are in BRPTI.
If you already have a personal login to BOSSWeb and have BRPTI access:
1. Access BRPTI via BOSSWeb!Training/BRPTI.
2. In the "Resources" box, click on "Courses".
3. Check "English", click on "Start search - GO".
4. Find 2011 Sea-Doo Technical Update in the list of courses.
5. Click on the Info/Enroll icon at the right of the course name.
6. Click on "Enroll" at the bottom right of the screen.
7. Click on "OK" in the pop-up box to enroll to this course.
8. Click on "updated learning plan" in the confirmation paragraph or click on "Home" in the "Resources"
box. This will take you back to your home page where you will see the course (exam) is now in
your "Training Activities T O COMPLETE" section.
9. In the " Training Activities T O COMPLETE" section, click on the 2011 Sea-Doo Technical Update
course title to start your exam.
- To pass the Technical Update Exam, a technician must pass with a 75% or greater score.
- To achieve or maintain Technician Level status, a technician must have completed all applicable
Technician Level Exams after viewing the DVD series, and pass all Update exams for the appropriate
products carried by the dealership.
- To qualify for the Certified Technician Level course, a technician must first achieve and maintain
Technician Level Status.
- To maintain Certified Technician Status, a technician must stay current by passing all subsequent
Technical Update Exams for the product lines completed at the Certified Technician hands-on school.
- To qualify for Master Level Status, a technician must meet the criteria below.
Master Technician Level criteria:

- Minimum of 5 years as a Powersports Industry mechanic.
- Minimum of 2 years at your current BRP dealership.
- Maintain Certified Technician Level for at least one year.
- 90% or higher, on 1st completed score, on Technical Update exam(s).
Table of Contents
Page
General Information ... .... .. .... ...... ... .............. .. .. .......... ............. . 1
IT'S EASY TO REACH US ................. ........................... ............................ .. 2

.
North American Service Toll-Free Number ................................................................. 2

Before You Call the Service Department . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . 4
DEALER TECHNICAL SUPPORT .......... .............. ................. ...... ........ ............ 5

Canada and USA ................................................ ......... ....... . ............... ................ 5
Outside North America After Sales Support ....... . ............ ... . .............. . . ....................... 5
Australia and Asia excluding Japan .......................................................................... 6
BRP Japan ........................................................................................................ 6
Europe Middle East and Africa................................................................................ 6
Caribbean and Latin America ................................................................................. 6
BRP Scandinavia................................................................................................. 6
CUSTOMER ASSISTANCE CENTERS ...... ............... .......................... ..... ....... . 7

Call the Customer Assistance Center ........................................................................ 7
Customer Assistance Center for North America .. . . . . . .. . . . ..... . . . ..... . . . ..... . . . ..... . . . ..... . . . ..... . . 7
Customer Assistance for Countries within Europe, Middle East, Africa, Russia and CIS ........... 7
Customer Assistance for Scandinavian Countries ......................................................... 7
Customer Assistance for All Other Country................................................................. 8
Legal Coordinator ............................................................................................... 8
WARRANTY ........ ................ ........................... .. ........................... .... ........ 9

Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Parts Return ....................................................................................................
10
Fiberglass Warranty and Repair ............................................................................ 10
B.E.S.T. (BRP EXTENDED SERVICE T ERMS) .............................................................. 10
SUPPLIER INFORMATION ........................................................................ 12

Radio, CD Player, Remote Control, and Speakers........................................................ 12
Infinity Wakeboard Tower Sound System................................................................. 15
ROSWELL Tower Speaker System.......................................................................... 15
Wet Sounds Amplifier Warranty ............................................................................ 16
.................................................................................................................... 18
GPS Warranty and Repair for North American Dealers:................................................ 18
GPS Warranty and Repair for All Other Country Dealers:.............................................. 18
Trailer Warranty and Repair ................................................................................. 18
SEA-000 BOATS INFORMATION............................................................... 19

Fishhawk (For dealer only)................................................................................... 19
Johnson/Evinrude (For dealer only)........................................................................ 19
Mercury (For dealer only).................................................................................... 19
BOSSWEB ACCESS FOR SERVICE DEPARTMENT PERSONNEL . .. ..................... 20
"WHAT'S NEWS" LETTER........................................................................ 26

Hot Tips and Tricks From Your After Sales Group, Posted Weekly.................................... 26
WHAT'S NEWS ARCHIVES . ............ ... ...... ................... .... .. ...... ................. 28
REPORTS ON PERFORMANCE AND QUALITY . ...... ............................. .......... 33

RPO .............................................................................................................. 33
IMPORTANCE OF POI .............................................................................. 34

Was the POI Check List properly filled and filed? .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2011 Technical Update Book - Sea-Doo PWC and Sport Boats

Table of Contents
BRP ELECTRONIC PARTS CATALOG ..................... ............................ .......... 35

PartSmart version 8.9.28 ..................................................................................... 35
BOSSWEB TIPS AND TRICKS: E.T.A............................................................ 36

Parts Availability Screen ............... ................ ...................................................... 36
BOMBARDIER RECREATIONAL PRODUCTS TRAINING INSTITUTE .................... 37

The four steps to technician training....................................................................... 38
BOOK AND DVD QUICK PN REFERENCE ..... ........ ....................... ....... .......... 39
Training publications............................................ .............................................. 39
ACCIDENTS INVOLVING BRP PRODUCTS.................................................... 40

What To Do . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
What Not To Do................................................................................................ 40
Important Contacts In The Event Of A Major Accident, Serious Injury, Or A Fatality.............. 40
What's New .................................................................................. 41
ENGINE ... .... .. ...... .. ......... ........ .... ...... ..................... .. ........ .................... 42
WATERCRAFT ..... ........................ ............................. ............................. 45
SEA-DOO BOATS ............ .................................. ............................. ........ 55
Troubleshooting and Tech Tips..................................... 63
New Technologies ................................................................... 93
SEA-DOO INTRODUCING THE ALL NEW GTI SERIES...................................... 94
Special Tools............................................................................. 101
Specifications .......................................................................... 123
Annexes ........................................................................................ 163
BRP REBUILD CENTER ...... ................................ ........................... ......... 164
REPAIRS COMPLETED WHILE VEHICLE'S WARRANTY EXPIRED . .. .................. 170
QUICK REFERENCE CARD .. ........... ... ..... ....................... .... .. .. .... .............. 171
BRP OILS AND LUBRICANTS .............................. ........................... ......... 173
REPORT ON PERFORMANCE QUALITY (RPO REPORT) ........ ..... ...... .............. 174
BRP ACCIDENT INCIDENT REPORT . ..................... ........................... ......... 175
2011 Technical Update Book - Sea-Doo PWC and Sport Boats

SED...•�DD. 0 Section
------ i1-
General Information
The objective of Section 1 is to make contacts between dealers and BRP as easy as possible.
In this section you will find the most important phone numbers, key contact names and the latest update
procedures to help you being more efficient.
2011 Technical Update Book - Sea-Doo PWC and Sport Boats 1

IT'S EASY TO REACH US
NORTH AMERICAN SERVICE TOLL-FREE NUMBER
NOTE: These references are only for North American dealers. If you are calling from a country outside
of Canada or the United States please refer to the DEALER TECHNICAL SUPPORTsection in this book.
2 2011 Technical Update - Sea-Doo PWC and Sport Boats

BEFORE YOU CALL THE SERVICE DEPARTMENT
Be prepared
The BRP Service Department values your call. In fact, you are the reason that we are here! Your input
and information are vital to our department, and accuracy is critical. In an effort to provide the best
service to you, we ask that you observe the following guidelines:
Review the service material that you already have
Check your service library for any publications that may assist you with your problem. Often the answer
is already in your hands in the form of manuals, bulletins, spec books, technical update books, What's
New letters, etc.
Check BOSSWeb
All bulletins and campaigns can be found on BOSSWeb. Verify the unit history on each vehicle to see
if there are any pending campaigns.
Have vital information close at hand
Many times you will be asked for your dealer number, the vehicle model, serial number and the
vehicle mileage/hours. You will also be asked if there is already a call identification number logged on
the vehicle or customer in question. Not having this information readily available is very common and
slows the system down for everybody.
Verify the customer's complaint
If you are contacting your Service Representative for assistance, you should be able to describe the
problem accurately, with factual information. Make sure the vehicle does what the customer says it
does; when he says it does it. If you cannot verify a problem, do not work on the vehicle. Do not
attempt needless repairs.
Verify the warranty status
Is the unit in warranty, out of warranty, or covered by a BEST contract (if applicable)? If it is covered by
BEST, have the contract number available as well as the maintenance history if available.
Take names and Call ID
Every BRP representative will identify themselves when answering your call. Do not complete the call
without noting who you spoke with. Your call may be logged in the computer system. Ask for the call l.D.
number and put it on the repair order.

WARRANTY
TIPS
NOTE: Please, do not forget:

- You have 21 days from the repair date to submit a claim.
- You have 45 days from the credit date to ask for a claim resubmission.
- North American dealers have 21 days to return your parts (please keep tracking number) and
documents to BRP from the date your claim is accepted.
NOTE: For North America, If you feel you will not be able to complete the repair before the end of
Warranty, but the vehicle before the end of warranty, please complete the Repairs Completed While Ve
hicle's Warranty Expired form available in the ComCenter section of BOSSWeb under Warranty Guide
and Forms. Fax this form before the end of the Warranty to the number at the bottom of the Form.
NOTE: For other countries dealers, please contact your local distributor or BRP Regional Office.
- You must keep the parts that are not requested to be returned to BRP 90 days after the credit date.
- You must register all vehicles within 10 calendar days from the date of delivery to the customer.
NOTE: You must keep on file all the following information about a vehicle.
- Signed POI checklist (keep for 10 years).
- Signed rider form (ATV only).
- Warranty registration form.
- Work/repair order (keep for 3 years from the credit date).
- Warranty claims (keep for 3 years from the credit date).
- Sublet work/repair receipts (keep for 3 years from the credit date).
- Notes on customer call.
NOTE: Your work orders must be able to provide key elements which describe and justify the
warranty claim:
The 3 C's
- Condition or Complaint: Description of customer complaint(s).
- Cause: The determination of which component(s) failed.
- Cure: The corrective action taken to fix the problem (repair and/or replace).
And
- Vehicle serial number.
- Reported date of failure/date of repairs completed.
- Mileage or hours on the vehicle.
- If applicable, authorization number issued by a service representative.
- Punched timecards of mechanics.
- Customer's signed authorization to perform the work (signature).
2011 Technical Update - Sea-Doo PWC and Sport Boats 9

PARTS RETURN
CANADIAN DEALERS USA DEALERS INTERNATIONAL DEALERS
Use label (P/N 484 500 001) Use label (P/N 480 901 601) All requested Warranty Parts must
be returned to your distributor or
BRP C/0 Warranty Parts Center BRP C/0 Warranty Department BRP Regional office. Contact them
565 De La Montagne Valcourt 7575 Bombardier Court Wausau for complete address and shipping
Oc JOE 2LO WI 54401 information.
Ensure the part returned is properly tagged and the correct copy of the BOSSWeb claim is included in
the packaging, otherwise this may cause a delay in processing your claim.
Dealers dealing with North West Co. Inc. must forward the parts, warranty claim and documents to their
respective distributor's office.
NOTE: For complete details concerning returning warranty parts, please refer to the Warranty Service
Guide on BOSSWeb.
FIBERGLASS WARRANTY AND REPAIR
There is a 60 month hull structural warranty on all 15' and longer Sea-Doo Boats only.
To claim use system 12.
You will need to get an authorization from a Service Representative if the cost of the repair exceeds $250.
Use these part numbers on your Warranty Claims:
- Hull {P/N 999 999 000)
- Deck (P/N 999 999 001)
- Ass'y (P/N 999 999 002).
B.E.S.T. (BRP EXTENDED SERVICE T ERMS)
NOTE: for details concerning this program refer to the BEST GUIDE in the COMCENTER SECTION OF
BOSSWEB.
""d2000-0o 1 ·1 00

SUPPLIER INFORMATION
RADIO, CD PLAYER, REMOTE CONTROL, AND SPEAKERS
Oelectroilics.
THE MOBILE ELECTRONICS COt.1PANV SINCE IS/7
If you should run across a JENSEN®, Voyager®, or Audiovox® product issue, have
your repair ·technician call ASA's experienced troublesho oting team while the product
is still installed and we'll help you sort out the problem.
• If the unit is determined to be a possible manufacturing defect, you will have to

provide the ASA rep with the following information:
• Dealer a ddress, contact name & phone number
• Model number
• Serial number
• Date of sale & Date of failure
• Vehicle identification number
• Posted labor rate
• Preferred method of payment for labor reimbursement
• Description of suspected defect and environment the defect occured
(INOP not appli.cable)
• We will imme diately ship a replacement unit and a. return call ta g back to you
within 24 hours of receiving the phone ca Tl. (An invoice will not be generated for
the part.)
• Upon receipt of the repl acem ent unit, dealers can then reuse the box to pack up the
defective unit, write the RAii on the outside of the box, apply the enclosed call tag,
and ship the defective unit back to ASA for thorough testing. The unit must be
returned within 30 days in order to recejve labor reimbursement.
• Once the unit is fully tested, ASA will determine what type of failure occurred and
compute the BRP Dealer labor credit per the attached flat rate schedule.
• ASA will mail the applicable labor credit check within 10 business days.
-
-
• Labor reimbursement will not be provided if:
• the unit is physically damaged
the defective unit is not returned
�BRP
•
• the unit is not returned within the 30 days
AJDIOVOX Voyager. CESIGNEU ro MOIJ,f 11011)

sdd 2008-0 02-120_en_1

BOSSWEB ACCESS FOR SERVICE DEPARTMENT
PERSONNEL
It has been brought to our attention that in many instances BRP service department personnel do not
have complete BOSSWeb accesses to view information in specific roles (functions) they need to properly
service vehicles and maintain dealership records. Many times this is due to the fact that the dealerships
BOSSWeb system administrator does not know what accesses to grant these personnel.
These accesses can only be granted by the dealerships BOSSWeb system administrator.
The following is a list for the minimum recommended specific roles for service department personnel.
Service Technician
E-Tec Injector Coefficient (Ski-Doo Only) Messages
Online Parts Catalogs Shop Manual
Document Rebuild Program
BRPTI (BRP Training Institute) Technical Publications
BOSSWeb e-Z learning Warranty Flat Rate
Diagnostic software What's News
Instruction sheets
Service Manager
Parts Availability & Prices Customer Satisfaction Index
Claim Status Document
Clothing Claim BRPTI (BRP Training Institute)
Parts Claim BOSSWeb e-Z learning
Unit History B.E.S.T. Guide
Unit Claim Diagnostic Software
Campaign Monitoring Instruction Sheets
Campaign Claim Messages
Scheduled Unit Maintenance PAC Price List
B.E.S.T plus Maintenance Claim Rebuild Program
PartSmart CD Password Shop Manual
Dealer Certification Technical Publications
E-Tec Injector Coefficient (Ski-Doo) Warranty Flat Rate
Online Parts Catalogs Warranty Guide & Forms
B.U.D.S. Access Codes What's News

Parts Manager
Dealer to Dealer Parts/Clothing Search PartSmart CD Password
Request Online Parts Catalog
Return Status Licensed Products
Parts History Document
Regular Order Entry BRPTI (BRP Training Institute)
Parts Availability and Prices BOSSWeb e-Z learning
Back Order List B.E.S.T. Guide
Return Entry Instruction Sheets
Shopatron Orders Messages
Shopatron Enrollment PAC Price List
View All Dealer Parts/Clothing Request Promotions
PAC order status Rebuild Program
Claim Status Shop Manual
Clothing Claim Technical Publications
Parts Claim Warranty Guide & Forms
Invoice Display What's News

BOSSWEB SYSTEM ADMINISTRATOR TIPS
The following is a step by step procedure for the dealership BOSSWeb system administrator on how to
add or remove BOSSWeb Web Roles and Authorized Document Types for the Service Manager, Techni
cian, Sales, and Parts profiles. The suggested roles will help make your department staff more informed
and knowledgeable with BRP products and procedures.
To give access to the sub users, please go to the administration tab, select "users".
BOSS Web
• l.t'i' I f � 'i!•
-.
, 1.•�-
� ........ ..... tli!'t ......
�-(:f.lit",•f, ,. \,• ��lf!-»t•l--"lt
sdd2011-002-101
Choose the user you want to give the accesses_
BOSS Web
•• .,,,�., '\'l'-
-- ..... .-........ -·
� � •U·Jlf•llll ....:.�··
. ··....... . .....
� '"l�.O •)J.tl:"lltl ,,..
.,... ,_
.....__ ..
� O.,,.(y01tI •))-flt>Jttl �....JffV't. tll« 0
- Co>OI.& •H-tJN.tU t.\;p �Oltitt -.1HD
� ·- .,oe��' 0111>-UO -t.trht;-...,.....
"1.Cll ..... .....i;I' •1>-111·11�1 -•llM°J._....l.,,O
sdd20 11-002-102
Select the accesses you wish to give that user.
l!!l 1'€J ccount

A Information �I
Username Password o nfir m
C Password
JWausau
Organi:zatioM ViewOol y Moae Expiration Date CSI Access Leve�
J0000694il07-VIRTUALC IEI (yYyY/mm/dd) ICSI ·Full Access 1vl

Roles Authora:ed O
ocuine nt Type:5
8 0�11 8 DAii
8 Osales 0 B.E.S.T Gu;de
�Seasonal Promotions � Dealer Binder
�Unit Order Confirmation � Dealer Signage Program
�Promotion Simulation � Diagnostic Software
�Le.sd Management �Engine Mapping
�Promotion Status: � ln::: trudion Sheets
�8.E.S�T. Contract Regi:tration D Insurance Solutions
�Unit Sbipping Information 0 Message::
�Unit Registration � P.A.C Price List
�Unit Locator � Prcmoti.ons
�Change of Ownership � Rebuild Program
�Change of Owner Coordinates � Shop Manual
8 D Psrts �Technical Publications
�Dealer to Dealer ParU/Clothin.g Search Request � Warf'anty Flat Rate
�Return Status: 0 Warranty Gu;de & Forms 1"'11

:i_l==================:,:,:,:,:,:,:,:,:,:,:,:,:,:,�
';.:,:,:,:,-;========-====== =================.,.], L > l
sdd2011-002-103

Click on the blue arrow forward to save changes
BOSSWell
A•-W •r\ '""'
p l Protfle Qmt t'mulatfcn
sdd2011-002-104
B.U.D.S. ACCESS CODES ARE NOW AVAILABLE ON BOSSWEB
A new Feature in BOSSWeb has been added to allow you to automatically get your access codes for
MPl-2 without having to contact BRP Service Representatives. This section for the BOSSWeb adminis
trator and Sub-Users who were given the "get B.U.D.S. access codes" role.
NOTE: This access is only for B.U.D.S. version 3.xx or newer.
NOTE: Please remember that these access code needs to be entered in B.U.D.S. on the same day you
get them from BOSSWeb. The access code will be invalid after 24 hours.
Under the ComCenter Tab, choose the "Get B.U.D.S. Access Codes" menu.
B'OSSWeb
,., . . , .. . , ...
- -- -
-� �, _..._
,. , ,....
...-
-- �.
Skl·Doo 2010
End of So;u;on
Riding Gonr SnlG
\\" I I�·�9I�:-$•¥tE
\ �V S O'lll••
t•A'l�.1,,,
sdd2011-002-105

The following screen shows the registered MPI serial numbers recorded previously from manual entries
done at the Call Center, that were purchased by your dealership.
BOSS Web
....,. .... loo!
·�
es-...
P.J,.._,..,
e........
el.,..
s.......
sdd2011.0 0 2-106
Select the specific MPI serial number you want the access code for by highlighting the serial number.
Then push the single arrow to the right for that serial number to be moved to the "to be generated" section.
MPI arid Pro.ducts Parameters {step-1-)
rn1wstficn(
To, be Hinted
10C>000154 1100000153
1 Ql'.(!00156
ic·:ooo1sa
8
�
10C-00015S
lOC-005051
"PJ"oducbi
0 Sno\Ymobile
0wnucnft
�SportBo•u
0ATV
� Sk:'e-by-Sloe v,ehli;IE
PJ&He dick on th• n•xt/Submit button to dl!play next st•?•
sdd2 011.002-107

Then push the blue submit arrow on menu bar to get your code.
e�
,
,comcenter - Get B.U.D.S. access code
Copy the code and type it or paste it in B.U.D.S. Access screen.
BOSS We
�, .... ,, , ....
101 l·�l..,lf.U .,.""D

� .... .fiN.t
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MPIJD 8.U.D.S. Access Code

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NOTE: : If the MPI 2 serial number is not listed in BOSSWeb, you will need to contact your service
representative, as you did in the past to have him add the serial number to our master database for future
access in BOSSWeb. The service representative will be able to generate a temporary code for you, so
you can start using B.U.D.S. immediately.
NOTE: If you no longer have the MPl-2 as listed, contact a Service rep so that it may be removed from
your list. This will cause the missing MPl-2 to eventually be deactivated permanently preventing unau
thorized use.

"WHAT'S NEWS" LETTER
HOT TIPS AND TRICKS FROM YOUR AFTER SALES GROUP, POSTED
WEEKLY
Once a week, the "What's News" letter is published on BOSSWeb. It provides the latest news from the
After Sales Department.
3 ways to access the "What's News" letters.
Go to BOSSWeb (www.bossweb.brp.com).
On the home page, select the "What's News" banner (1) which provides rapid access to the newly
published letters for 3 days.
After 3 days, the recently published letters can be accessed through the BOSSWeb home page for an
additional 4 days. To access them, choose What's News in the DOCUMENT TYPE drop down menu (2)
on the right side of the page.
All What's News publications are archived from the first day of publication and available though the COM
CENTER (3) section of BOSSWeb.
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They can be accessed by first selecting Document in the COMCENTER drop down menu (3).

In the SEARCH CRITERIA FIELD, choose "What's News" in the Document Type drop down box [4],
select the appropriate information in the other applicable drop down boxes, and click on the Submit
arrow [5].
The archived publications shall be listed in the Search Results field at the bottom of the page. Double
click on the publication name to view it.
li Oor.ument • Mir.rosoft lnternf!I Explorer (;J(QJ(RJ

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This is an example of a What's News letter.

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WHAT'S NEWS ARCHIVES
SEARCHING WHAT'S NEWS FOR A PREVIOUS ARTICLE - FIND FUNCTION
What's News the weekly publication from the BRP after sales service department is not only posted
weekly on BOSSWeb, it is put into an archive f ile and stored on BOSSWeb after the week is over. The
What's News files are archived all the way back to the year 2004. Valuable information can be found by
simply searching the files as described below.
.
NOTE: News are also archived on the B.R.P T.I. website.
To access the What's News archive files, begin by clicking on "document" under the ComCenter pull-down
menu.
BOSS eb
It E S l' L ·r S , � I) W .
PaltSmart u�nse Key

-----
Select "What's News" under "document type".
Eloi:u1nent Type
B .E.S.Tl'�uit!e
Dealer Binder
Dealer Signage Program
Diagnosl:ic Software
Engine Mapping
Instruction Sheets
lm;urance Solutions
Messaqes
PAC P�ce List
Promotions
Rebuild Progrartl
Shop Manual
Technical Publications
Warranty Rat Rate
Y.larran Guide: � Forms.
•
sdd 2 0 1 1 .002-,, 1

Enter in "archive" in the "search by keyword" window.
s.earch Criteria
Search By Keyword Document Type
Iarchive I 1/1/hat's News

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Then push the blue submit arrow on menu bar to access the archives.
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Double click on the years archive you would like to view.
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If the date of a particular What's News is known simply click on the appropriate bookmark to bring you
directly to that page.
�What's News Archive 2010.pdf - Adobe Reader GJ(g](g'J

..
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LAT E
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1±1 l!I] February 2010 REM INDER!r !Im�Vff. ara rll'IC! ig r Ula ! &O(Oe ct.151o!'Dm
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rwno h 6RPTI ur.der tne-
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To search by a key word click on "find" under the "edit" menu.
�ew Q.oc:ument Iools Y:Lindow
(trl+Z
5tuft+Ctrl+Z
Ctrl+',
•_ttl+.:
Ctrl+V
Copy File to Clipb,oard
Select All Chl A

.....
D�select All shift+ctrl+A
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LQ.ok Lip 5,elected W&d.
E.ind Ctrl+F
aearch Shift+Ctrl+F
Segrch Results
Prefereo_ces... Ctrl+K
Enter in a key word in the find window. (In this case• B.R.P.T.I." was entered).
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Finally hit "enter" on the key board. This will bring you to the next time it is mentioned in the document.
Each time "enter" is pushed you will be brought to the next topic with that keyword in the article.
iB.R.,P.T.I.
�ed Technician Training:
We iStJ• t\011-e �ngs In 3le 1!110 caii,.lllTJ Roaoste.t
Sen� In UOITTM. GA Jun�� .Al>P4l�O!'I can 'be
.•
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ooos �en Qt on
oossw�omce�eall!C'Certtt'icaUoo �n.
sd<l2011-00 2· 119
B.R.P.T.I.
Dealership's Tra1rung Status
Need« ft3:1l�a kno'w yoor dea1ersnips tratr:n g
g;�? Df:j )'OU '11a� as manag�e�r prrndpal of
rour�a1m111p t! is poss.I� �a vle>.wyouceoureteatrts
tra�·og attJinE)i Cl'1 BR?'!. Tra.nln.g tnstrtute (BfU7T�)
weDGlte In Otlf: qllCI: �!M! You .v11 need Supervisor
� you oo not nav? �PEfV$0r
rigors to 1t,•::.w ml5 repm. ..
r1gJ'ts It lS �tlnJl'e by JU& !!fln:t:n� In eourt>e number
sdd2011.002-120
B.R.P.T. 1�
2010 CSI (Customef' Satisf3Ction lnd�x) i5
now LIVE on BRPTI..
The NEW! 2010 C!:I eY;am is oa.- .. l',IE. on a�
Otle aate or lne exam !ii ..\II)' t. 2010.
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sd d2011-002-12 1

REPORTS ON PERFORMANCE AND QUALITY
RPO
RPO is the method BRP uses to find out what is happening in the network.
By calling or faxing the Reports on Performance and Quality you are helping speed up the investigation
process.
Quantity Counts
The quantity of RPOs we receive on issues helps determining priorities; an issue that is occurring on many
units will most likely be put in priority. Do not hesitate to report the same issue on different vehicles,
especially on the current model year.
This is an example of the information the Service Representative will enter in the data base:
Link or unlink RPQ reports and RPQs
I� �11 I Q GreateRP�
Transaction Description
Family Gode
System
VIN
Model desc
Model number
Description
Model' Year
Sales Org
Goal
Status """"'
pe,.,.
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Created from 2006/0 2/28
JIUII
to 2007102/28
Transaction No. # . Description Mode.I Number Description
I� Search
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�
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You will be asked:

- Dealer number
- Vehicle model/year
- Serial number
- Mileage/hours
- Possible digital pictures
- B.U.D.S. report
- Riding conditions when the failure occurred.
You will also be asked if there is already a call identification number logged in the system and a detailed
description of the issue.
A form is also available in the Annexes Section; it can be filled out and faxed to a Service Representative.
It is important that you tell us about your concerns: Report on Performance and Quality.

IMPORTANCE OF PDI
WAS THE POI CHECK LIST PROPERLY FILLED AND FILED?
Sell Value for the Money

Give the customer assurance that a proper pre-de
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livery inspection has been performed on the vehicle.
As well as the ability to show all the steps required WATERCRAFT PREDELIVERV CHECK LIST
flNA l INS'PECTIDN
to justify the expense of "set-up charges".
Professionalism
NO'Tf St•'"" l'i!.ft� n1 a�11rv� t'l'flV �W'Y 111.a llo'."1�•1;'11
ftltJltl!!tlt"V Tulttn.IOlll'$\a,1t1l+c: �J! l1tlldl'l't.'6bl!tt!..iSOI ·'W'i:I
In today's market place, customers have come to �O'dll, lt;ICI ltiilPPIOl't•tJ1tf'10'-Jt1t·''16iJ/kt!Jf ll1fh :.•..1r- 011 .'(ll)ll ( lf"M"(Jtwwl "'•. ll'f' 1 ... •tTflglllC.
(
111•moa.tcat tUtu t:: J
expect nothing but the best from a well trained ser DEALER'S SE�"TION
PARTSTO SE i'4STA.ULD �f1Ul l ll!&l\l ! 1" lc ll:.f1.1 11tJ
r JM!lh lciL11n4ol� p �tllibl�
u
vice department. With the PDI sheet completed and 1 llleal. dl1CA.
lh
signatures from each person involved you can show

your commitment to excellence. When a customer
EXPUIN 100W8ER'
leaves your dealership he should be aware of and
Wlh 11 11 ! 11 il r .d !liA l� i' to'lilm,11d �
, ''Y'IVIJm 1 t "
have: FB• w�U1tc• 1Jlald "" c ..
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witfl'rtr.lll ll
lr
� i!OO tnt •tr.r.<libriC;(l Ol fe.llll '1!J i1l'd �
i
1110ll'tie: ckN:uniffil' titfDCtoplfll >aOf l� Wt1etfnf1
r'
JIR�itxi� tOll!l ,._;�• •I
All operators and safety guides. flflw-41 1MC• ll l lt0l!l it1 C •IJo ftl1ll
IUll l'ICIO� C'O..,.f\1111 11 11:.i.
11 :s !t-Qltra:l tot 'lltl : u• C'
u!!!Of lli11
Uon1md'1Y<Hr emvnota
His sales information. I '11'1''6Wi!!I t! U H <tl l U V rile(,\ lit.I l&Wl l'M J"l ll
. wHh �
The PDI sheet. I flUJDS

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I �1jll•Ml1fl0 Hoe ifll� Jf.c.! M Nilll! •U Ill bl!!. Ii� ,
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Proof of registration. 1'fliJINil01'
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.
NOTE: The checklist has been modified to include PllOi
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an "OWNER'S SECTION" on the second page that b1fal!\1 11Mtl!l'llrUI It.I l.

U(M1 f» .t 111 U f111$11""1) 11U0 :1
tlt�ft'HhA'r
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is to be read and signed by the customer. :t:J��::: �ci-.ut6IOCW&o•I !lU.H.tltlllflAllli!I[
'
Was the POI checklist reviewed with the cus

AOJUSTMlHTS
........, .,,_. ./
tomer? Was the "OWNER'S SECTION" of the """"''-
POI Check list read and signed by the customer?
I I./I
fU[l SYST£M 1'11£SSUK1U\UON
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Documented proof that you have reviewed with the

· =��C:�::!T ...WZi-:.t:::='·--
,.._.. o. �..... 219000687
·
._ .
customer the operation and maintenance proce .Wfllo.,._...
S<kl2009-00 1- 1 1 3_on_1
dures for the vehicle.
Where Do I Find these Documents?
They are shipped with every BRP recreational
vehicle or can be found in BOSSWeb (www.
bossweb.brp.com), ComCenter tab, Document
Type (Technical Publications), Category (Checklist).
How Do I Learn More About It!
An easy way to learn more about the delivery
process is to view the DVD: Introduction to Dealer
Development Training DVD Volume 1; (P/N 219
700 256) from the BRPTI (Bombardier Recreational
Products Training Institute) DVD series.

BRP ELECTRONIC PARTS CATALOG
PARTSMART VERSION 8.9.28
By the end of May you will receive the new electronic PARTS CATALOG PART SMART version 8.9.28!
If you need detailed instructions (including pictures of example screens) or for network install instructions,
access a file called instructions pdf on the PART SMART CD.
License Keys
A license key is required for new installations of PartSmart 8.9.28, or if a new license key has been issued
for some other reason.
Installation
Server-only Installations. When 8.9.28 is installed from the Server, the software on the client work sta
tions will be updated to the newest version without any additional action required. All Client work stations
must exit PartSmart before running the update from the server.
NOTE: If you are using the PartSmart Updater feature, when installation of PartSmart 8.9.28 is com
plete, you will need to reset the schedule you have in place. To update, click on Start ALL Programs ARI
PartSmartUpdate, choose the tab to review and or set up your preferred schedule.
Overall Install
You will be prompted to enter your license key after you launch PartSmart, and to select a catalog which,
requires an updated key.
Catalog Install
The catalog data installation has been designed to ensure that catalog updates do not "hang" during the
installation and successfully complete regardless of size.
The license key can be found on BOSSWeb.
For assistance in obtaining a license key, please communicate with our technology support group.
BRP E lectronic Parts Catalogs (PartSmart and Empart ) are included in the monthly fee, so there is NO
extra billing.

BOSSWEB TIPS AND TRICKS: E.T.A.
PARTS AVAILABILITY SCREEN
You can now see on various BOSSWeb screens, Estimated Time of Arrival (E.T.A.'s) for some our your
critical back ordered items:
Parts - Parts Availability & Pric�
Other
b. P�rtNumbQr l>osaiptfon CompctU;ive VefW 0/0
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'f:xpe-t�d
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86joo;:zog KlT•SlEAT
COM 2 0()9 90 PC 1 PC PC :t 444.99 0% $-44•1.98 C.AD :t 664.99 35%
I +I 81.ACK
Parts - Regular Order Entrv

Select Pmd uct Lino
P rodu c-tllne
Snowmdliles Pool P•.V On l y
Od
r er Amounts
-ht<S 'i66U7.00
.. cJoc.Mng
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Pro9r.am Oth<>r
C1'4>Sf l>tfoe Nt:tPlice. NetMat�ln
Discounts Discounts
1.0 861002700 � 150 1 PC COM PC
KIT•$EAT 11-1 &I.ACK � 6S4.99 * "44.9S o� 0,.. t .�...98 35,..

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da te ;
Expected av.ailabillty
200$/10/22 Qu6"tity I �
vdd2009-001-108
Parts - Back Order List

S earch Resul ts
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415129424 · Ej'IS SOULON• FASTENERKIT 20 llJ 100599SS3S 10 S/O Re1J4Jlar 2008/09/11 0
Stock del•y•d. Qu..dty: 20
•I 7300383 • DRIVE BELT ;:s i$ l 0057672•9 2SO 10 PMTS SKI 2009 lnl1'•1 2008/0S/OI
Stock d•l•y•d. Qu•ntlty• 25
420620011 •CAMSHAFT I 1006009600 30 19511 R!i9Ufir 2008109/18 01577500 D
E•p•ct•d.v•ll•blli<>i datt' 2008/10/l:S Qu•ntity: l
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Stock del•'l•d· Qu•ntitv; I
vdd2009-001-109

B OMBARDIER RECREATIONAL PRODUCTS TRAINING INSTITUTE
se�·�aae l�·
Certified Technician
ski-dDa
Certified Technician
l�
can-am
Certified ATV Technician
l(i)
can-am
Certified Roadster Technician
I�
wd2009-001 -115_e n

THE FOUR STEPS TO TECHNICIAN TRAINING
1. Getting Started
How to become a better BRP service technician
GO to BRPTI via BOSSWeb, review your dealership copy of the BOMBARDIER RECREATIONAL PROD
UCTS GUIDE TO SERVICE FUNDAMENTALS BOOKS (English (P/N 484 800 168) or French (P/N 484 800
167) which was automatically shipped to every dealership. T hen complete the Entrance (Qualifier) Exam
on the web site. A passing score of 75% allows you to proceed to the Technician level.
2. Technician Level Training

Watch the series (all product lines are DVDs Vol.
1-2-3-4-5, DVD Vol. 6 Sea-Doo Supercharger, DVD
Vol. 7 Roadster Technical Overview, and USB Vol. 8
Sea-Doo iControl Advanced Training). Complete all
the exams in the Technician Level of your choice on
BRPTI. Passing scores of 75% qualifies you for the
BRP Technician Level.
vdd2000-001-105
3. Certified Technician Level

After the Technician Level and current Technical Up
date exams are completed with a passing score, you
can register to attend the Certified Level, hands-on
training at one of three locations:
- Sherbrooke, QC
- Wausau, WI
- Atlanta, GA
These courses are 100% hands-on and very chal

lenging. Students receive credits toward their
Certified Technician Level for each task completed.
Enroll on BRPTI to Course no. 0060 to see the latest
information.
4. Master Technician Level

After being at the Certified Technician Level for one year, if you have 5 years Powersports Industry expe
rience
as a technician, have worked at your current dealership for 2 years, and pass all subsequent applicable
Technical Update exams with 90% or higher on the first completion, you may qualify as a Master Techni
cian. Enroll on BRPTI to Course no. 0070 to see the latest information.

BOOK AND DVD QUICK PN REFERENCE
TRAINING PUBLICATIONS
ENGLISH FRENCH
Technical Update Books
2011 Sea-Doo Watercraft and Boats Technical Update Book 219 600 051 219 600 052
Technical Book
BRP Guide to Service Fundamentals and Principles 484 800 168 484 800 167
Competitive Edge DVDs
2011 Sea-Doo Watercraft and Boats Competitive Edge Only available on BRPTI
201O Sea-Doo Watercraft and Boats Competitive Edge DVD 297 001 534 297 001 536
2009 Sea-Doo Watercraft and Boats Competitive Edge DVD 297 001 339 297 001 396
2008 Sea-Doo Watercraft and Boats Competitive Edge DVD 297 001 185 297 001 195
Technical Training Materials
Intro to BRPTI DVD 219 700 196
Vol 1 Engines 219 700 197
Vol 2 Electrical Systems 219 700 198
Vol 3 Fuel Systems 219 700 199
Vol 4 Suspensions/Chassis/Steering 219 700 200
Vol 5 Transmissions/Drive Lines 219 700 201
Vol 6 Supercharger (Sea-Dool 219 700 273

Vol 7 Can-Am Roadster Technical Overview 219 701 329
Vol 7 Can-Am Roadster Technical Overview Workbook 219 600 032 219 600 033
Vol 8 Sea-Doo iControl Advanced Technical Training 219 701 672 219 701 673
Dealer Development Training DVDs
Vol 1 Introduction to Dealer Development Training 219 700 256
Vol 2 Dealer Development Training CSI 219 700 325

Vol 3 Dealer Development Training Service Department Operation 219 700 329
Vol 4 Dealer Development Training Parts Accessories Management 219 700 403
Vol 5 Dealer Development Training Selling Skills 219 700 518
Vol 6 Dealer Development Training Merchandising 219 700 519

--��-2-
What's New

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ew
Engine

INi
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--- � 2�� at N--
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ROTAX 1503 DT ETC (130 HP)

What's New:
New Engine Type

Main differences between OT and OT ETC include
• Bosch ECM
• Electrically controlled throttle body
• PTO cover
• Oil Filter cover
Why:
1503 OT now gets Bosch engine management sys- sd<l2010-001 -101

----------------
tern and Electric Throttle Control to meet the require-
ments of the intelligent Throttle Control system (iTC)
now used on more models.
ALL 1503
What's New: OLD
Oil Pressure Regulator
Why:
All engines use double spring oil pressure regulating NEW

system for more stable oil pressure. Running Pro tMWNNfff((tli'ffOl
duction change. Will retro fit.
sdd2011-002·21 7
1503 OT, 1503 NA ETC, 1503 HO,

1503 HO ETC, 1503 SC IS ETC
What's New:
Ball bearing with bellows assembly
Why:
Bellows assembly includes ball bearing and stainless

steel inner sleeve on ALL engine executions. This is
for standardization and use with the stainless drive
shafts.
sdd2011-002·21 9

SEG�IQN��- - __-�- __
.- � 2��INihat� New
---
ALL 1503
What's New:
Oil filler tube
Why:
A slight modification to the rib on the side of the tube

allow more room to accept the throttle body on the
new platform. This new tube is used in all engine
executions.
1503 HO AND 1503SC IS ETC

What's New:
Supercharger friction washer
Why:
Molybdenum coated friction washer for improved

durability. To be included in all rebuild kits.
sdd201 1-002-221

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Watercraft

SEG�IQN��- - __-�- __
---
ALL iCONTROL MODELS

What's New:
iBR Actuator Module

- 2 different part number actuator modules:
• HO Models
• BVIC and NA Models
Why:
End of iBR shaft is now keyed. Locking sleeve

no longer used. Different software calibrations
between HO and BVIC/NA models.
ALL iCONTROL MODELS

What's New:
" U Arm
"
Why:
Now keyed to except the new iBR.
ALL
What's New:
Drive shaft
Why:
Stainless steel drive replaces carbon steel over

molded with rubber coating shafts on all models.

INi
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--- � 2�� at N--
ew
ALL
What's New:
Venturi
Why:
Diameter has changed from 87mm to 83 mm to help

improve performance consistency from unit to unit.
ALL
What's New:
Muffler hose barb
Why:
Diameter of the barb has been increased allowing

more consistent and improved cooling hose reten
tion.
ALL
What's New:
Fuse box
Why:
New fuse box. Will use one single fuse box instead
of two separate as found on previous years.
sd d201 1 -002-226

SEG�IQN��- - __-�- __
---
ALL
What's New:
Battery support plate
Why:
Redesigned to attach new single fuse box.
ALL ETC EQUIPPED MODELS

QUICK REFERENCE CARD
What's New: se�·.aaa.i�
MPDRllM WOAMATl:w
Pr"ac;dct AOObtcOlll-O°"l(lflClonlWlittM di!'ltrtl'lltMM'*•
Quick Reference Card o:Mcool!oborvocaS•u.Ooo1Wtbtlortntfng.Thnq\ic:k
rdwGflC(Iterda pro�Wiiod:u a tlillf'1n4wotthtlflitiin
11U.CllOT£HiJ.DkJ
Aobrto flt4'9ra¥0 C\tOiiklrtO'J'lclot»lmtrv�tcns
«nde'Mtlabll:llirn.*"°".
Son'.lt�&t99tl"O�nH'(OlrtertiotnNO"IQI
lf'llliftliiutlVtJ•• F\o\'t
Why:
... .
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. .....
111-.�-·-•ll.-llt1>i..
.� u..ci.- _._ , _ ,._..,. ,,,,,, ��,. 1 �..--
This reference card will be included with all units to

CONTROLS IDENTIFICATION
be used as a quick guide for customers regarding
most commonly used features. (See full card in the
ANNEXES section).
' . SPORT MODE ---=-

t;OOOat
... Bri°'Vl"n ... HMJ$�flll'lli�ACICCiAI!:
51Mf/StDP Mt•O• oa,.16fft ENTERINGSPOITT MOOE
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AWUll TO Elin SPORTNODE
Ji. lb%iSfflof'3£0(f.l'l\k 1._ QJ
or'l\11tdo�t�nt
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�nalr19ot.ql'!
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CHANGING GAUGE DISPLAY
... Pn11MOOfro11t11tdlv\tl1'0l�PlAY
I> Ah11doli>lo i,1-UOQl.!f!Pptreil•
•hWO•fl4•nton9'1 ... PnhSET
STMTl'HOP
.. ftle.,sl/PJUlmNtlftlfpflll11J(Oi1JOOll!J1:dlll
...�il•dl'!>loltd
"' Prvn SU'ottttl:I
Sdd2 0 1 1-002-228

INi
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ALL
What's New:
Part Number stamped on all Impellers
Why:
Easier to indentify.
ALL
What's New:
Depth finder gelpad removed
Why:
Will no longer use gelpads between hull and trans

ducer. Silicone will now be utilized to help eliminate
manufacturing tolerances between hull and tranduc
er.
ss i 2
009-00 2-01 3_a
1. Gel pad
2. Depth finder
ALL
What's New:
Steering cable thru hull attachment
Why:
Ease installation. Standardization.

INi
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.- � 2�� at New
---
RXT-X as 260
What's New:
Manually Adjustable Suspension
Why:
Race-inspired RXT-X aS 260 is now offered with a

new, manually adjustable suspension.
$dd201 1 -002-231
RXT-X as 260
What's New:
Complete new shock and coil spring

- 25% stiffer spring rate vs RXT iS Suspension
calibration
Why:
sdd2011-002·232
Allows for an easily tune able suspension for more
aggressive riding.
RXT-X as 260
What's New:
Adjustable spring under seat
Why:
Adjustable with tool for additional passenger or

heavier rider.

SEG�QN.��- - __-�- __
--- �2 INi
hat��
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New � --
RXT-X aS 260
What's New:
Adjustable compression damping
Why:
Easily adjustable clicker allows for 65% to 115%

compression damping vs RXT iS via Nittrogen
charged remote oil reservoir located in glovebox.
sdd2011.002·234
ALL iTC
What's New:
Handlebar Switch
Why:
Individual switches improved to give a more positive

feel when selecting.
sdd2011.002-235
ALL s3 HULL
What's New:
Fixing Plates
Why:
Nut inserts improved. Insert has improved knurling

for better fixation.
sdd20 11.002-236

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.- � 2�� at New
---
ALL s3 HULL
What's New:
Hose from pump to adapter
Why:
Reinforced over molded mesh design for increased

durability.
1 . Water pressure hose
ALL s3 HULL
What's New:
Ride Plate top cover
Why:
Deeper hole and threads for pump retention block

bolts for more consistent pump bolt torque.

SEG"RQN.�� INi
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. a
---.
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---r
What's New:
Intake grate
Why:
All s3 hull vehicles get the RXT-X intake grate that

was introduced last year. Grate scoop is designed
to curve the water flow more upward into the inlet
as opposed to more parallel water flow design.
sdd2011-002-237
ALL s3 HULL
What's New:
Seat corner protectors
Why:
Standardization of parts within BRP Will retro fit to

earlier years and models.
sdd2011-002-239

SEG�IQN��- - __-��- __
.- � 2��INi
h at New ---
ALL 1503 HO
What's New:
lntercooler
Why:
To match H.O. calibration and ETC. Standardization

for all models. Can retro.
ALL 53 FIXED DECK

What's New:
Rear access panel rubber bumper
Why:
Added tab to the bumper for better retention.

INi
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--- � 2�� at N--
ew
Sea-Doo Boats

SEG�IQN��- - __-�- __
---
ALL MODELS
What's New:
Challenger Models:
• 180 Challenger/SE
• 21O Challenger/SE
• 230 Challenger/SE
Sport Models
• 210 WAKE sdd2011-002-201
• 21O SP
• 230 WAKE
• 230 SP
Speedster Models
• 150 Speedster
• 200 Speedster
ALL H.O. MODELS

What's New:
lntercooler
Whv:
To match H.O. calibration and ETC. Standardization

for all models.

SEG�QN.��- - __-��- __
--- � 2 INi
h a
� �
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t New � --
ALL MODELS
What's New:
New capacity label
Why:
'6:�5i1:�5.!��a�'$·E°f!:":T-:
To meet ISO standards. - - , , ,.,
•<:M4��\l.-� -..... OJtd1Milit!llHf � • 1 � -.
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1I
-
- �.e.-�1""'... � .. -tfO.
.... .-.... .- .... .......
. ........ ...... . .... . .. .. . """" .,,,
... ....... ...... . ...._ .......... 1 ...
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....,.. _o1_.. _ 0(!0o"""6 t f'0 ...; 1 _ .,..,.. .,. ""'""•• ..... .
-��-w =::. .� =·. �.l:::: :--:::.::

·\=; ��=- ..
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.·.. :
:::::.":4
.:..: c !"" _..,. �, "' ....." •·
sdd2011-002·203
200 SPEEDSTER, ALL 230

What's New:
New shifter assembly with dual throttles
Why:
New neutral detent shifter and styling to keep the

boat from shifting into forward or reverse.
sdd2011-002·204

SEG�IQN��- - __-�- __
---
200 SPEEDSTER, ALL 210 AND 230

What's New:
Ride shoe
Why:
Ride plate extensions now integrated with ride

shoe. Previous year model had ride plate exten
sions screwed on with two rows of screws. Allow
for more consistent handling characteristics be-
...
"'
<- 12-01 _1-00_ 2.2_os
______________
tween boats.
210 AND 230 CHALLENGER

What's New:
Heat exchanger
Why:
Standardization of parts used on 210 and 230 mod

els.
$dd2011-002·206

What's New:
Walk through door and latch assembly
Why:
Fold n' stow door now discontinued on 230 mod

els. Simplification of parts and standardization for
( ---
210 and 230 models. New latch assembly used for
model year 2011.
sdd2011-002·207

SEG�QN.��- - __-��- __
--- � 2 ��
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ew �

What's New:
New tower and bimini top
Why:
New easy to fold, forward swept tower with mod

ern design. New bimini top to fit with new tower
design. Integrated levers release cam latch mecha
nism on port and starboard sides to lower the tower. � .... -
sdd2011-002-208
Please see Service Bulletin 2011-4 for tower func

tionality details.

What's New:
New tower speakers and wakeboard racks (Wake

models)
Why:
Comparable sound and less intrusive. More reliable

and possibility to add two additional speakers.
230 CHALLENGER
What's New:
iTC engines
Why:
230 models now feature the same electronically

controlled throttle technology found on the 210
Challenger.
sdd2011-002-2 1 0

SEG�IQN��- - __-��- __
.- � 2��INi
h at New ---
230 CHALLENGER
What's New:
Helm console and gauge cluster with iTC functions
Why:
The 230 Challenger will now use the same gauges

and cluster found in the 21 O models. This allows for
several new features such as ECO mode.
210 CHALLENGER
What's New:
Rear swim platform storage area drainage
Why:
Hose routing and length has been changed to aid in

draining. New fittings are also used.
180 CHALLENGER
What's New:
New dash and console
Why:
New gauge fascia and black console. Clock and

depth finder now separate gauges. New rocker
switches now standard for all Challenger models.
Gauges are backlit with red color.
$dd201 1 -002-2 1 3

SEG�QN.��- - __-��- __
--- � 2 INi
��
h a
� �t New � --
180 CHALLENGER
What's New:
New black port console and glove box tub
Why:
One radio door and one glove box door. Glued in

storage tub.
sdd2011-002·214
180 CHALLENGER
What's New:
New tower and bimini top
Why:
New easy to fold, forward swept tower with modern

design. New bimini top on SE models to fit with new
tower design. The 180 has a single removable lever
that can be used on port and starboard sides to re
lease a cam latch mechanism to lower the tower (an
8 mm Allen wrench will also work). Please see Ser-
vice Bulletin 2011-4 for tower functionality details. sd d2011-002
-- .21 s
��---

SEG�IQN��- - __-�- __
.- � 2��INihat� New ---
150 SPEEDSTER
What's New:
Rub rail mounting and deck to hull bonding
Why:
Rub rail screwed on and hull laminated with Trivera

core around shearline (Same as all other models in
2010). Trivera core offers better grip to screw. Bead
hull/deck joint with urethane all the way around the
shear, no longer Sikaflex. Standardization with all
other 2011 models.

0 Section
--��-3-
Troubleshooting and Tech Tips
In this section you will find the most current tips and solutions concerning situations that occurred during
last season, as well as the latest updated procedures information concerning the latest technologies used
by BRP. All the troubleshooting procedure should be used in conjunction with the SHOP MANUAL and
other BRP service publications.

, ,7"- SECT1o, __N��==== TI=
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nd
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- s
3
TROUBLESHOOTING AND TECH TIPS INDEX FROM TECH UPDATE BOOKS

THROUGH 2010
-
2002
ENGINE SUBJECT YEAR BOOK DISCUSSED

Idle 2005 RFI single cylinder idle explained
3-D steering bushing 2005 New bushings offered
OTAS 2005 3-D OTAS facts
RFI 3-D TPS 2006 TPS performance issue
3-D OTAS switch 2006 Discussion on new OTAS switch

Cylnders 2008 Identifying RFI cylinders differences 2004 and 2003
TPS settings 2010 When you may want to check TPS settings and how to set
Connectors 2002 Connectors that can be plugged in to the wrong component
Oil consumption 2002 Oil consumption facts
Injector carbon dam 2002 Installation tips on the carbon dam and 0-rings
Fuel pumps 2002 Issues with the fuel pump
Fuel pumps 2002 Unseating the check valve on a fuel pump

Direct injector shorting out causing the 15 amp injector
15 amp injector fuse 2002
fuse to blow
Fuel filter 2002 Fuel filter direction
CPS faults 2002 Reasons why CPS fault P0335 becomes active
Air pump 2002 Reasons why air pressure could be low

947 DI
Oil tank venting 2002 Oil tank venting
TPS faults 2002 Detailed info on the 2 types of TPS faults
Reed valves 2002 Comments on reed valves

Spark plugs 2002 Spark plug tip s
Rave valve solenoid 2002 Detailed explanation of the rave valve solenoid
Cylinders and injectors 2004 Component differences between a DI and DI LE
Loss of ground 2005 Running problem caused by a bad ground

A review of the differences between the DI S T D and DI LE
Engine review 2008
engines and parts interchangeability
MPEM replacement 2010 Detailed procedure on how to replace an MPEM
947 carb RX-X 2002 Similarities of the RX-X engine and 947 carby
B.U.D.S. on 947's B.U.D.S. 2002 Fault screen info; terms and meanings on 947 Di's
Total review on the installation and functions of B.U.D.S.
B.U.D.S. 2003 Detailed info on B.U.D.S. functions and cluster displays

B.U.D.S. on 4 TEC's Fault screen info; terms and meanings on 4-TEC's
SERVICE BULLETIN 2006-9. What is needed for the
MPl-2 hardware 2009
MPl-2
64 2011 Technical Update Book - Sea-Doo PWC and Sport Boats

1 o_N��======= =Ti
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=r= - l=e=s=h=o=o=-
ub
_ __
_T.
n _,g _a_n_d
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e ch __ Ti1__
Valve cover gasket 2003 Model year 2002 valve cover gasket tab removal
D.E.S.S. (digital
An involved explanation on D.E.S.S. recognition on 2002
encoded security 2003
models
system) recognition
4-TEC all 2003 What to do if there is water in engine
Ring installation 2003 Extra info on piston ring installation
Oil level check 2003 Defining the proper procedure to check engine oil
Reasons why oil collects in the PTO cover, what are the
Oil in PTO cover 2003 consequences, and what to do about it. See also 2004
TECHNICAL UPDATE BOOK
Crankcase venting theory, why P1202 becomes active,
Fault code P1202 2003
and what to do about it
Dipstick blowing out of
2003 Reasons why what to test
crankcase
Cam timing 2003 Step by step cam timing procedure
Head torque 2003 Head torque and sequence explained
Flywheel balance holes 2003 Assembly procedure of the encoder wheel and flywheel
Powering up the MPEM

2003 The sequence of how these components are powered up
and ECM
ECM fuse 2003 Special procedure on checking the 5 amp ECM fuse
General info 2003 Details about various sensors and fault codes
Detailed info and troubleshooting procedures on the OPS
OPS and OTPS 2004
and OTPS
More theory of why oil collects in the PTO cover and what
Oil in PTO cover 2004
4-TEC to do about it
New oil filter cap 2004 Aluminum cap replaces the plastic cap
Rebuilding a 4 TEC 2004 Helpful facts and tips on rebuilding the 4-TEC engine
Electrical power loss 2004 A fuse that could cause a power loss
Detailed information on the ECM connectors and

ECM Kostal connectors 2004
troubleshooting tips
Dept finder message 2004 Why 'Sensor' is displayed on the cluster
Supercharger slip Checking a supercharger clutch for slippage, and what to

2004
clutch do if it does
Ventilation 2005 Reason why a carbon seal can cause ventilation
Intermittent bogs 2005 Troubleshooting running problems
Rare oil leak on the front engine mount and procedures

Engine mount oil leak 2005
to repair it
Overheating 2005 Different reasons the high temperature is displayed
Lanyards 2006 Lanyard will programmed ECM will not recognized it
Bent encoder tooth 2006 Discussion on the encoder wheel
Flywheel bolts 2006 Non reusable flywheel bolts
Air silencer restriction 2007 Internal defector that may cause a restiction
Recorded hours 2007 What hours are recorded
Long blocks 2007 Introduction of long blocks
Long block
2007 What to do to fit the new longblocks on previous models
interchangeability
Head interchangeability 2007 Head interchangeability on different year model engines

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Valve guides 2007 Finished guides now available
Cylinder head screws 2007 Cylinder head screws are no longer reusable
CPS 2007 Test spec's 2006-2007 CPS's
Fuel pump filter 2007 Discussion on lower fuel pump filter
Stick coils 2007 Misfires and type of grease to use
Counter balancers 2007 Differences of counter balancers
Crankcase breathing 2007 Crankcase venting theory on 2006 and up engines
OPS wire diagram 2008 Error on wire diagram
Depth finder 2008 New depth finder
Fuel pressure gauge 2008 Superseded RFI gauge
ECM 2008 Polarity protection discussion
Oil pressure 2008 Oil pressure taken at the head
Exhaust overheat 2008 Plugged gooseneck injection holes
Cluster 2008 Ability to flash new cluster SERVICE BULLETIN 2008-3

Over molded drive
2009 Installation procedures
shafts
ECM replacement 2009 ECM replacement with B.U.D.S.
ECM 2009 Replacement ECM speed issue
Diode cap 2009 Diode allows the main relay to energize
Review of TOPS switch function and identification of

Tops switch 2009
4-TEC different types
(cont'd) 1503 crankshaft
2009 Changes starting in year 2006
differences
Oil spray nozzles 2009 Oil spray nozzle identification
Hose clamps 2009 Inspection of clamps
Venturi bailer tubes 2010 Bailer system operation
T-code on cluster 2010 Cluster displays T-Codes when replaced
s3 hull 2010 s3 Hull repair system
Drive shaft turning

2010 Details on which tools are used for different models
tools
Over molded Battery
2010 Hidden corrosion causing various electrical issues
cable corrosion
iS fault codes 2010 Detailed review of various iS fault codes
iS battery box retaining
2010 Retaining bolts hard to remove or stripped
nut issue
1503 oil pressure
2010 OIL light comes on LCD display
regulator
Overheating facts 2010 Explanation of H-TEMP on LCD and possible cause
iS analog inoperative 2010 Analog needles inoperable
iS fault code strategy

2010 WARRANTY BULLETIN 2009-3 P0232 & C2232
update
Collapsed oil filter 2010 What causes oil filters to collapse
1503 long blocks 2010 Descrption of assembles and associated part numbers
Bent rods 2010 Pictures and causes of bent rods

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4-TEC GTI rental Battery 2008 Installing a 2008 GTI rental battery on previous GTI
RXP recalibration 2005 Facts about the 2004 RXP recalibration

ECM's and wire Explanation of the knock sensor adapter, wire harness and
2005
harness ECM facts
Wire harness on BVIC 2006 Wire harness updates
lntercoolers 2006 Testing intercoolers
4-TEC SCIC Superchargers 2006 Kit P/N's and rebuild facts
Dirty superchargers 2007 What a dirty supercharger can do to performance
Supercharger repa ir kits 2008 Kit part numbers and repair procedures
External intercooler
2009 Engine may stumble, until water is processed
condensation
Fault code P0106 2010 Intake pressure sensor out of range/ Booster
Spark plug and piston
2002 Detailed failure modes on spark plugs and pistons
failure analysis
Vinyl cleaners 2006 Recommended vinyl cleaners
Miscesllaneous Wire diagram book 2007 Part number of the book

Fiberglass and Gelcote Reminder on what is needed when contacting Technical
2010
warranty claims Service for warranty claiming
Electrical current draw 2010 Electrical draw specifications

Ma intenance light
RFI, DI & 4 TEC 2010 Review on how to reset maintenace light
flashing
Perfect pass 2008 User's guide

Wakeboard tower
2008 Infinity instruction and installation guide
sound system
Sea-Doo Boat Sea-Doo Boat reverse

2010 Reverse gate difficult to move. SERVICE BULLETIN2009-6
gate bushing seizing
08-09 Challenger 230
sliding door end cap 2010 New thicker cap part numbers l isted
failure
OPAS equipped
OPAS 2003 OPAS info and facts
models
All injected engines Fuel filter 2004 Mesh filters now available on the bottom of the fuel pumps
D.E.S.S. switch and Detailed info and schematic diagrams of these 2

2004 2-stroke 2004
cut-off relay components
2004 2-stroke Mag wire chaffing 2005 Prevention of mag wire chaffing
D.E.S.S. KEV RECOGNITION

Intermittent D.E.S.S. Key Recognition
We have written about D.E.S.S. key recognition and the proper procedures to follow in order to get the
iControl units to recognize the key and then start but have continued to receive reports of issues with
this.
Remember the D.E.S.S. lanyard has two functions. One is the magnet inside the lanyard draws up and
closes the switch inside the D.E.S.S. post when attached, waking the ECM. The ECM then "Searches"
for the computer chip inside the lanyard and determines if it is a code that has been programmed to the
ECM. The logic in the ECM was originally programmed as follows. After the switch has been closed by
the lanyard, the ECM has one second to find and accept the code in the lanyard. Thus, if the lanyard is
held close to the post the magnet is strong enough to close the switch and start the timer. If the lanyard
is not attached fully within 1 second the ECM does not recognize the key and the single beep will be
heard.

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Since then a Warranty Bulletin was produced and the procedure raises the time limit from the original 1
second to a longer time of 5 seconds. This update greatly reduces the chance of a false start up of the
unit.
If there are any customer complaints of inconsistent tether operation please reference and perform War
ranty Bulletin 2010-9. All unsold units should have Warranty Bulletin 2010-10 performed before delivery
to the customer
Following the procedure found in the Operator's Guide and Shop Manual every time you are attempting
to start the vehicle will allow proper D.E.S.S. recognition and ease the staring procedure.
1. D.E.S.S. key should be at least 6 inches from D.E.S.S. post.
2. Push START/STOP button. This is important because this allows the main relay to activate and
continue the power up sequence.
3. Next firmly and with purpose install the D.E.S.S. key. If the key is programmed the unit should give
you a double beep showing it is being recognized.
4. Next push the START/STOP button for the engine to start. If not done in this order (if key is installed
first then the start/stop button is pushed), the start up procedure may be inconsistent.
NEW ENGINE ALIGNMENT PROCEDURE FOR ICONTROL UNITS

The 2010 Technical Update Book discusses the change in alignment specifications to the alignment shaft.
Then Service Bulletin 2010-6 was created to list the changes in the alignment tools to modify the original
alignment tools produced, for the 2009 and 2010 model year units. To simplify all this, the 201 O Shop
Manual has a complete updated procedure utilizing the new alignment tools. This procedure can be found
starting on page 24 in the 2010 RXT/GTX/l!VAKE PRO SERIES SHOP MANUAL.
All 2009 and 2010 iControl units should be aligned with this updated procedure.
P0127 FAULT CODE ON 1503 NA

When ever a customer with a 2010 Sea-Doo, produced with a NA (normally aspirated) engine, is expe
riencing a Check Engine light, warning buzzer and the unit has a rev limit of 6700, check the unit with
B.U.D.S. for an active or occurred P0127 code. This normally will occur during hot engine re-starts in very
warm ambient climates. A likely scenario would be while skiing or tubing on a hot day and restarting the
engine shortly after stopping it.
This is caused by a fault code that was intended to detect inoperable intercoolers on intercooled models
only. The air temperature sensor (ATS) is located in the engine air intake plenum and will sense very
warm air accumulating in the plenum on a hot engine when it is stopped. Upon restart the ECM software
is setting a fault because it is sensing air over 120 degrees and therefore reports that the lntercooler is
not working, even though the NA does not have one.
This situation has been remedied by performing Warranty Bulletin 2010-10 (unsold units) or Warranty
Bulletin 2010-9 (sold units).
Please locate and read these bulletins as related to the effected units.

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2010 FIXED DECK GTX, RXT AND WAKE MODELS

Some iControl fixed deck models may have a gap
between the access panel and the hull when fully Double �l!l9.d
Tape
closed. In certain extreme riding conditions or un ln(!Jj,s area
covered mooring situations during very heavy rains,
some customers may experience what they feel is
unacceptable leakage from the rear access panel
seals. A Double Sided Tape Kit (P/N 293 740 037)
has been developed to address the issue, however
it must be understood that these panels are not
l ns.rallan un p;,�.@.�
C �
designed to be water tight in submersed conditions.
1 Pull on the« D • �!WJle.(j ��I ttiat 1�91\1.t>,d
Always keep unattended watercraft covered. on tne <19.QfJllSJ to ueJ �ilrul.9� m�� t•) put
1he Double $J�M Tape on place.
2 Put 1111! Double Si��d Tape as mdi.rn(51<)

3 Put tho • D •'ill�tl.e.i.J &mli back 1n 111<> groovo
end ;;p,pJy pressure all �.QUOO Wi1� '/QlJI'.
itllJJ!l�
sdd2 011-002-301
Double sided tape kit P/N 293 740 037.
Remove access panels.

Pull up "D" shaped seal that is glued on the door just
to get enough space to put the new "double Sided"
tape in place.

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Install Double Sided Tape starting 25 mm or 1 inch

from recess edge as shown.
Reinstall the o shaped seal back in the groove and

· ·
apply pressure all around with your thumb.
WATERCRAFT BULLETIN OVERVIEW

When prepping any new model year 2009 or 201O watercrafts it is important to perform all the outstand
ing Service and Warranty Bulletins. This will eliminate the need for the customer to bring the unit back
to your dealership for updates, after the unit is originally delivered.
Listed here is a quick reference guide to bulletins that may need to be finalized before the unit is delivered
to the customer at the time of sale.
2009 iS:
Warranty Bulletin 2009-2 Supercharger outlet hose inspection, front splash deflector rivets, seat inspec
-
tion and adjustment and iBR software Update

Warranty Bulletin 2009-3 - iS Fault Code Strategy Update
Warranty Bulletin 2009-4 - D.E.S.S. Key replacement at POI for iS models.
Warranty Bulletin 2009-5 -- Replace the cluster
2010 Various Models:
Warranty Bulletin 2010-1 Rear view mirror broken

Warranty Bulletin 2010-6 Supercharger hose inspection
Warranty Bulletin 2010-7 iBR Inspection at POI

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BOARDING PLATFORM AND STORAGE COVER SHOCK ENDS

REPLACEMENT
When removing these shocks you must first cut the tie wrap holding the protective bellows. Then un
screw the gas shock from the shock nut. The complete procedure can be found in the 2009 and 2010
Shop Manuals or the 2009 Interactive Shop Manual which was sent to your dealership 2 years ago. If
your customer accidently breaks the shock nut, it is available separately, without having to order the en
tire shock. Simply order P/N 269 501 717 and replace it. Warranty does not pay claims for the entire
shock assembly if the shock is not defective.
FRONT PANEL MELTING AND DEFORMING

A very important step in the POI process is getting
the unit out of the crate. We have found a potential
issue that may arise if the following steps are not
followed.
It is critical when uncrating a Sea-Ooo Watercraft,
to take the unit out of the shipping bag or protective
wrap as soon as the top of the crate is removed. We
have found that if the unit is left inside the enclosed
bag with exposure to the sun, temperatures can rise
to significantly high levels. This increase in temper
ature may be hot enough to start to melt and distort
the plastic hood. Please make sure your POI team is
aware of this communication.
sdd2011-002-306

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GPS OPERATION
The GPS found on the new iS Watercrafts has many
functions. This GPS is located in the craft's dash
cluster. There is a GPS INDICATOR LIGHT located
on the cluster to show if the satellites have been lo
cated. The GPS needs at least 3 locked satellites to
have the LED ON and use GPS speed.
One function of the GPS is to monitor the speed of
the vehicle, which was obtained on prior models thru
the use of a paddle wheel on the stern of the craft.
With the new system the vehicle speed will still be ._
sm
_o2_00_9-002 .aoo
_______________ __.
displayed even if the GPS signal is temporarily lost,
by using a default mode that is calculated in the iBR.
Because the GPS is located in the cluster of the ve-
hicle, it is always powered up, even after the main
relay is powered down. After the ECM is shut down,
if the watercraft is used within 2 hours, the GPS will
be ready within 3 seconds because the GPS uses
the satellites almanac data in its memory. If the wa-
tercraft is used after the 2 hour shut down, the GPS
will need to find the satellites. It can take up to 30
seconds after the satellites are found, for the speed
reading to show on the cluster.
Because the clock, altimeter and compass functions
on iControl craft's are set thru the GPS, the craft
must have a satellite signal for these to operate.
The clock time in hours can be set if needed, as
stated in the owner's manual, but the minutes can
not be altered.
Care must be taken when troubleshooting a cluster
related issue, and keep in mind that the issue could
be caused by a failed satellite signal to the GPS.
Most of the time troubleshooting is performed
inside a shop environment and it is likely the GPS
WILL NOT get a signal indoors.

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ICATCH TRAILER UPDATES
Several updates have been written since the iCatch trailer was 1st introduced last season. The POI
bulletin was updated reflecting the Extremely important changes in trailer set up, utilizing the optimum
location of the "fit", since the iCatch system is adjusted specifically to the PWC hull type. The iCatch
system must be used along with the iCatch bow cup for proper mounting at the front of the craft. It is
also mandated to be sure the craft is properly strapped at the rear as stated in the owner's manual. A
thorough understanding of the trailer operation, discussed with the customer at the time of delivery, will
help to eliminate all the trailering concerns of the customer.
When performing a POI on an iCatch trailer please reference this quick overview of the appropriate War
ranty and Service Bulletins.
2010 Models
Predelivery Bulletin 2010-5, Rev 3
Warranty Bulletin 2010-5 iCatch alignment and Safety Cable Installation
Warranty Bulletin 2010-8 iCatch Handle Cable Breakage
2011 Models
Predelivery Bulletin 2011-1 Rev 1

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REAR ACCESS COVER RUBBER BUMPER

T l P: To keep the rubber bumpers that cover the Allen
bolts on the access panels from falling off, a possible
preventive procedure is to apply a drop of adhesive
to the rubber bumper (P/N 291 003 038) before in
stalling it onto the bolt. Loctite 414 (P/N 413 705
800) should be used. Loctite 406 (P/N 293 800 100)
can be substituted if needed.
Sd d2 0 1 1 .002-309

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f BRP ,,.
I I
B.U.D.S.
I
(j
Utility and
Diagnostic ... I
Softvvare
�
Bulletin ]
December 15, 2010 Subject: New Version of B.U.O.S. (3.0.3.5) for No. N/A
Watercraft and Boat
All All Sea-DooTM Watercraft and Boat All All
GUIDELINES Get B.U.D.S. 3.0 Access codes

This B.U.D.S. version is for Sea-Doo watercrafts on BOSSWeb ComCenter
and boats only.
NOTE: You will not able to read any other produc t Refer to the following table for detail of the new
line. Other product lines should be usi ng the fol- versi on.
lowing versions available on BOSSWeb. NEW FEATURES
B.U.D.S. VERSION PRO D UCT LINE - Support all MY2011 SeaDoo/Boat models
3.0.5.4 Can-Am™ Ro adster - Integration of all published FC files for Watercraft
I Boat:
P2.3.31 Can-Am ATV
. 296000339.FC / 296000340.FC : ECM update
3.0.1.2 Can-Am S id e-by- Side for Watercraft MY2010 (fix for intermittent
tether cord recognition and POl 27 issu e per ,
3.1.2.0 Ski-Doo® and Lynx®
warranty bulletins 2010-9 and 2010-10
REMINDER: All MY2006 and older products must - 296000341.FC: Cluster update for Boat
still use the version P2.3.14 as per the B.UD.S. MY2010 (fix Ul 301 is sue. per warranty bulletin
2010-8)
REVISED BULLETIN P2.3.26dated September of
2009. ·296000343.FC: ECM update for Boat (Sync
mode functionality improvement)
The new B.U.D.S. version is now av a ila ble on
BOSSWeb, go to: •296000344.FC: Cluster update for GTXt/RXTTM
215/260 Premium, RXTTM-X™ and RXT™-X™
- www.bossweb.brp.com
aS™ (fix distance to empty, 'speed not plausible"
- ComCenter = Document ECM error and cluster buzzing 1n severe wate r
- Document Type = Diagnostic Software conditions)
- Select the following version
IMPROVEMENTS
I B.U.D.S. 3.0.3.5 I - Disappearance of hidden dia lo g boxes . Hi dden

boxes caused B.U.D.S. to appear frozen.
IMPORTANT: Like previous version of B.U.D.S. .
- D.E.S.S. POST INTERFACE (P/N 529 036 019) is
this new version 3 requires an access code. Start- now detected on a ll models. No more need to go
ing wit h version 3.0, the access code is now avail- in MPI menu to select informations
able on BOSSWeb there is no need to call your
,
- Fault information reported when clicking on the
service representative. Go to: "more details" button
- www.bossweb.brp.com - Validation of model number
- Co mCenter = Document - Automatic procedure for ECM replacement
- D ocument Type = D iagnosti c Software
- Select the following document
Pnnted 1n Canada l dbb2010-010 en AB) 1I 2

rgh
©2010 Bombard1e1 Recreational Products lf)c. and BAP US Inc All i ts reserved.
®™ and the SAP 1090 are uademarks ot Bombardier Recreat1ona1 Products Inc or Its aHillates
sdd201 Hl02-31 0.en.1

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B.U.D.S. SOFTWARE
INSTALLATION
Proceed with the regular installation procedure.
If you are not famlliar With B.U.D.S. or how to in
stall it please go to:
- www.bossweb.brp.com
- ComCenter = Docurnent
- Document Type= Diagnostic Software
- Category= 8.U.D.S.
- Select the following document
B.U.D.S. PROGRAM
INSTALLATION INSTRUCTIONS
1 G'TX 1s tJ 1 eglstered tr<i0e111ar� of Castro! Lld, used uncler license
2 I 2 N/A 8.U.D.S.
sdd 2 0 1 1-002-<J I O_en_ 2

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NEUTRAL SWITCH FAILURE ON 210 CHALLENGER MODELS

In 2010, a number of Challenger 21O models were built with a new style shifter that uses a typical marine
grade neutral safety switch. Some of these switches have the potential to fail, thus rendering the starting
system inoperable. This issue was identified and a Warranty Bulletin issued. The bulletin number is
2010-5; it is a campaign that should be performed at POI if possible. To Recap: the symptom is both
starter motors being disabled, leading to a no-start condition.
210 AND 230 CHALLENGER B.U.D.S. TIP

21O and 230 Challenger Sea-Doo Boats have iTC (in
telligent throttle control) along with two engines and
two ECMs that can communicate with each other
through the CAN network. The wiring harnesses are Write Data
identical so there are two diagnostic connectors but
it makes no difference which one is used when con Vehicle Setting ::il vation
1-
nected to B.U.D.S. However, when connected you 1 2

must choose what engine/ECM you want to com lmr20 1 ()-0 1 9 -006 _a
municate with. This can be done by choosing the R

1. Port {L) ECM selected
or L icon as shown below.
2. Starboard (R) ECM available
Another good tip is to ensure that BOTH engines
have had the "maint." reminder reset properly dur
ing a service {this is the small wrench icon in the
gauge cluster). In the event that only one motor has
been successfully reset, the boat may leave the deal
ership only to have the other engine soon begin to
warn that the service interval is due, causing unnec
essary frustration and wasted time for both the deal
er and customer. This is why it is critical to ensure
both engines have been reset, and data written to
both ECMs.

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O.T.A.S Fault Codes
sea..•..Gaa.
A I '�
"�
Last season we received several reports of OTAS SERVICE
fault codes being stored with no problems being Bulletin
found. Many times the technicians report that after

troubleshooting the system, the faults did not reoc December 16, 2010 Subject:Shop Manual and Wiring Diagram No. 201CMI
Corrections for the O.T.A.S.
cur. We have had many of these sensors returned

for evaluation, and have found that 100% of them YUR MOOEL M ODEL NUMBER SERIAL NUM BE R
GTX L.m:ted iS
have had no problem found. 2009
RTX iS
GTX. GTX iS and GTX Lim ited iS "" All
After investigating we believe the faults may be 2010 R1X. RlX IS. RTX·X end RT
WAKE Pro
X X
· RS
caused by an excessive amount of dielectric grease

1he information provided is
applieabae to the fc>. WIRING DIAGRAM
in the three pin Deutsch connector. It appears that bwing shop manuals:
CORRECTION
- 2009SHOP MANUAL (P/N 219 100 371)
the grease may be opening the female terminals - 2010SHOPMANUAL (P/N 219 100429)
O.T.A.S. Switch Wire
(hydro-lock) causing an intermittent connection. Identification To ECM
SHOP MANUAL
Update wiring diagram fOf the O.T.A.ST•
CORRECTION (Ott-Throttle Assisted SteBfing) &witch wire
When troubleshooting this system you should check Where to find informatk>n lO update: identificatk>n.
- STEERINGAND PROPULSIONsecU:>n - ECM termNI H1 SHOULD be the Btack wire
that all the terminals are fully seated in the connector .
- STOERINGAND 0. r AS. stbsection - ECM t&fminal H3 SHOULD be the 81ad;/Green
- 0. 'f.A.S. SWTlt'Htop;c. wire.
housing and that there is not an excessive amount Update tabfe of the foOowing test. O AS
T
of grease inside the connector.
NOTE: Improper use of dielectric grease may cause
O.T.A.S. Switch Ground Wire
Continuity Test
ECM
3-PtN RESISTANC'E
ADAPTER
'''��- -�
electrical connection issues.
CONNECTOR !l(OHMi
�
TOOl
PIN S HI o;; n
circuit, caused by an error in the 2009 and 201O

There has also been some confusion in testing this r•� ...
SHOP MANUAL and WIRING DIAGRAM The ECM

,
r. o F UNBalt
r
terminal H1 should be the Black wire and the ECM

terminal H3 should be the Black/Green wire. Please
make sure to make the corrections to your Shop
Manuals. This information can be referenced in the 1I 1
Service Bulletin 2010-8. sdd2011 -00 2-310_en
NEW! IBR ACTUATOR PART NUMBER AND SUBSTITUTIONS

All 2009 and 2010 iBR Actuators will substitute to the 2011 iBR Actuator along with the needed
parts to install this new execution.
The iBR Actuator unit that was previously installed on 2009 and 2010 models has been updated to stan
dardize and ease the installation of replacement iBR units. This is a direct bolt on application that will
not need a calibration update. Only the correct vehicle model number and serial number will need to be
reflect the additional parts needed for installation. Simply order the part number in the PARTS CATALOG
matched to the cluster, with B.U.D.S. as with past replacements. The iBR job code has been adjusted to
and you will receive all the correct parts.

Units: model year2009 and 2010 GTX, RXT and WAKE Models Equipped with iBR
P/N 278002321 (2009) and P/N 278002476 (2010HO)
Substitutes to 278002321a or 278002476a which will substitute to and includes:
1 - 278002606 iBR assembly
1 - 268000087 U-Arm Bracket
2 - 207382060 M8 x 20 Bolt
2 - 234081600 M8 Washer
1 - 293900007 Bushing
1 - 268000067 LH Support Plate

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P/N 278002418 (2010BVIC)

Substitutes to 27S00241Sa which will substitute to and includes:
1 - 27S002605 iBR assembly
1 - 26SOOOOS7 U-Arm Bracket
2 - 2073S2060 MS x 20 Bolt
2 - 2340S1600 MS Washer
1 - 293900007 Bushing
1 - 26S000067 LH Support Plate

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DECEMBER 2010
SEA-DOO ADVANCED TEC TRAILERS:

IMPORTANT UNLOADING INFORMATION
The Sea-Doo Advanced TEC™ and

Advanced TEC™ iCatch™ trailers
will be shipped out starting this month.
This year, the trailers are shipped fully
assembled and crate-free, which affects
how you will unload them. Please see
enclosed information on how to unload
each of these trailer models, without
injury to your personnel or damage
to the trailers.
The trailers are shipped in packages of two.

The photo on the left shows a shipment
of six trailers, two per protective cover.
REQUIRED EQUIPEMENT:
• Forklift with unloading forks of at least

72 inches (183 cm) in length.
sdd 201 1-002�7-• 11.. 1

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Advanced TEC iCatch Trailers
Unfasten the cover ties. Lift the cover to reveal

the wheels and frame.
Insert the forks under the two-trailer package, as shown. Make sure the forks reach the frame
pipe on the other side of the trailer.
Unload a single two-trailer package at a time. The upper support tubes will slide upwards
and out of the support tubes of the two-trailer package directly underneath.

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Advanced TEC Trailers
1
Insert the forks under the two-trailer package, as shown.
2 Unload a single two-trailer package at a time. The upper support tubes will slide upwards
and out of the support tubes of the two-trailer package directly underneath.
sdd 20 1 1-002�7_e n_ 3

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ADDITIONAL INFORMATION
WHERE TO POSITION TIE-DOWN STRAPS FOR SECURE TRANSPORT
Advanced TEC iCatch Trailers
Always position the tie-down strap to the frame on the inside

of the roller-bunk system. Be careful not to over tighten the straps.

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Advanced TEC Trailers
Position the tie-down strap

on the axle between the
support tubes and the frame.

�
...
... � 2006 INDEX
(;! �.:.. &EL'.•�aa.1 {I)
� $
�·
-
PREDELIVERY SUBJECT MODEL
2006-1 rev.3 Predelivery All4-TEC
� 2006-2 Predelivery 30
1"111
2- ,.Ill (")
iti """ :::l!
gi SERVICE SUBJECT MODEL 0
0
:II:" 2006-1 Impeller Chart ALL 2
I 2006-2 Carbon Monoxide Warning Label (Canfornia Only) A.LL
� 2006-3
2006-4
Importance of POI
New Version of B.U.Q.S. 2.3.8
All
All
�
0
2006-5 High Altitude All
"1:1 2006-6 rev 1
. Paint Codes and Gelcoat All
�
QI
2006-7
2006-8
Transport Canada-Safety and Security- Compliance Labels
Premium Gauge Compass Feature All
:::i
Q. 2006-9 MPl-2 Hardware for B.U.D.S. All
.g> 2006-10 New Version of B.U.D.S. : 2.3.8 All
� 2006-11 New Optional Service Toots All

2006-12 MY 2006 1503 4-TEC Run-ability Issue
gi
QI 2006-13 Serv1ce Tools All
� 2006-14 GTI Wind Deflector GTI 130 SE,GTI 130 STD,GTI 130 STD-R ::;t
2006-15 Storage Procedure for 4-TECT"' All ()
t
2006-16 Storage Procedure 30 94701 PREMIUM
2006-17 Pre-Season/Annual Safety Inspection All (except 30 Of)
2006-18 Pre-Season/Annual Safety Inspection 30 94701 PREMIUM
::r
WARRANTY SUBJECT MODEL ()
()
2006-1 rev .1
:::!'
Fuel System ChecK Valvee Cracking RXP-RXT-GTI SE-GTI
2006-2 Storage Bfn Hinge. Storage Cover Seperation GTISE :::s.
iCQ
ADMINISRATIVE Inspection MODEL Q)
:::s
Q.
2006-1 Operator's Guide Availibility ALL
2006-2 PartSmart New Version Notification ALL
q;t
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co
st
"»
c.n
co
al
I I <I:
se�·..aaa. IS 2007 INDEX
I 11w �
2007-1 Predelivery 30
2007-2 Predelivery 4-Tec North America/International
-'I
0
SERVICE SUBJECT MODEL I I I 2
2007-1 rmpeiler Chart Sea Level H1gn Altitude All
2007-2 Importance Of POI All
2007-3 Transport Canada Compliance Labels All Canadian Models
2007-4 Carbon Monoxide Label lnstallatior\ California Models Only
2007-5 Safety Lanyards All
2007-6 Service Tools AU
2007-7 Paint Codes and gelcoat All
2007-8 4 TEC's Aluminum Jet Pump Wear Ring All
2007-9 Long Block Service Parts All
2007-10 Electric Probe Tool AH
�
... 2007-11 B.U.D.S. 2.3.13 All
...
2007-12 Model Year 2007 4-TEC Single ECM All
;t
g.
::i
2007-13 Storage Procedure for 4 TEC Equipped Vehicles AJJ 4 TEC's �
2007-14 Storage Procedure for 4 TEC Equipped Vehicles 3 0 Q
�- 2007-15 New Valve Guide Tools All 4 TEC's c:
tr
-
i 2007-16 Pre Season Inspection All 4 TEC's .....

AH 4 TEC's
2-
�
2007-17 Fuel' Pump Activation Procedure
m
ti) ::r
QQ Q
:it- WARRANTY SUBJECT MODEL Q
I 2007-1 Steering Cable Stem Arm Bott 4-TEC's ::!'
(/) =·
QI
ID 2007-2 Fuel System Pressure Relief Valve 4-TEC's
�
6
QQ Q)
:I
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ADMINISRATIVE SUBJECT MODEL �
� 2007-1 Operators Guide Availability on the Web All
QI
::i
Q.
�
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.g> ::r
Q
::i.
ti)
QQI
I:
�
...
�
Q
�g
SE�•4JDD ,• 2008 INDEX
(;!
6
-
g.
0
�
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:;,
�· PREDELIVERY SUBJECT MODEL

2008-1 Predelivery All
� 2008-2 1"111
2-
Install the Correct Software in gauge Cluster All
(ti
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""" :::l!
OJ
0 0
0
:II:"
SERVICE SUBJECT MODEi- 2
I 2008-1 CO warning label installation (CA only) All
2008-2 Transport Canada Compliance labels All
�
C/)
2008-3 Ability to flash new cluster (Rev 1) series
6
All except GTI
0 2008-4 Importance of POI All
0
2008-5 Sea Level and High Altitude Impeller Chart All
"1:1
2008-6 Paint Codes & Gelcoat All
�
QI
2008-7 Fuel Tank Venting System All
:;, 2008-8 Service tools All
Q.
2008-9 Battery care reminder All
.g>
-
2008-10 Storage procedure All
� 2008-11 RXP I RXT Storage Cover Shock Bracket Location RXP, RXP-X, RXT, RXT-X
OJ
0
QI
2008-12 2003 to 2009 Supercharger Service Part Update All supercharged models
� 2008-13 Pre-Season I Annual Safety Inspection All
::;t
()
t
WARRANTY SUBJECT MODEL
2008-1 RXT Storage Cover Replacement RXT, RXT int.
2008-2 Exhaust and Supercharger hoses coming off RXP-X, RXT-X
2008-3 SAFETY RECALL - Fuel Vent Hose Chafing RXP-X
::r
()
ADMINISRATIVE SUBJECT MODEL ()
:::!'
I 2008-1 Operators guide availability on the web All
I :::s.
iCQ
Q)
:::s
Q.
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"
00
00
se�·..aaa. I� 2009 INDEX

tA
2009-1 Predelivery All Except GTX LTD and RXT iS (North America) m
2009-2 rev 1 Predelivery All Except GTX LTD and RXT iS (International)
1.1'
1. 0
2009-3 rev 3 Predelivery GTX LTD iS 255 and RXT iS 255 {All Countries) w ::::!
0
2
SERVICE SUBJECT MODEL
2009-1 SeN1ce Tools All

2009-2 Carbon Mono.xide Warning label lnstalfatlon All (California Only)
2009-3 Transport Canada-Safety and Security- Compliance .labels All
2009-4 Sea-Doo Battery Activation, Charging and Maintenance All
2009-5 Sending and Savlng B.U.D.S. files
2009-6 Replaclng and Updating the ECM's caHbratlon parameter table All
2009-7
�
lgnitlon Coll Long Term Reliabllfty All'
... 2009-8 GTX 255 LTD I RXT 255 IS New Special fools GTX Limited iS 255, RXT iS 255
2-009-9
...
;t
Sea Level and High Altitude lmpelfer Chart All
2009-10
g.
Paint Codes and Gelcoat All
2009-11 �
::i Storage Procedure All
Q
�·
t
-
i
2-
� WARRANTY SUBJECT MODEL
::r
gi 2009-1 255, RXT 255 Q
Q
Update for Early Release Boat Show Watercraft GTX Limited iS iS
� 2009-2 rev 1 Supercharger Hose & Seat Inspection.Splash Deflector, iBR Software Update Limited iS 255, RXT iS 255
::!'
GTX
I 2009-3 Limited iS 255, RXT iS 255
IS Fault Code Strategy Update GTX
=·
� 2009-4 Limited iS 255, RXT iS 255
(/)
DESS Key Replacement on iS Models - Unregistered Vehicles Only GTX
2009-5 rev 1 Limited iS 255, RXT iS 255 iCQ
� Q)
Cluster Not Working on iS models - Unregistered Vehicles Only GTX
2009-6 rev 1 Limited iS 255, RXT iS 255
() Cluster Not Working in iS models - Registered Vehicles Only GTX
:I
�
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�
Qi
::i �
ADMINISTRATIVE SUBJECT MODEL
Q.
.g> �
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2I: [
�
�
I {I)
...
� se�·�aa. 2010 INDEX

...
(;!
� i
�·
-
PRE DELIVERY SUBJECT MODEL
� 20 10- 1 Predelivery RXT,GTX and WAKE PRO (North America) 1"111

2- 20 10-2 rev 1 Predelivery RXT, GTX and WAKE PRO (International)
,.Ill (")
iti 20 10-3 Predelivery RXP, GTI and Wake (North America) """ :::l!
gi 20 10-4 Predelivery RXP, GTI and Wake (International) 0
0
:II:" 20 10-5re v 1 Predelivery ADVANCED TECT<il and ADVANCED TEC iCatch trailer 2
I 20 10-6 PredeHvery ADVANCED TECTM ICatch trailer (International)
�
�
0
"1:1
SERVICE SUBJECT MODEL
�
QI
20 10- 1 Compliance Labels AH (Canadian models only)
:::i 20 10-2 Carbon Monoxide warning label installation All (California models only)
Q.
20 10-3 Sea Level and High Altitude Impeller Charts All
.g> 20 10-4 Batteries Activation, Charging and Maintenance Al1
� 20 10-5rev 1 Paint Codes & Gelcoat All
gi 20 10-6 Alignment tool and diagnostic harness All iControl
�
QI
::;t
()
WARRANTY SUBJECT MODEL
20 10- 1 rev 1
20 10-2
20 10-3
20 10-4
Rear view mirror broken
Steering Extension Block Bc:>lts Tightening
Sponson Bolts without Thread Locker
Parts Missing in the POI K1t
GTX(STD, LTD, iS) and RXT (iS, X)
RXT�x and RXT- X RS
GTI and WAKE
GTI (International)
t
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()
20 10-5 SAFETY iCatch trailer system I Securing the PWC ADVANCED TEC™ iCatch trailer ()
20 10-6 Supercharger Outlet Hose Inspection GD< LTD iS, RXT iS, RXP-X, RXT-X (unregistered only) :::!'
20 10-7 iBR inspection at POI GTX LTD iS and RXT iS (unregistered' only) :::s.
20 10-8 !Catch handle cable breakage ADVANCED TECTM fCatch trailer
iCQ
20 10-9 Tether Cord Recognition. Fault Code P0127 All iControl (Previously Registered) Q)
20 10- 10 Tether Cord Recognition, Fault Code P0 127 All iControl (Non Registered) :::s
Q.
A.DMINISTRATIVE SUBJECT MODEL q;t

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20 1 0 - 1 rev 1 Registration of ADVANCED TEC™ trailer ADVANCED TECTt.1 & ADVANCED TEC™ iCatch trailer
st
20 10-2 U.S. EPA Regulations and BRP warranty changes All (U.S. only}
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HARDWARE PARTS Tools Required
�
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@@)@ �, UtllttyKnile
mr� o
lanyard
'
X2 Crimp Plyers
_,.:"'��- � Heal Gun
A
� Wiring Harness
X2 eC
.
: : : :
@E§Y
WireS!fippers
I I I I
I I I I
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�
1/8" Allen Key �
t 6
w
A e 7/32" Allen Key
�� S
Mounting P a
:::>
l te Rubber Gasket ·�
5/16" Allen Kf'y
x8 x2 x2 x4 X2 X2 ..
Rernove speaker from the speaker ho using by removing Place the rubber gasket between the speaker housing and
.
bolt 'B'. Repeat each step for both speakers. tower nub, place the internal mounting plate inside the
speaker housini;i and line up the holes. Insert the 4
\1( .....} I\ ,
,,-BollB assembly bolts with pre-applied Loctite, and attauh the
speaker housing lo lhe tower nub.
(�' . /
,� �:->-'\
·--
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@ \ "f·\ y,
RUbber G.'.lsket
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8
'J A
x8
I
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51
f
Internal
MounUng Plate
\
Pass the small end of the lany ard around the speaker
spine and through the large end or the lanyard. Gently pull
until taught.
0x2
Rev. 02-November-10 Pg.112

sdd 2 01 1-002�1 , _,

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Lining up locator bolt with the slot on the speaker, insert On the tower, gently pull the black rubber plug lo access
the speaker and spine into the speaker housing. Apply the wires. Carefully cul the shrink wrap with a utility knife to
Blue Loctite to a flat head bolt, insert at the back of the expose the speaker wires within and remove the plug. Be
speaker housing and attach lo lhe speaker spine inside. very cautious not to cut through the wire's insualtion.
, I / I
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8
x2
1) Use wire slippers to expose 1./4" of wire on all wires. 2)
Slide matching wires (as Illustrated) Into opposing ends of
the connectors and crimp. 3) Heat shrink the connectors.
i{�L--/
Plug the red RCA connector t o Its corresponding speaker
jack.
4) Carefully push the wlres back into the tower tubing.

/ //,. //. I
I
Tower S�eaker Harness
rP/
Port Cr�mp
Purple Red
et±lD
�
Purple & Black Black
'� 7'L-�
Starboard :
tjn J,(� :�I

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Green Red
Green & Black Blank
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Connectors,
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www.RoswEL.L.WaKEaIR.com
\.4' If you have any questions please call : 1-780-962-0868 Rev. 02·November-10 Pg. 212
sdd2011.002-311_2

------ ·4-
New Technologies
In this section you will find the most current information concerning the latest technologies used by BRP.

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Sea-Doo
Introducing the All New GTI Series

New Technologies
GTISE
sdd2011-002-402

.----. ,�-,7�- SECTION��-
N--� T.
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i.--4
GTI Platform
Quick overview of new Gli platform:
- Gli LTD 155, Gli SE 155/130, Gli 130 Models,
WAKE 155, GTS Pro.
- New entry level GTS 130 Model.
- Improved hull.
- All models include iTC, iBR, OTAS.
- All models include mirrors.
- Larger bow storage area (116 liter/31 gal total
storage).
- New Deck increased platform length, 3 inches
longer. Same width.
- Finger Throttle operation.
sdd2011-002-403
- Hull Ventilation provided using corrugated tubes.

- New ergonomics for increased stability and
more comfort.
- Optional functions on some models: VTS, Cruise
control, ski mode, ECO Mode etc.
New Improved GTI Hull
New 2011 GTI maintains the same handling charac

teristics of the 2010 GTI, with several refinements:
LFI {long fiber injection) construction (same
process as s3 hull). 20 lb.(9 kg) weight reduction.
- Unique Ribbed construction makes it more
durable.
- Improved water inlet - more stable RPM and
reduced potential for cavitation on acceleration.
- More efficient manufacturing.
sdd2011-002-404
- Environmentally Friendly.
- Improved splash deflector for dryer ride.
- Better wave penetration in rough water.
- Longer hull (same width) -3 inches (7.6 cm)
longer.
All New GTI Deck
sdd2011-002-405

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New deck design incorporates several ergonomic

improvements:
- Multi position footwell allows rider to move foot
position around without loosing grip.
- New footwell profile reduces ankle fatigue and
enhances overall comfort.
- Lower center of gravity increases stability over
the previous GT models.
sd<l2011-002-406
Narrow Seat Design

- The new narrow seat provides the best comfort
while optimizing a more aggressive riding style.
- In stand-up position the new seat also provides
the narrowest distance between the rider's
knees.
ECO Mode
Fuel economy mode now offered for new GTI plat

form on some models. The iTC (intelligent Throt
tle Control) system allows the PWC to maintain a
steady speed and constant RPM to reduce fuel con
sumption. When ECO mode is selected, the oper
ator simply keeps the throttle fully applied, and the
ECM uses a predetermined mapping program to fine
tune the RPM and speed for maximum fuel efficien
cy.
sdd2011-002-4 1 3

.----. ,�-,7�- SECTION��-
N--� T.
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s
i.--4
VTS now Available on Some GTI Models

VTS accessed differently on LTD vs. SE models:
- "High Performance VTS" on LTD model - utilizes
rocker switches on handlebars.
- VTS is adjusted before riding via the gauge
menu on SE models.
- Base models and GTS do not have VTS.
New GTS Model
New model provides an economical, value minded

entry level PWC offering - the standard for value:
- Basic model still retains many of the GTI platform
highlights.
New updated hull and deck, with many of the
same ergonomics.
iTC including sport and touring mode.
More power then other brands competitive
models (130 hp on GTS). ._
sd<1_2_0, _1-00_ 2...
_ , s_ ---------------
No reverse or iBR on this model.

Speedometer is not GPS linked.
Thru Hull Fitting

Thru-hull fitting now bolted on to the hull.

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iBR Bolted from Outside of Hull

The iBR is now through bolted from the outside of
the watercraft easing removal.
New Fixing Plates
New redesigned fixing plates.
New Pump Support
New pump support with two molded alignment

tabs.
NOTE: Pump is mounted to back of hull instead of
ride plate like found on the s3 hull.
!d<l201 1 -002-4 1 0

.----. ,�-,7�- SECTION��-
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Integrated Stops Molded in Venturi
Sdd2011-002-411

seni...•�aa. � Section
------ 5,-
Special Tools
In this section you will find the most current special tools to service efficiently BRP vehicles. All manda
tory tools will be shipped automatically.
T.__/s
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-- -5
WATERCRAFT
SERVICE
SE�DD. � Bulletin
Date : December 9 2008 Subject: Service Tools No 2009-1
Year Model
All AU
BRP is proud to introduce its latest Service Tools

Bulletin. These special tools were designed to help
you efficiently service BRP vehicles.
Please always make sure to use special tools along
with the appropriate Shop Manual(s) and respect all
safety measures.
Mandatory Tools: These tools are absolutely

needed to perform certain service procedures.
They will be automatically shi pp ed to dealerships.
They do not need to be ordered separately.
Recommended Tools: These tools will facilitate

the Technicians work. They will not be
automatically shipped to dealerships. They need to
be ordered separately.
Table of contents
Tools by System:
Engine ......................................................................................................................... P 2
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ . . . . . . . . . . . . . . .............. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 10
Cooling ........................................................................................................................ P 11
Electrical ................................................................................................................ -.... P 12
Lubrication ..........................................................................................,........................ P 15
Transmission I Propulsion ............................................................................................ P 15
Steering ....................................................................................................................... P 18
Suspension .................................................................................................................. P 18
Various ........................................................................................................................ P 19
Index of tools by Part Number: ..............................................................................P 21
Pnnted in Canada (sbs2009-008) 1/21

©2008 Bombardier Recreational Products inc. and BRP US inc . All rights reserved.
®TM an d the BRP logo are trademarks or Bombardier Recreational Produ cts Inc. or its affiliates.
sdd201 i-002..soo_en_ 1
�-- �eenoN
·��-�-_ ia___
�___
S e c / o o /s
�-s
Engine
-
- I�) I
I
-
-
--
e
-
Protective Rubber Pad Gear I Bearing Puller Male filling
PIN 290 877 032 Recommended PIN 290 877 665 Recommended PIN 295 000 086 Recommended
947 DI engines 787 engines 4-TEC 1503
No lon,ger sold: a standard puller can be To test jet pump tightness on 2-stroke
used.
r
e
-
- 1•...1' �·
-
--
--
6
Protective Carpet leakage Tool MIKUNI BN Pump FtYWHEEL HOLDER

7171787 RFI engines All carbureted engines 587/6571717 engines
So piston bearing does not fall In base To laaK test carburetor pop-off pressure. Use witl1 420 876 080.
during replacement.
I I
295.000141
Timing Gauge 717 Timing Gauge alignment shaft

PIN 295 000 130 Recommende(l PIN 295 000 135 Recommended PIN 295 000 141
717 ei1gines 787. 787 RFI, 947. 947 DI engines All models
TDC Dlat Indicator Frywheel Puller engine leak lest Kit

2-stroKe engir�es except DI, 1203 787 Rfl All 2-stroKe engines
!<It Includes vacuum pump 529 021 800.
Service 2009-1 2/21

sdd2011.002..soo_en_ 2
T.__/s
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S ec a o o
-- -5
Engine
TDC dial indicator HALF RING PULLER MAG Screw M6x40 (item fl7)
PIN 414 104 700 Recommended PIN 420 276 025 Recommended P/N 420 840 681 Recommended
For ignition liming static measurement 717 engine All 2-stroke engines
To temove cranKsl'\aft bearings.
MAG •ldt V fO a;ide
Screw M8x70 (item #8} Screw M8x35 (qty 3) Sleeve

P/N 420 841 201 Recommended PIN 420 841 591 Recommended PIN 420 847 220 Recommended
All 2-slroke engines 717 engines 711 engines
To be used with P/N 420 877 635, To be used with 529 035 533 Use with 420 876 080.
Half ring puller Rotaiy Valve Shaft Puller Rotary Valve Bearing Pusher
PIN 420 876 330 Recommended PIN 420 876 488 Recommen<;led PIN 420 876 501 Recommended
947 & 947 DI engines 717, 787 & 787 RFt engines 717, 787 &. 787 RFI engines
To remove 52 mm O.D. bearings from the. Kit includes ·420 240 860 I 232 400 414.
crankshaft.
StarterDrive Seal Pusher Crankshaft Protector Crankshaft Protector

PIN 420 876 502 Recommended PIN 420 876 552 Recommended PIN 420 876 557 Recommendeq
947 & 947 DI erigines All 2 stroke. 1203 717 1787 RFI I 600R / 600 HO
For starter drive Use with 420877635
Service 2009-1 3/21

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0
Crankshaft Distance Ring (MAG) Rotary Valve Shaft Installer Rotary Valve Shaft Installer
PIN 420 876 569 Reconimended PIN 420 876 605 Recommended PIN 420 876 609 Recommended
All 2-stroke engines 717 engines & older than 1990 767 & 767 RFI engines
Use with 420 677 650
l= 0
0 0
0 oo�
Cylinder Alignment Tool PISTON RING COMPRESSOR 86mm PISTON RING COMPRESSOR 82mm
717 engines 947 & 947 DI engines 717, 767 & 767 RFI engines
Crankshaft Protector crankshaft bearing puller Oil Seal Pusher

PIN 420 877 414 Recommended PIN 420 877 635 Recommended PIN 420 877 740 Recommen(led
947 DI engines All 2-stroke engines 767 RFI engines
Used with 420 877 660,
Replacement Puller Boll (item 119) Flywheel puller half rings

PIN 420 940 755 Recommended PIN 420 976 .235 Recommended PIN 420 977 475 Recommended
All 2-stroke engines 247, 787, 787 RF!, 947 & 947 DI engines 717 1787 RFI engines
To us.e with puller PIN 420 877 635. Replar..em ent holt PIN 529 035 .549.
Service 2009-1 4/21

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Engine
MAQ clO. PTOs�
HOLDER RING (i!em#3) puller ring Vacuum pressure pump

947DI engines 717/787RFI engines All models
Distance Gauge 14 mm Distance Gauge 15.4mrn Distance Gauge 1·.smm (PTO)

717 engines 787 RFI engines 947 DI Engine
____o
__
No picture available
Distance gauge115mm (MAG) Piston pin puller Exhaus.t Wrench 15mm

947 DI engines All 2-stroke engines 947 DI engines
Replacement Protector Sleeve Flywheel Tool Sleeve kil 18 mm

To be used with PIN 529 0'35 503. All 947 and 947 DI Ski-Dao 277, Sea-Doo 587
Use in conjunction with 529 035 547 puller To install cageless bearings. Used with
and 295 000 125 holder. 529035503
Service 2009-1 5/21

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Sleeve kit 20 mm SLEEVE Kit 21 mm magneto puller

P/N 529 035 542 Recommended P/N 529 035 543 Recommended PIN 529 035 547 Recommended
717, 787 RFI, 600, 800HO 947. 947 DI, 800 R Engines Replacement bolt 529035549. Use
Used with 529035503 To Install cageless bearings. Used with 208760811295000125/420841591/29084 72
529035503 20
Boll M16 x 1,5 x 65mm Spring installer remover piston circllp Installer i8 mm
P/N 529 035 549 Recommended P/N 529 035 559 Recommended P/N 529 035 561 Recommended
DS 450 Replaced by 529035983 or 529035989 Sea-Doo 587. Ski-Doo 277 engines
Goes with 529 035 547 &A20 976 235.
Circlip insertior1 Tool 20 mm Circlip Insertion Tool 21 mm 20 mm Sleeve

PIN 529 035 562 Recommended P/N 529 035 563 Recommended P/N 529 035 567 Recommended
593. 670, 693, 717, 787 & 787 Rfi engine 947 & 947 DI engines Use with 529 035 562.
Sleeve without groove PIN 529 035 567 Sleeve without groove. P/N 529 035 569
also available. also available.
21 mm Sleeve Insert .Alignment Tool Degree Wheel

P/N 529 035 569 Recommended P/N 529 035 590 Recommended P/N 529 035 607 Recommended
Use with P/N 529 035 563. XP & XP DI models All rolairy valve engines
Service 2009-1 6/21

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529035 887
.
(I I
Engine leak down test kit Valve stem seal installer Intake Plug
All 4-stroke engines 1503 engine 947DI engines
To perform a leak down test on engine,
COMPRESSOR RING Carbon Dam Guide Carbon Dam Compressor

947DI engines 947 DI engines 947 DI engines
529 0 35 719 529 035 765
shart alignment adaptor Valve spring compressor Piston circlip installer

PIN 529 035 719
•&@ffl!·IM PIN 529 035 724 Recommended PIN 529 035 765
•·1t!1MMM•
4-TEC engines 4-TEC engines 610150011503N-1000 engines
To be used with valve spring compressor
cup 529 035 764 and 529 036 073
CRANKSHAFT LOCKING TOOL Oil SEAL GUIDE Engine lifting ring

PIN 529 035 821 M&t!iMM'·'fW PIN 529 035 822 PIN 529 035 830 Recommendeq
4-TEC 1503 engines 4-TEC 1503 etigines 2-slroke engines with 14 mm spark plugs
Service 2009-1 7/21

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CAMSHAFT LOCKING TOOL RING GEAR BLOCKING TOOL Suction pump

PIN 529 035 839
MM!ftj!M(.jfW PIN 529 035 846 Recommended PIN 529 035 880 Recommended
V1000, V1300 &1503 engines 787 & 787 RFI engines
.. lill
- ----- -
TORX ADAPTOR 2-stroke engine lifting hook RING GEAR BLOCKING TOOL
PIN 529 035 938
wmfflf!Q<.1.w PIN 529 035 940 Recommended PIN 529 035 946 Recommended
4-TEC 1503 SC engines All 2-stroke engines 947 & 947 DI engines
• •
•
•
�
. -�
J'
t :: J.
SUPPORT PLATE 4-pin socket BEARING SUPPORT/PUSHER

PIN 529 035 947 PIN 529 035 948 PIN 529 ()35 950
•M•f"i!ttffi""'-·'l!lffll'll!J.llllJ;"W•
4-TEC 1503 SC 1503 supercharged 4-TEC 1503 SC engines
To hold the supercharger assembly In a To Install bearing of the supercharger
vise for disassembly and assembly. ground plate.
Crank shaft bearing puller Supercharger Gear Holder Supercharger Retaining Key
PIN 529 036 004 Recommended PIN 529 036 025
•@-�l".'l!ifflit!""'-•'1!1$1'11!(.lll!Jl"W• PIN 529 036 027
•@•t1".'1!1fflit!""'-•'1!1$1'11!(.llllj,"IM•
2 strokes Engine 4-TEC 1503 SC 4-TEC 1503 SC
Service 2009-1 8121

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Valve spring compressor cup Valve Guide Remover 6 mm Valve Guide Installer 6 mm
449, 991, 150 3, 610/500, Traxler 500 1503 1503.Traxter 500, Quest 610/500
To be used with 52.9 035 724
L
rt________________,,
.,,.
Strap Tool Piston ring compressor Torque angle gauge

PIN 529 036126 Recommended PIN Snap-on RC 980 Recommended PIN Snap-on TA362 Recommended
1503 HO 4-TEC Used on most 4-stroke engines.
Not sold by BRP Not sold by BRP
Valve stem seal removal pliers

P/N Snap-�n YA 8230 Recommended
1503, 991 engines, DS650
Not sold by BRP
Service 2009-1 9121

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Fuel
'
Fuel pressure gauge Pressure gauge Fuel Gauge T Adaptor
PIN P/N 529 035 710
529 035 591 Recommended PIN 529 035 709 MM!fft!M!.IfW
787 RFI. 793 SOI & 4-TEC engines Injection type engines 947 DI engines
Replaced by 529 035 709, Spare plastic Use with 529035652, 529035714 & Use with gauge PIN 529035709 and PIN
clip PIN 275500429 529036023 529 035 714.
529 036 714
Pressure Relief Valve Adaptor Air Compressor Adaptor disconnect tool

PIN 529 035 711
MMffif!M!·lf• P/N 529 035 712 @,l,lffttltj(.jfW PIN 529 035 714
MMfflit!Mi.tW
w
941 DI engines 947 DI engines Injection models
Use with gauge P/N 529035709 and P/N Use ith gauge P/N 529035709 and P/N Used also with gauge PIN 529 035 709,
529 035 714. 529 035 714. 529 035 652 & 529 036 023
Fuel hose adapter Fuel hose disconnect tool fuel pump· module sock.et
PIN 529 036 023 P/N 529 036 037 •M•r.l.&f"'1'1
l!ll1if!,¢. '-(.]lll
!!1 1 ilW• PIN 529 036 125 l@•!!ii"'1
.fflit!l!l ,tj!!l.'ll!
1j, lll!
lj,IW•
Injection type vehicles 1503, 1203 1503 2008
To be used with 529 035 709. Replacement Disconnect fuel hose
clip 513 033 135
Vented cap test adapter

PIN 529 036 141 MMffif!M(.jfW
Vented cap moctel
Service 2009-1 10/21

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Cooling
Flush Kit Flushing Kil Hose Flushing connector adaptor

P/N 295 500 068 Recommended P/N 295 500 258 Recommended PIN 295 500473 Recommended
97-98 GTS All models (except GTS) All models
Coolant oil pump gear holder Radiator C a p Pressure Test water pump seal pusher
P/N 420 277 905 Recommended P/N 529 021 400 Recommended PIN 529 035 823 Recommended
717, 583, 670, 599, 699. 779, 809 engine 4-TEC models 4-TEC 1503
Replacement part for item also Included in
kit861749100
Test cap
P/N 529 035 991 Recommended
All models
To be used with Vacuum/Pressure Pump
5.29 021 800.
Service 2009-1 11/21

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Electrical
MPI communication cables only D.E.S.S. Adaptor Magneto Harness 4 Pins

MPI not included MY 2003-05 787 RFI models 717 engines
To be used with the MPI or MPl-2. To. test the magneto.
Magneto Harness 6 Pins Suction Cup ECM adapter tool

PIN 295 000 136 Recommended P/N 295 000 163 Recommended PIN 420 277 010
Wit
7B1. 787 RF.1947 & 947 DI engines To remove gauges. All models
Replaced by 259 035 604 All injected 2-TEC & 4-TEC h YOO ECM
�. =-e
MPEM programmer guide Digital lnducljon tachometer Stroboscopic Timing Light
PIN 484 300 139 Recomme nde d PIN 529 014 500 Recommended PIN 529 031 900 Recommended
Guide: how to use hand held programmer All models All 2-stroke
Has been replaced by B.U.D.S., the MPI
and recently by the MPl-2.
529 035 604
Choke Nut Removal Tool Magneto harness Diagnosttc adaptor for VCK
Replaced by 529035943 787, 787 RFJ. 947 & 947 DI engines To be used with the MPI. connects to 529
To test magneto. 035807.
Service 2009-1 1212·1

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Electrical
9 Pins lo 25 Pins Adaptor D.E.S.S 4 Pin Adaptor MPl-2 Communication Cable Extension
To connect communication cable P/N 529 1998-2002 787 RFI engines Male/female 089 extension can be
035 697 o f MPI to older PC. Disconnect the D.E.S.S . p ost and connect purchassed at any PC store; max. 25 ft lg,
in series, then to MPI.
629 035 730
529035868
Crimping tool ( heavy gauge wire) Fluke 115 multimeter MPEM programmer kit
.All models All m o dels All 2-stroke models
Ex.: To crimp battery cable terminals. No longer sold, replaced by MPl-2, PIN 529
036 018.
• ---::;-\I •
D.E.S.S. Aclaptor KOSTAL Die AMP die
PIN 529 035 904
M{Jf!iMM(.jW PIN 529 035 906 Recommended PIN 529 035 908 Recommended
Connects to the diagnostic cable of the MPI All models with KOSTAL ECM connectors All models with AMP connectors
or MPl-2. To use with crimping tool 529 035 909 to To use with crimping tool 529 035 909 to
crimp ECU connectors crimp Deutsch connectors.
Crimping tool (Kostal) D.E.S.S. Post Remover MPI communication kit

PIN 529 035 909 Recommended PIN 529 035 943 Recommended PIN 529 ()35 981 Recommendeq
To use with compatible die to crimp All DESS equipped models Spare cables are still available. See MPl-2
different connectors
Service 2009-1 13/21

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Handheld MEM Pro gram me Cable 3-pin magneto harness adapter 787 RFI Timin g Tool
PIN 529 035 993 Recommended PIN 529 036016 Recommended PIN 529 036 017 Recommended
6 pin connedor 1503,449 MY 2005, 787 RFI
To test the magneto. To replace temperature sensor during
timing procedure.
MPl-2 interface card D.E.S.S. Post Interface Back probe test wires
PIN 529 036 018
MMttfitiM<.t.W P/N 529 036019
M1•1ttfitiMMk• P/N 529 036 063 Recommended
Replaces the MPI. To programm D.E.S.S. keys with the MPl-2. All models
To back probe various connectors.
ECM adapter tool MPl-2 diagnostic cable Multilock terminal extraction tool
P/N 529 036166 P/N 710 000 851
MMM*ffil.i&W P/N AMP 755430-2 Recommended
RXT iS and GTX iS All DESS-equipped vehicles Not sold by BRP
Service 2009-1 14/21

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Lubrication
Adapter Hose OIL FILTER COVER EXTRACTOR on Filler Cover Puller

P/N 529 035 652 MKtfflt!M<.llW P/N 529 036 038 Recommended PIN 529 036 057 Recommended
4 strokes engines 4-TEC 1503 4-TEC 1503
Used with 529 035 709. Replaced by 529 036 108
Oil filter cover puller Supercharger Oil Spray jet tool

P/N 529 036 108 Recommended PIN 529 036134 M?•tfflt!ffil·lf•
1503 1503 Supercharged (2008 and newer)
Used with 529 036 038.
Transmission I Propulsion
PTO FLYWHEEL IMPELLER TOOL IMPELLER SHAFT GUIDE TOOL Bearing I Seal Installer Tool
PIN 295 000 001 Recommended PIN 295 000 002 Recommended P/N 295 000 107 Recommended
All 2-stroke All 2-stroke models All 2-stroke engines
Service 2009-1 15121

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295 000 133
(o _(
VTS socket tool Jet Pump Bearing Remover Alignment Adaptor

All VTS equipped All 2-stroke models HX & XP models until 1998
Engine alignment Tool Plate for engine Alignment Pump Plate

PIN 529 035 506 •M*f!MMM P/N 529 035 507 M?i!ffiflMI·'• PIN 529 035 508 Recommended
All 155.6rnrn and 139.Smm jet pump 155.6 rnm jet pump 139.5 mm jet pump
Used with 529 035 506
529 035819
Inner Seal Installer Pump Bearing Pusher SEAL/BEARING PUSHER

P/N 529 035 609 P/N 529 035 818 PIN 529 035 819
Mbfffi!MMM M.f1!ffiflffll·'·• •M•f"'l!ffifl!ll!ll!','l!lfflPll!i."Ji"W•
All 155.6mtn jet pump models 4-TEC 1503 models 4-TEC 1503 models
529 035842
impeller remover/installer Floating ring tool I PTO support tool

PIN 529 035 820 PIN 529 035 841 PIN 529 035 842
•@•tP.'l,@fl!ll!ll!''!@l'll!(."Ji"·M• Mft!ffiflMHW
4-TEC 1503 NA and BV 1503 engine without super charger 4-TEC 1503 models
Also used to turn the engine.
Service 2009-1 16/21

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Pressure Cap Drive Shall holder Drive Shaft Adapter

P/N 529 035 843
M&tfflt!Mt.JgW P/N 529 035 871
MMfflt!M!.!W PIN 529 035 892
•&tfflt!Ml.IW
4-TEC 1503 models 4-TEC models, except RXP 4-TEC 1503 engines (except BV IC)
Replaced by 529 035 986 (RXP) tool that Install on drive shaft to turn engine as
fits all 4-TEC. required.
529 (}35955
lmpeler shaft installer/ Pusher impeller removerfinstaller Drive Shaft Adapter

P/N 529 035 955
•&tfflt!M(.JfM PIN 529 035 956
•M@M(.JfM P/N 529 035 985 Mfitfflt!M!.IW
4-TEC Plastic & Aluminum Jet Pump SC IC Models RXP (BV IC)
Tool used to push out impeller shaft and Tool used to remove and Install Impeller To install on drlveshaft lor turning engine
Install back bearing in pump. as require d.
Drive Shaft Holder FloaUng ring tool Drive Sh afi C-Clip Remover
P/N 529 035 986 P/N 529 035 987
•&tfflt!M!.!W P/N 529 036 026 Recommended
All 4-TEC 1503 RXP SCIC 4-TEC 1503
To hold drlveshaft In place when using the Tool used to push lhe floating ring to
floating ring tool. epxose C-clip on drive shaft
Floating ring tool II driveshaft wrencl) Impeller shaft bearing removal tool
P/N 529 036 116
•&tfflt!Ml.JfM PIN 529 036 167 P/N 529 036 168 Recommendeq
GTX SCISCIC, RXT SCIC RXT iS and GTX iS Starting from 2009
Service 2009-1 17121

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En9ine alignment tool

PIN 529 036 170
MM!f#!M(.jfW
RXT iS and GTX iS
Steering
(o --
ID
steering cable tool
PIN 295 000 145 Recommended PIN 529 035 840

All All O.P.A.S. models
Suspension
No picture available
gas fill tool kit Shock preload adjustment wrench Spring compressor
TIA shocks No longer sold, replaced by PIN 529 036

To be used with PIN 529035570. Spare 007.
needle P/N 529035930
Service 2009-1 18/21

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Suspension
529 035 504 Remplacemenl Component gas shock valve tool (tire valve type) Spring Remover
HX&XP TIA shocks All models

To easily remove HX & XP suspension, To remove coil spring from shock.
Various
296 000 054
co
Caillau pliers Oetiker Pliers Oe!iker p liers
PIN 295 000 054 Re mmended PIN 295 000 069 Recommended P/N 295 000 070 Recommend ed
All models All models All models
.small hose pincher LIFTKIT LIFT KIT

PIN 295 000 076 Recommended PIN 295100 204 Recommended PIN 295100 205 Recommended
All models LRVDI HEC
Service 2009-1 1!1/21

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Various
- -- --
.
•• •• �
• •
LIFT KIT LEAK SUPPLEMENT KIT Flexible spout For 011

P/N 295 100 206 Reconimended P/N 295 500 780 Recommended PIN 414 837 300 Recommended
All 2-slroke models. except LRV 787 RFI / 947 DI All models
Kit Includes 296 000 024/ 296 000 025/ 296
000 026/ 296 000 027
Handle Supertitanium drill bit 3/16'' Large hose pincher

PIN 420 877 650 Recommended P/N 529 031 800 Recommended PIN 529 032 500 Recommended
All 111odels To drill/remove many kinds of rivet. All models
To be used with many pushers.
-
I 0I
529 035 989
'
�
spring installer/remover spring Installer/remover (small) Blind hole bearing puller set
P/N 529 035 983 Recommended P/N 529 035 989 Recommencted PIN 529 036 117 Recommen<,led
All models All models

Replaced by 529036056
Slide hammer
PIN Snap-on CJ125-6 Recommended
All
No sold by BRP
Se rvi ce 2009-1 20/21

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Index
Tool Part Numbers ... Page These tools are mandatory
278001052......... ..... 12 420876569.............. 4 529035590 .............. 6 529035946.... "........ 8

278001978.............. 12 420876605.............. 4 529035591.............. 10 529035947 . ....... .. ..
. . 8
290877032.............. 2 420876609.............. 4 529035604 .............. 12 529035948 .............. 8
290877665.............. 2 420876904........ ...... 4 529035607.............. 6
I,529035950 .............. 8
295000001.............. 15 420876965.............. 4 529035609 ... ........... 16 529035955 .............. 17
295000002..... ......... 15 420876979.............. 4 529035652 .............. 15 529035956 .............. 17
295000054 .. .... ........ 19 420877414 .............. 4 529035661.............. 7 529035981. ............ 1.3
295000069......... ..... 19 420877635.............. 4 529035679........ .. .. . . 12 529035983.............. 20
295000070.............. 19 420877650.............. 20 529035681... ....... ..
. . 13 529035985 .............. 17
295000076 .............. 19 420877740.............. 4 529035685............. . 13 529035986 .............. 17
295000086.............. 2 420940755.............. 4 529035687.............. 7 529035987 .............. 17
295000101 .............. 2 420976235.............. 4 529035697.............. 13 529035989...... ......... 20
295000107.............. 15 420977475.............. 4 529035708 .............. 7 529035991.............. 11
295000114.............. 2 420977480....... ....... 5 529035709 .............. 10 529035993.............. 14
295000125.............. 2 420977490.............. 5 529035710 .............. 10 529036004............. . 8
295000130 .............. 2 484300139.............. 12 529035711 .............. 10 529036007.............. 19
295000131.............. 12 503190102.............. 18 529035712 .............. 10 529036016............ . . 14
295000133.............. 16. 529014500.............. 12 529035713.............. 7 529036017..... ......... 14
295000135.............. 2 529021400.............. 11 529035714 .............. 10 529036018 .............. 14
295000136.. -. - ,...... 12 529021800.............. 5 529035715.............. 7 529036019 ............. 14
295000141 ..... . .. .... 2 529031800.............. 20 529035716.......... .... 7 529036023 ............. 10
295000143............. . 2 529031900.............. 12 529035719 ............ .. 7 529036025 ............. . 8
295000144.............. 16 529032500 .............. 20 529035724......... .... 52903602.6 '""""""' 17
295000145.. .. .. .... 18 529032900...... .... .. '!8 •I 529036027 ............ 8
295000156.............. 2 529034600.. ......... .. 12 529035765 ....... ....... 7 529036037 .............. 10
295000157 .............. 16 529034800....... . ... .. 5 529035818 .............. 16 529036038............ .. 15
295000163.............. 12 529034900.............. 5 529035819 .............. 16 529036057.............. 15
295100204 ............. 19 529035000.. ........... 5 529035820 .............. 16 529036063..... ,........ 14
295100205 .............. ,9 529035100. .. ........... 5 529035821 .............. 7 529036073.............. 9
295100206.............. 20 529035503.. ... ......... 5 529035822 ....... ....... 7 529036086........... ... 9
295500068.............. 11 529035504........... ... 18 529035823 .............. i1 529036087.............. 9
295500258......... ..... 11 529035505........... ... 5 529035830 .............. 7 529036108.............. 15
295500352......... ..... 2 529035506 .............. 16 529035839 . ............. 8 529036116 .............. 17
295500473.............. 11 529035507 .............. 16 529035840 .............. 18 529036117.............. 20
295500780.............. 20 529035508.............. 16 529035841 .............. 16 529036125 ............. 10
414104700 ............. 3 529035513.............. 5 529035842 .............. 16 529036126. ........ .... . 9
414837300....... ...... 20 529035533.............. 5 529035843 .... ....... .. . 17 529036134 .............. 15
420276025..... ......... 3 529035541.............. 5 529035846.......... ... . 8 529036141 .............. 10
420277010 ... . ·· · ···· 12 529035542 ..... . . �... 6 529035868 ....... ...... . 13 529036166 .............. 14
420277905.............. 11 529035543.,............ 6 529035871 ····· ·· ··· ··· · 17 1529036167 .............. 17
420840681 ..... -....... 3 529035547.,............ 6 529035878 .............. 13 529036168............. , 17
420841201 .............. 3 529035549 ....... ...... 6 529035880 .............. 8 529036170 .............. 18
420841591 .............. 3 529035551............. 19 529035892 .............. 17 710000851 .............. 14
420847220 .............. 3 529035559... .,.... ..... 6 529035904 .............. 13 AMP 755430-2........ 14
420876330............. . 3 529035561 .............. 6 529035906.............. 13 Snap-on CJ125-6.... 20
420876488.............. 3 529035562.............. 6 529035908.. ............ 13 Snap-on RC 980..... 9
420876501 .............. 3 529035563.............. 6 529035909..... ......... 13 Snap-on TA362... .... 9
420876502..... ......... 3 529035567.............. 6 529035938 .............. 8 Snap-on YA 8230.... 9
420876552.............. 3 529035569.............. 6 529035940..........,... 8
420876557.............. 3 529035570.............. 19 529035943 .... ...... ,... 13
Service 21/21
sdd2011-002..soo_en..21
seni...•�aa. � Section
Specifications
Objective in this section you will find the most important specifications concerning this year line up.
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6
2011 SEA-000 BOAT IMPELLER CHART/

TABLEAU DES HELICES POUR BATEAUX SEA-000 2011
PITCH ANGLE @
P/N IMPELLER
IMPELLER O.D.
MODEL/ ENGINE/ ASSEMBLY/
MODELE MOTE UR
(deg)/ N/P DE HELICE
PAS DE L'HELICE AU DIAM.
COMPLET
EXT. DE L'HELICE (DEGRE)
150SPEEDSTER 1503 NA 10-21 204 160 350

150 SPEEDSTER 1503HO 14-24 204 160 353
14·24. 204 160 353
200SPEEDSTER 2X1503HO
14-23 267 000 569
180CHALLENGER 1503SCIC 10-20 204 160 355
180CHALLENGER SE 1503SCIC 10-20 204 160 .355
180CHALLENGER SE 1503 HO 14-23 267 000 569
10-20 267 000 434
210 CHALLENGER 2X1503 NA
11-17 267 000 527
10-20 267 000 434
210CHALLENGER SE 2X1503 NA
11-17 267 000 527
10-20 267 000 434
210CHALLENGER SP 2X1503NA
11-17 267 000 527
10-22 204 160 358
210CHALLENGER SE 2X1503SCIC
10-21 204 160 355
10-20 267 000 434
230CHALLENGER 1503NA
11-18 267 000 431
10-20 267 000 434
230CHALLENGER SE 2X 1503 NA
11-18 267 00.0 431
10-21 204 160 358
230CHALLENGER SE 2X1503SCIC
10-20 204 160 355
10-21 204 160 358
230CHALLENGER SP 2x 1so3 sere
10-20 204 160 355
14-25 267 000 442
230CHALLENGER SE 2X1503 HO
14-23 267 000 569
10-20 267 000 434
210 WAKE 2X1503NA
11-17 267 000 527
10-22 204 160 358
210 WAKE 2X1503.SClC
10-21 204 160 355
10-21 204 160 358
230 WAKE 2X1503SCIC
10-20 204 160 355
14-25 267 000 442
230 WAKE 2X1503 HO
14-23 267 000 569
sd<l201 1-002-600
.---... ,�-,��- SECTIO N��-�-- ----_ __
S e ci� ica tio n s
6
SEA·DOO BOAT HIGH ALTITUDE IMPELLER CHART/

2011 I
TABLEAU DES HEL.ICES POUR BATEAUX SEA�DOO 2011

(HAUTE ALTITUDE}
PITCH ANGLE @
P/N IMPELLER
IMPELLER O,D.
MODEL/ ENGINE/ ASSEMBLY/
(deg)/
MODELE MOTEUR N/P DE HELICE
PAS DE L'HEUCE AU DIAM.
COMPLET
EXT. DE L'HELICE (DEGRE)
150SPEEDSTER 1503NA 11-16 267 000 449

150SPEEDSTER 1503HO 14-23 267 000 456
14-23 267 000 456
200SPEEDSTER 2 X 1503HO
14-23 267 000 456
180CHALLENGER 1503SCIC 10-21 267 000 452
180CHALLENGER SE 1S03SCIC 10-21 267 000 452
180CHALLENGER SE 1503HO 14-23 267 000 456
11-16 267 000 449
210 CHALLENGER 2X 1503 NA
11-15 267 000 447
11-16 267 000 449
210 CHALLENGER SE 2 X 1503NA
11-15 267 000 447
11-16 267 000 449
210CHALLENGER SP 2X 1503NA
11-15 267 000 447
10-21 267 000 452
210CHALLENGER SE 2X 1503SCIC
10-21 267 000 452
11-16 267 000 449
230 CHALLENGER 1503NA
11-15 267 000 447
11-16 267 000 449
230 CHALLENGER SE 2X 1503 NA
11-15 267 000 447
10-21 267 000 452
230CHALLENGER SE 2X 1503SCIC
10-21 267 000 452
10-21 267 0004 52
230CHALLENGERSP 2X 1503SCIC
10-21 267 000 452
14-23 267 000 456
230 CHALLENGER SE 2X 1503HO
14-23 267 000 456
11-16 267 000 449
210 WAKE 2X 1503NA
11-15 267 000 447
10-21 267 000 452
210 WAKE 2X 1503SGIC
10-21 267 000 452
10-21 267 000 452
230 WAKE 2X 1503SCIC
10-21 267 000 452
14-23 267 000 456
230 WAKE 2X 1503HO
14-23 267 000 456
sdd2011-002.eo<l
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6
2011 SEA-000 WATERCRAFT IMPELLER CHART/

TABLEAU DES HELICES POUR MOTOMARINES SEA-000 2011
PITCH ANGLE @
IMPELLER 0.0. P/N IMPELLER
MODEU ENGINE/ MODEL NUMBER/ (deg)/ ASSEMBLY/
MODE LE MOTEUR NUMERO DE MODELE PAS DE L'HELICE AU N/P DE L'HELICE
DIAM. EXT. DE COMP LET
L'HELICE (DEGRE)
GTI 23BA
1503 OT 11-18 267 000 532
GTI inti 23BB
GTI SE 24BA,24BC
1503 OT 11-18 267 000 532
GTI SE inti 24BB
GTI Limited 39BA
1503 NA 11-18 267 000 532
GTI Limited intl 39BB
GTI SE 30BA
1503 NA 11-18 267 000 532
GTI SE inti 30BB
GTS 43BA
GTS inti 1503 OT 43BB 11-18 267 000 532
GTS inti (RENTAL) 25BA
GTS PRO 1503 OT 44BA 11-18 267 000 431
GTX 38BA
1503 NA 11-18 267 000 577
GTX inti 38BB
GTX 42BA
1503 SCIC 10-21 267 000 575
GTX inti 42BB
GTXiS 1503 SCIC 33BA 10-21 267 000 575
GTX LTD iS 18BA
1503 HO 14-23 267 000 567
GTX LTD iS inti 18BB
RXP-X 32BA 14-24 267 000 444
1503 HO
RXP-X RS inti 32BB 14-25 267 000 481
RXT 17BA
1503 HO 14-23 267 000 567
RXT inti 17BB
RXTiS 34BA
1503 HO 14-23 267 000 567
RXT iS inti 34BB
RXT-X 31BA
1503 HO 14-23 267 000 567
RXT-X RS inti 31BB
RXT-XaS 41BA
1503 HO 14-23 267000567
RXT-X RS aS inti 41BB
WAKE 35BA
1503 NA 11-18 267 000 532
WAKE inti 35BB
WAKE PRO 26BA
1503 SCIC 10-21 267 000 575
WAKE PRO inti 26BB
sdd2011.002.eo6
.---... ,�-,��- SECTIO N��-�-- ----_ __
S e ci� ica tio n s
6
2011 SEA-DOO WATERCRAFT HIGH ALTITUDE IMPELLER CHART/

TABLEAU DES HELICES POUR MOTOMARINES SEA-DOO 2011
{HAUTE ALTITUDE)
PITCH ANGLE @
IMPELLER 0.0. P/N IMPELLER
MODEU ENGINE/ MODEL NUMBER/ (deg)/ ASSEMBLY/
MODE LE MOTEUR NUMERO DE MODELE PAS DE L'HELICE AU N/P DE L'HELICE
DIAM. EXT. DE COMP LET
L'HELICE (DEGRE)
GTI 23BA
1503 OT 11-17 267 000 600
GTI inti 23BB
GTI SE 24BA,24BC
1503 OT 11-17 267 000 600
GTI SE inti 24BB
GTI Limited 39BA
1503 NA 11-17 267 000 602
GTI Limitedint! 39BB
GTI SE 30BA
1503 NA 11-17 267 000 602
GTI SE inti 30BB
GTS 43BA
GTS inti 1503 OT 43BB 11-17 267 000 600
GTS inti (RENT AU 25BA
GTS PRO 1503 OT 44BA 11-15 267 000 447
GTX 38BA
1503 NA 11-16 267 000 594
GTXinti 388B
GTX 42BA
15031C 10-19 267 000 596
GTXinti 42BB
GTXiS 15031C 33BA 10-19 267 000 596
GTX LTDiS 18BA
1503 HO 14-22 267 000 598
GTX LTDiS inti 18BB
RXP-X 32BA
1503 HO 14-23 267 000 456
RXP-X RS inti 32BB
RXT 178A
1503 HO 14-22 267 000 598
RXTinti 178B
RXTiS 34BA
1503 HO 14-22 267 000 598
RXTiS inti 34BB
RXT-X 31BA
1503 HO 14-22 267 000 598
RXT-X RS inti 31BB
RXT-X as 41BA
1503 HO 14-22 267 000 598
RXT-X RS aSinti 41BB
WAKE 35BA
1503 NA 11-17 267 000 602
WAKEinti 35BB
WAKE PRO 26BA
15031C 10-19 267 000 596
WAKE PROinti 268B
sdd2011-00 2-006
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ALL-NEW MODEL FOR 2011
/BR ITC CLCS
Specifications
DIMENSIONS
Length . .
........ ...
.... ......... 132.6' /336.8 cm
. ..............
Wtdlh . . .. ..
...... . . .... . . . ..48.5' f 123 I cm
....... ...... ........ . .
Height .. . .. . .. .44' / l I l.8 cm

...... . . ...... ......... .... ... ....
a
Weigh! (dry).... ... . ...745 lb./ 338 kg
........................
Rider cap city ...............................3

Fuel capacity................... ......15.9 US gai i 60 l
.
Storage capacity . . .. . . . . . .30.8 US gal 1116.6 I

.......... . .... ..
ENGINE
Typc .............................................. .1503 Rotax$> 4-TEC• engine

Intake system ................................ Naturally aspirated with
60 mm throttle body
1BR Untelli&ent Bnlile l Reverse) ITt" 1ocludm& lounog I Sport mode Bore x stroke .................................. 100 mm x 63.4 mm
01splacemenl .. ...... ..... ... ...... ........ .. 1,494 cc
Compression 1at10 ......................... 10.6:I
Coollng •........... ...... .............. ........ .. Closed·loop cooling system
Fuel lype ....................................... .87 octane
DRIVE UNIT
Propulsion syslern .. . .. . . .. ...... .... ..Sea-Ooo"' Direct Drive

... .
Jet pump .......................................Aluminium. axial now. single stage.

large hub with IO·vane stator
Transmission iBR'"
Wlde-anale m1rron
..........•.•..........•••.......
Clmd·luop caoltng tr•t•m JtlCS)

1n1peller ......................... ...... .. ..
... ... Stainless steel
ELECTRICAL
lgnftion .
................. .................... ... . Oigijal Induction
Starter...........................................Electnc
Battery .......................................... 12 v
HULL AND COMPONENTS
Type ............................................... Ln. composite
Di&i�l lnform a � on cenue a

IC011trol" proantmm•blo le rnlna �Cl'-
Colour ............................................ Black and White
sdd20 1 H l02-Mr _en_ 1
.---... ,�-·��- SECTION
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Standard Features GTI 130 �

::u
HULL AND COMPONENTS
fT1
Touring ISport mode........... ... Offers a choice between two lhrollle responses for �
dittcrent riding styles. Touring mode is the default
0
setting offering a more progressive acceleration 2
curve tor a more confident ride -Ideal for cruising
and 2-up riding. Sport mode c an be e sly activated
usmg the Set button. It provides all acceleration
ai N
0
.......
performance for a more aggressive throtUe 1espo11se. .......
3-up seat ....................... ..... Comfortable room for three- permits
rear-lacing spotter for watersports. ENGINE
Elevated luel li1le1........... .... Easy access and prevents water inlrusion while
1,494 cc lour-stroke, ............ t503 Rotax 4-TEC engine provides reliable
refueling.
Rotax with tout valves perto1mance in fresh ot salt water, increased torque
Multifunction Digital............ Reports 19 key operatrng functions:
per cylinder al low RPM. optimised power al all RPM levels and
Information Centre Fuel level, Tachometer, Speedometer, Touring I throttle positions.
Sport mode, Hour meter, Compass, f-N-R Indicator,
Multi-port fuel injection_. ... Better control ot exhaus1 emission and power at all
Low fuel levef. lowoll pressu re, Low V(lllage,
Overheat, HI voltage, Check engine. Sensor check. RPM ran ge s to reduce emissions and reduce iuel
Battery p1otechon, Key (wrong key), L-key I R-Key , consumption.
Maintenance info. Error codes. ITC (Intelligent ..................... Operating electronically, this advanced throttle system
Throttle C-OntrolJ system starts yoo In neutral tor easier dockside starts. II also
Digitally Encoded Security ... Industry's first drgl t al!y encoded thett-deterrent
fealu1es an activity-specific cruise wntrol, Touring I
System (0.E.S.S.�) system.
Spor1 mode and VariableTrim System that can all be set
Foam flotation ...... -.............. Ride with security and peace of mind. Meets 01 to accommodate your riding style. The result is a more
exceeds USCG standards.
responsive. moie intuitiveride.
Ott-Throttle Assisted .... Provides the opera!orwllh additional steei r ng iControl learning Key ........... The programmable learning Key allows you to limi t the
Steering (0.T.A.S."l effect in off-th1ottle si tuatrons for greater performance ol the PWC based on rider skill-level. Each
manoeuvrability.
of the two settings can be fine-tuned using the mode/
Sponsons set bultons,
Bumpers D-Sea-Bel'" system .............. Combines a series of resonators and vibrat1on
Footwetl c a1pets absorbinR romPi)nenls to make Sea-Ooo watercratt
some of the quietest on the water.
Ski tow hook
Closed-loop coohng system ... Uses coolant to keep the engrne running at the ideal
Reboarding platform temperature, much like a car's radiator. Also keeps out
Wide-angle mirrors corrosive saltwater and debris.
Rear grab handle Water/air separalor .............. Provides maximum a lrtlow to engine and reduces
Dual drain plugs water intrusion.
External exhaust cooling flush attachment Watertight digital ignition.... Provides optimal energy for a consistent spa1k.
ens uring maximum performance.
Double density comfort hand grrps
RPM l1m1ter .......................... Protects engme trom over-rewrng.
Eme1ge11cy floating la11ya1d
Warning devrce..................... \Yarns operator of engine and exhaust overheating.
Cut & sew seal with three colours engine management and system failure.
Seat strap Handlebar-mounted ..... ........ Engine sta r1s and stops with single,
Operator's guide, instructional video and booklet start/stop button user-friendly control button.
Tip over Protection-............. Protects engine an case of turn over.
OPTIONS System (l.0.P.S.")
Fold-down reboarding step rop/average speed/RPM PROPULSION SYSTEM

3-position retiactable ski pylon lap timer
Sea-Ooo Direct Drive ............ Delivers optimum perlom1ance with the Rota�
Removable wakeboard rack Engine temperature propulsion system engine.
Depth finder fligh-performance VTS™ IBR (Intelligent Brake .. The world's only on-water braking system, !BR leis you
Crulse control Removahle di)' bag !or front storage & Reverse) system stop up to JOO feet sooner than any other watercraff1•
All with the squeete of a feve1. And with its electronic
Ski mode Skr tow eye
reverse. It gives you a level of manoeuvrability that
Slow mode Speed Tie"
makes docking easier.
Clock Safety kit Aluminium stator vaoes ....... llandles the h1gh-performance engine without erosion.
fuel consumption mete1 Sandbag anchor Dual automatic vacuum ....... Continuously removes waler entenng the
New ECO mode Protective cover siphon pumps engine compartment ,
Time/d1sta11�-e to empty Fire extinguisher Large diameter drive shaft... Maintains engine and pump alignment at all
with c101Vned spline design operating speeds.
Replaceable UHMW* ............ Provides long impeller file, less maintenance
wear ring a11d maximum thrust.
WARRANTY
Stainless steel ...............,..... Delivers imp1ovecl acteleration, higher lop spee<I
BRP limited wananty covers the watercralt for one year.• Impeller and less cavitatlon.
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All-NEW MODEL FOR 2011
IBR iTC CLCS EC�

Specifications
DIMENSIONS
Length........................................... 132.6' / 336.8 cm
Wtdth............................................. 48.5" /123.1 cm
Height ........................................... 44' / 111.8 cm
Weight (dry)...................................745 lb. / 338 kg
Rider capacity ............................... 3
fuel capacity . . ....... ........ . .... .... 15.9 US gal/ 60 I
.... .. .
Storage capacity ........................ .. 30.8 US gal/ 116.61
ENGINE
Type ... ... .......... ............. .. ... .......... ...1503 NA Ro1ax" 4-TEC"engine
Intake system.............. ..-............. Naturally aspirated with
60 mm throttle body
Bore x stroke .... 100 mm x 63.4 mm
Displacement.. ...........................1,494 cc
Compression ratlo..... .....10.6:1
Cooling................ ....Closed-loop cooling system (CLCS)
Fuel type...... ........................... .... 87 octane
DRIVE UNIT
Propulsion system.........................Sea·Ooo8 Direct Drive
Jet pump ....................................... Alumrn1um. axial llow, single stage,
large hub with 10-vane stator
Transmission.... ....1BR
c.. , •• cont tol l rco mode Wld•·•nP
le
. mlnou
..
Impeller........ ........................... ...Stainless steel
ELECTRICAL
lgn ilion......... ..... Digital l n duction
Slarter.......... .......................... ....Electric
Battery......... ... 12V
HULL AND COMPONENTS

Type............................................... LFI, composite
Colour............................................Manna Blue
t.lultr 1unctloo dl11talJnlotentre
sdd2011.002.eo1 _en_ 3
.---... ,�-·��- SECTION
��-�------_ __ �ic i
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6
Standard Features GTI LIMITED 155

HULL ANO COMPONENTS ENGINE
Touring I Sport mode.......... .... Offers a choice between two throttle responses for 1,494 cc four-stroke, ............ 1503 NA Rotax 4·TEC engine provides reliable
dltterenl riding styles. Touring mode is the default Rotax with rour valves performance in rresh or saltwale1, increase<! torQue
setting offering a more progressive acceleration per cylinder al low RPM, optimised power at all RPM levels and
curve tor a m01e confident ride - ideal for cruising throttle pos11!ons.
a11d 2-up riding. Sport mode can be easily activated iTC (Intelligent ..................... Operating electronically, this advanced th1oltle system
using the Set button. It provides all acceterahon Throttle Control) system starts you in neutral tor easier dockside starts. It also
performance tor a more Aggressive throttle response. features an act1v1ty-spec1fit cruise oontrol, Touring/Sport
ECO mode ............................ The newest iTC'" function that automatically mode, ECO modeand Variable Trim System that Clln all
determines the most economical power delivery and be set to accommodate your riding style. The result ls a
sets the optimal speed tor greatest fuel eoonomy. more responsil'e, m01e intuitive ode.
Elevated fuel llller................ Easy access and prevents water intrusion whlfe 1Conlrol Learning Key�........ .The programmable Learning Key allows YQU to limit
refueling. the performance of the PNC base<! on rider skill level
Touring seat ......................... Ergonomically designed tor comtort and great looks Each ot the two settings can oo tine-tuned using the
providing ultra-plush seating tor three. mode/set buttons.
Mult1tunctlon Digital ............ Reports 29 key operahng !unctions: D-Sea-Bel'" system.............. Combines a series of reS-Onators and vibralion
lnfo1malion Centre Fuel level. Tachometer. Speedometer. Touring I absorbing components to make Sea-Ooo watercraft
Sport mode, Crmse control, Slow mode, New ECO S-Ome ot the quietest on the water.
mode. Altitude, Hour mete� Compass, Clock, Fuel Multi-port fuel in1ection ....... Better control or exhaust em1ss1on and power at all
consumption mete1. Time/Oistanoe to empty, VTS, RPM ranges lo reduce emissions and reduce fuel
VfS preset, f·N·R indicator, low fuel level, low oil consumption.
pressure, Low voltage, Overheat Hr voltage, Check
Closed-loop coolmg system.. Ensures the proper operaling lem!J{lrature at all
engine, Sensor check, Battery protection, Key (wrong
speeds and improves conosion durability.
key). l-Key IR-Key, Maintenance mfo. Error codes.
Water/air separator.............. Provides maximum airflow to engine and reduces
Digitally Encoded Secunty.... lndustry's first digitally encod8Q theft-deterrent
water Intrusion.
System IO.E.S.S.�) system.
Waterllght d1g1tal rgmhon .... Provrdes optimal energy for a consistent sparl\,
Foam liotalton . ._...... ........ ... Ride with secu1ily a11d peace of rnind. ensuring ma�imu111 performance.
Meets or exceeds USCG standaids.
RPM limiter .......................... Protects engine from over-revving.
OU-Throttle Assisted ............ Provides the operator with additional steeling
Warnrng device..................... Warns operator of engine and exhaust overheating,
Steering (0. T.A.S.'") ellect in ott·lhrottle situations tor greater
engrne management and system failure.
manoeuvrability.
Handleba1-mou11ted ............. E11gine starts and stops with single,
Fold-down reboardmg step .. Makes reboarding from the wale1 easier
start/stop button user-frlendly oontrol button.
and quicker.
Tip over Protection ............... Protects engrne tn case ot turn over.
Sponsons
System (T.0.P.S.�l
Bumpers
Platform carpets double colouration PROPULSION SYSTEM
Reboardi11g platform
Sea-Ooo Direct Dnve ........... Delivers optimum �rformance with the Rotax
Wide-angle mirrors
propulsion system engine.
Rear grab handle iBR (Intelligent Brake........... The world's only on-water braking system, iBR lets
Dual dram plugs & Reverse} system you stop up to 100 feet sooner than any other
External exhaust cooling flush attachment watercraft'. All with the squeexe of a lever And
Double density comfort hand grips with its electronic reverse, ii gives you a level of
manoeuvrability that makes docking easie.r
Emergency floating lanyard
Aluminium stator vanes....... Handles the high-performance engine without
Cul & sew seat with three colours
erosion.
Seat strap
Dual automatic vacuum....... Continuously removes water entering the
Operator's guide, instructional video and booklet siphon purnps engine compartme11L
Large diameter drive shalt... Maintains engine and pump alignment at all
with cr�vned spline design operating speeds.
OPTIONS
Replaceable UHMW" .......... Provides long Impeller llle. less maintenance
3-posilion retractable ski pylon Lap timer wear ung and maximum thrust.
Removable wakeboard rack Engine temperature Stainless steel ..................... Delivers improved acceleration. higher ton
Impeller speed and less cavitation.
Depth finder Spe8Q rie··
Ski mode Protective cover
LIMITED PACKAGE
Top/average SIJ{led/RPM Fire extinguisher
Additional gauge functions.. Cruise control, Time/Distance lo empty, Altrtude.
Chrome parts ............ -......... For extra style and premium looks.
WARRANTY
Removable dry bag .............. Keeps contents dry and converts to backpack when
BRP limited warranty covers the watercraft ror one year.• removed.
Sandbag anchor................... Easy way to hold YQur boat In one positron.
Safety kit........... _................ Contains alf the essential safely equipment.
Custom boat cover ............... Protect your PWC.
High-performance electric ... Provides pre-set positions 101 quick settings
vrs (Vartable Trim �fem) when adjusting boat trim, maximises accelerallon
and high-speed stability.
Ski Tow Eye........................... For easy and secure attachment ot �kl rope.
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iBR iTC CLCS EC�

Specifications
DIMENSIONS
length ...........................................132.6" / 336.8 cm
l'lidlh .............................................48.5"/ 123.I cm
Height ...........................................44" / l ll.8 cm
Weight (dry)................................... 745 lb./ 338 kg
Rider capacity ...............................3
Fuel capacity................................. 15.9 US gal/ 60 I
Storage capacity ...........................30.8 US gal/ 116.6 I
ENGINE
Type ...... ..... ...................... .... ........ .. 1503 NA Rolax* 4-TEC•engme
lnlake system...... .. ..Naturally aspirated with
60 mm throttle b-Ody
fuu11naseat 1BR" llnlllb11nl Brake l Reverse) Bore x stroke..................................100 mm x 63.4 mm
Oisplacemenl ................................ 1,494 cc
Compression ratio .........................10.6:1
Coolirrg....................................... ...Closed-loop cooling system {ClCS)
Fuel type .... .
.. .. ...... ...... . ... ....... .... . .. 87 octane
.
DRIVE UNIT
Propulsion system .........................Sea-Doo"' Direct Drive
EC� let pump ........ ....................... ....Aluminium, axial flow, single stage,
large hub with IO-vane stator
Transmission .... ........... ..... ...IBR
... .. .. .
Fold-down roboard1111 stcp ECO model v1s• 1vanabl1 lnm Systoml

Impeller. ........................ .....
... .. .... Stainless steel
ELECTRICAL
lgmhon. .... ..... ..... ...
.. . ..... ... . . .. Oigital induction
..... ... .
Starter .. ..... ... .... ..

... ... ...... ...... ... .... .. Eleclric
Battery . ..... .... ..
... .... ... .... ... .... ... .... .. 12 V
HULL AND COMPONENTS

Type............................... ................ LFI, composile
Colour ............................................ Black and Sunshine
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Standard Features GTI SE 155 fT1
()
HULL AND CDMPOHENTS ::0
fT1
Touring I Sport mode........... ...Otters a choice between lwo throttle responses for
ditferenf riding styles. Touring mnde Is lbe d efaull �
selling offering a more progressive acceleration 0
curve for a more contldenl ride -Ideal for cruising z
and 2-up riding. Spurt mode can be easily activated
using lhe Set butlon. II provides all acceleration I\.)
perforrnauce for a more aggre s
s ive llrroltle response. 0
,......
ECO mode ............. .............. The newesl ITC'" tunclion that aulomatically ,......
determines the most economical power deliveiy and
sets lhe oplimal speed for greate sl tuel econom.v.
Elevated fuel filler... ............ Easy access and prevents water rnlrusron whrte ENGINE
refu eling.
1,494 cc four-stroke ............. 1503 NA Rotax 4-TEC engine provides reliab le
Touring seat ......................... Ergonomically designed for comfort and great looks
Rotax with lour valves performance in fresh or saltwater, increased torque
providing ultra-plush seating fo r l h ree .
per cyhnde r al low RPM, optimised power at all RPM levels and
Mullitunct1on Dlg1tal ............ Reports 23 key operaling funclrons:
throttle posilions.
Information C ent re Fuel level. Tachometer. Speedometer, Touring I Sport
ITC'" (Jnlelllgent .................. Operaling etectrnnlcally. this advanced throttle system
mode, New ECO mode, Hour meter, Compass, Clock,
Fuel consumption meter. VTS'", F-N·R indicator. Throttle Control) system starts you in neulrat tor easier dockside slarts. It also
Low fuel level, Low 011 pressure. Low voltage. features an activity-specific cruise conlrol, Touring I
Overheat, HI voltage, Check engine, SensOf check, Sport mode, ECO mode and Variable Trim System that
Battery protection, Key (wrong key), L -Key IR-Key, can all be sel to accommodate your riding style. The
Maintenance info, Error codes. 1esull is a more responsive, 11101e inluilive ride.
01g1tally Encoded Secunty... . lnduslly's frrsl d1gilally encoded the1t· dete rrenl !Control Leaming Key ........... The programmable learning Key allows you to limit the
System (O.E.s.s;·) syslem performance ol the l'WC based on rider skiU-levei. Each
Foam flotalron ...................... Ride wrth security and peace of mind. Meets or of the two settings can be fme-tuned using lhe model
exceeds USCG standards set buttons.
Off-Throttle Assisted ............ Provides the operator with additional steering D-Sea-Bel'" system... .......... Combines a series of resonators and vibration
Steering (0 T.A.S.") effect in off-throttle-situalions lor greater absorbmg components to make Sea-Doo watercraft
manoeuvrab1hty. some of the quietest on the water.
Sponsons MullI-port fuel Injection ....... Better conlrol ol el(haust emission and power at all
Bumpers RPM ranges l o reduce emissions and reduce fuel
Platform carpels double colouration consumption.
Ski low hook Closed-loop cooling system.. Ensures the propei operating lempelal ure a l all
speeds and improves corrosion durabiltty.
Reboarding p la tform
Waler/air separator .............. Provides maximum airflow to engine and reduces
Wide-angle mirrors
waler intrusio11.
Rear grab handle
Watertight digital ignition .... Provides optimal energy for a consistent spar1\,
Dual drain plugs
ensuring maximum performance.
External exhaust cooling llush atlachment
RPM limiter ,_... ...... . ........ . .. . Protects eogine irom over-1evvrng.
Double density comfon hand grips
Warning device........ ............. Warns operator of engine and exhaust overheating,
Emergency floating lanyard engine management and system farlure.
Cut & sew seat wilh three colours Handlebar-mounted . .....-... Engine starts and slops with single,
Seat sl1ap start/slop button user-friendly control button
Operalor's guide. Instructional video and booklel Tip Over Protec tion ... ........... Protects engine In case of turn over.
Syslem ( r.O.P.S.'")
SE PACKAGE
Fold-down reboarding step. ..........Makes reboarding 1ron1 the waler easier and PROPULSION SYSTEM
quicker. Sea-Doo Direct Drive ............ Delivars oplimum performance wilh the Rotax
Chrome parls ..., ................... ........For extra slyle and premium looks. propulsion system engine.
Addltlonal gauge !unctions. . ...... .. .VTS, lu el consumpflon meter. clock, IBR (Intelligent Brake........... The world's only on-wate1 brakmg system. tBR tels you
& Reve rse) system �top up to 100 feet sooner than any other watercralt'.
OPTIONS All with lhe squee1e of a lever. And with its eleclronic
reverse, It gives you a level ot manoeuvrability that
3-posilion retractable skr pylon Engine temperature
Removable wakeboard rack High-performance VTS
Aluminium stator vanes....... Handles lh e high-penormance engine without erosion,
Oeplh fin de r Removable dry bag for fronl storage
Dual automatic vacuum . ...... Continuously removes water entering lhe
Cruise control Ski tow eye
siphon pumps engine companment.
Ski mode Speed lie�
Large diameter dnve shaft ... Maintains engine and pump alignment al all
Slow mode Safely kit
with crowned spline design operating sp ee ds.
lime/dlslance to empty S<indbag anchor
Replaceable UKMW' • .......... Provides long impeller ltte, less maintenance and
Top/average speed/RPM Proleclive cover wear nng maximum thrust.
Lap timer fire exlingulsher Stainless steel .. Delivers improved acceleration, higher lop speed
impeller and less cavitation.
WARRANTY
BRP limited warranty covets the wateicraft lor one year.•
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iTC CLCS
Specifications
DIMENSIONS
length...........................................132.6"/ 336.8 cm
Width. ... ... . ...
. .. ..... .. .. . ..
. . . . . .. .48.5'/ 123.I cm
..... . ... ..
Height ........................................... 44'/ l l l.8 cm

Weight (dr;).................................. .735 lb./ 333 kg
Rider capacity............................... 3
Fuel eapacity ................................ .15.9 US gal/ 60 I
Storage capacity ...........................
30.8 US gal/ 116.6 l
ENGINE
Type ............................................... 1503 Rotax" 4-TEC"'englne
Intake system ................................Naturatly aspirated with
1TC' lncludrn1 lourln1/ Spoil mad• LilT&eswim plJtfarm GO mm throttle body
Bore x stroke ..................................100 mm x 63.4 mm
Displacement ................................1,494 cc
Compres sion ratio .........................10.6:1
Coollng.......................................... Closed-loop cooling system (CLCS)
Fuel type ........................................87 octane
DRIVE UNIT
Propulsion system .........................Sea-Ooo" Direct Drive
Jet pump .......................................Alumi1liu111, axial tlow. single stage.
W1de-an1le mirrors Clmd·loup tool1111 sr>l•m !ClCS)
Impeller.........................................Stainless steel
.:· ELECTRICAL
lgnition ..........................................Oigital induction
C'() ' .�
Starter........................................... Electric
Battery .......................................... 12 v
HULL ANO COMPONENTS
.� Type . .. ... . .. .. .. . LFI, composite

• �1· .... ...... .... ... ..... ..... . ...
Colour.............. .............................Viper Red and While

Dlgltal lnform;tlon cenlre wit� S11 eed ome1e• ICowo1- orogrammabl o lmnln& Key"
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Standard Features GTS 130

HULL AND COMPONENTS
Tou11ng/Sp011 mode .. ..-.-.....Offers a choice between two throttle 1esp-011ses 101

d iffe rent riding styles. Touring mode is the defaull
�etting olfering a more progressive acceleration
cum for a mor e c ontidenl ride-Ideal for cruising
and 2-up riding. Sport mode can be easily activated
using the Set button. II provides all acceleralion
performance for a more aggressive lh1ottle response.
3-up seal............ .... Comfortable room lor thre e -permits
rear-facing spotter for watersl)l)rts.
Elevated fuel hller ..... ...... .. .. .Easy access and prevents water intrusion whlle ENGINE
refueling.
1,49� cc four-stroke........... 1503 Rota� 4-TtC engine provides reliable
Multifunc tion Digital ...... ..... Reports 17 key operating functions:
Rolax with tour valves performance In lresh or sallwater, increased torQue
Information C entre Fuel level, Tachometer. Speedometei. Touring I
per cylinder at low RPM, optimised power at all RPM levels and
Sport mod e . Hour meter, low fue l level, Low oit
throttle positions.
pressure, low voltage, Overh!lal, Hi voltage, Check
engine, Sensor check, Battery protectio n , Key {wrong iTC (Intelligent... .. . .. ...
. _ . .... .. TI1e most advanced throttle control oo a FWC. For
key), L-Key IR-Key, Maintenance info, Error codes. Throttle C-Onlrol) system improved en gine resp onse .
iControl Learnrng Key .. ......... The programmable Learning Key allows you to limit
Digitally Encoded Secunty .... lndustry's first digitally encoded theft-deterrent
the performance of the PWC based on rider skill-level.
System (D.E.S.S.") system.
Each of the two settings can be fine-tune d using the
Foam flotation. .... . ........ ....... Ride with secu1ity and peace ol mind. Meets oi modelsel buttons.
eiceeds USCG standards.
Mutti·port fuel Injection .•••... Better control of e�haust emission and power at all
Off· Throttle Assisted ........... Provides the operator with additional steering RPM ranges t o reduce emissions and reduce luel
Steering (0.T.A.S.") effect In off-throttle situations f o r greater consumption.
manoeuvrability,
D-Sea-Bel'" system .............. Combines a series ot resonators and vibratlon
Sponsons absorb1ng components to make Sea-Doo watercratt
Bumpers some of the quietest on tl1e water.
Foolwell c�rpels Closed-loop coolinR system .. Uses coola nt to keep the en Rine running at the Ideal
temperature, much like a car's radiator. Also keeps
Ski tow hook
out corrosive saltwater and debris.
Reboarding platform
Waterla1r separator .............. Provides maximum arrttow to engine and reduces
Wide-angle mirrors water intrusion .
Rear grab handle Watertight d1g1tal ignrtlon .... Provides optimal energy tor a consistent spark.
Dual drain plugs ensuring maximum performance .
External exhaust cooling flush allachment RPM limiter .......................... Protects engine from over-rewrng.
Double density comlort hand grips Warning device ..... .... .. .. ..... ... Warns operator of engine and exhaust overheating.
engine management and system failure.
Emergency ltoallng lan yard
Handteba1-mounted ............. Engine starts and stops with srngle,
Cut & sew seat wtth three colours startlstop button use1-hiendly control button.
Seat strap Tip Over Prote<:tion ...............Protects engine 1n case ot turn over.
Ope1ator's guide. instructional video and booklet System (T.O.P.S.")
OPTIONS PROPULSION SYSTEM
fold·down reboarding step Speed lie� Sea-Doo Direct Driv e ............Delivers optimum performance with the Rot ax
3-poslllon retractable ski pyl on Satety kit propulsion system engine.
Aluminium stator vaneL.... Handle s t he hig h-performance engine with out
Removable wakeboard r ack Sandbag anchor
e rosion .
Depth nuder Pr otective cover
Oual aut om atic vacuum._ ... Continuously removes water entenng the
Removable df'I bag for front storage fire extinguisher siph-00 pumps engi ne compartment.
Ski tow eye Large diameter drive shaft... Maintains engine and pump alignment at all
with crowned splrne design operat ing speeds.
WARRANTY Replaceable UHMW" .... ...... Provides long Im peller life , less maintena nce
wear nng and maximum thrust.
BRP Omited warranty covers the watercraft tor one year.'
Stainless steel .. Derl�rs Improved acc el eration, higher top
Impeller speed and less cavitation.
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GTX' 2151155
iBR iTC s� CLCS
Specifications
DIMENSIONS
Length ...........................................139'/ 354 cm
Width........ . ....................... ......48' I l22 cm
Height .. ..... .
. .... ... . .-..........-.....45.9' I 116.6 cm
. .
Weigh! (dry)...................................GTX 215: 855 lb. I 388 kg

GTX 155: 825 lb. i 374 k g
Rider capacity...............................3
Fuel capacity .. ........... ..................15.9 US gal I 60 I
Storage capacity ...........................13.7 US gal/ 521
ENGINE
Type ...................... ....................... . . 6TX 215. 1503 SC Rotax H£C err&me
GTX 155, 1503 NA Rotax 4-TEC engine
Intake system................................GTX 215: Supercharged with lntercooler,
60 mm throttle body
GTX 155: Naturally aspirated,
60 mm lhroltle body
Bore x stroke......... ........................100 mm x 63.4 mm
Oisplacemenl .
...... ................ ........ . 1,494 cc
Compression ratio .........................CTX 215: 8A: I
GTX 155: 10.6:1
Coollng.......................................... Closed-loop Cooling Syslem (CLCS)
Fuel type........................................GTX 215: 87 oclane - minimum
91 octane - recommended
GTX 155: 87 octane - mcommended
DRIVE UNIT
Propulsion system Sea-Ooo" Oirecl Drive
........................
lei pump ............. ........................Aluminium, axial llow, single stage.

large hub w1lh 10-vane stator
Larae reboardillf pl�de<m l:ilu• glove b•• Transmission . .
.. ....... ....... ..... .......... iBR'"
Impeller.........................................Stainless steel
ELECTRICAL
Jgnition ..........................................Digttal induction
Slartec. .
.... ..... .. ....
.. ....... .
.... .... ... .
. .. Electric
Battery ... ...... .. . .
............ ...... ........ .. . 1Z v
HULL AND COMPONENTS
Type...............................................S' Hull'"
Colour............................................Autumn Red
Tilt >teenna f1uwm& edge des1go ·Hew for 201 I
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Standard Features GTX 215I155

HULL AND COMPONENTS
1cont1ol "········-" .....The ''Braln" Iha! integrates and controls all systems
lo create the be.st possible ride
S1 Hull .................................. Stepped, stable & strong. Lightweight matenal, nbbed
and stepped. Creates a low-pressure zone lo reduce
drag for nimble handling and rail-light corneiing.
Tounng/ Spm1 mode ... ........ ... Olfers a choice between two throttle responses lor
different riding styles. Touri11g mode is the delaull
setting offenng a mo1e progressive acceleration
curve tor a mOle confident ride- ideal tor cruising
and 2-up riding Sport mode can be easily activated
using the Set buttort H provides all acceleration
performance tor a more aggressive throttle response. ENGINE
Electric
Variable Trim .......... Provides boat tnm ad1ustments, maxrmises 1.494 cc four·shoke.....-.• .. Supercharged. intercooled 1503 SC Rotax 4-TEC e11gine
System (VTS'") acceleration and high-speed stability. Rotax with tour valves (GlX 215) or 1503 NA Rotax 4-TEC engine (GlX 155)
Bow and stern eyes..... .... ..... ..Designed tor towing 01 securing the cratt to a traile1 pe1 cylinder p1ovides reliable perfo1mance in hesh 01 saltwate1.
or dock. Increased torque al RPM, opt1m1sed power at all RPM
Watertight, removable_. ... ...Provldes dry slo1age for luggage and necessities levels and lhrottle positions.
storage bin with easy access. iTC'" (lnteiligenl..•••
-- . . .._... Operating electio11ically, this advanced tlnottle system
..
.
Till steenng ..........................Ad1usts Ille steering and information cent1e angle Throttle Cont1ol) system starts you rn neutral tor easier dockside starts. It also
for maximum ease and comfort. features an activity-specific cruise control, Touring I
Touring seat .......................... Ergonomically designed for comfort and great looks Sport mode and Variable Trim System that can all be
providing ultra-plush seating tor three. set to accommodate your riding style. The result is a
Carpeted lootwells ...............Otter extra comfort. non-skid surface and more responsive, more intuitive ride.
and deck pads great looks. 1Control Learning Key�........ . The programmable learning Key allows you to limit
lhe performance of the PWC based on rider skill-level
Ski tow eye . . ..... . ........ .. .. . ... ...for easy and secure att achment of ski rope.
Each of the tvro settings can be fine-tuned using the
Fold-down reboarding step ..... Makes 1�boa1diog from the waler easier and quicke1
mode/set buttons
Multitunct1on 01g1tal ............ Reports 26 key operating functions:
0-Sea·Bel'" system ..... ..... Combines a series of 1esonators and vibration·
Information Centre Fuel level, Tachom eter, Speedometer, Hour meter,
abso1b1ng components to make Sea·Doo wateicrafl
Compass. Clock. Fuel consumption meter,
some of the quietest on lhe waler.
Vlater temperature (GTX 215), New ECO mode
(GTX 155), louring I Sport mO<le, Cruise control, Closed-loop cooling system... Uses coolant to keep the engine running at the ideal
Slow mode. VTS, F-N·R indicator, Low fuel level, temperature, much like a car's radiator. Also keeps
low Oil level, Low oil pressure. Low voltage, out corrosive saltwater and debris.
Overheat, fli voltage. Check engme, Sensor check, Water/air separato1 .............. Provides maximum airflow to engine and reduces
Bat tery protection, Key (wrong key), L-Key IR-Key, water intrusion.
Maintenance info. Error codes. Watertight digital ignition . . . 1'1ovides optimal energy lor a consistent spa1k,
D1g1tallyEncoded Security . .... Industry's first d1g1tally encoded ensuring maximum performance.
System (O.E.s.s:·) theft- deterrent system. RPM limiter ..........................P1otects engine from over-1ewing.
Foam flotation ..................... ... Ride with security and peace ot mind. Meets or Warning devlce... . ......... .... ....Warns operator of engine and exhaust overheating,
exceeds USCG standards. engine management and system !allure
Off-Throttle Assisted...............Provides the operator with addrtional sleenng ettect Handlebar-mounted . . .. ... ... ...Engine starts and stops with single.
SteerlnR (0.T.A.S."') In ot!-fhrottl e situatlons for greater manoeuvrability. start/slop button user-friendly ccntrol butlo11.
Quick latch luel filler design lip Over Prntection ...............Prntects engine In case of turn over.
Sponsons System (T.O.P.S.'"t
Bumpers
Adjustable mirrors PROPULSION SYSTEM
Reboa1ding platform
Reboarding handles on rear platform IBR (lntelhgent Brake .......... .The world's only on-water braking system, 1BR lets you
Rear grab handl e & Reverse) system stop up to 100 feet sooner lhan any other watercraft'.
Front splash deflector All with the squeeze of a lever. And with its electronic
Dual drain plugs reverse, il gives you a level of manoeuvrability that
External exhaust cooling flush attachment makes docking easier.
Special comfort hand grips Sea·Doo Direct Olive . ........ ... Oelive1s optimum pe11onnance wilh the Roiax
Emergency floating lanyard propulsion system engi ne.
Cul & sew seal with 2 colours Aluminium stator vanes.,..... Handles lhe high-performance engine withoul erosion.
Seat strap
Replaceable UHMW'" ..•. . ... Provides long impeller lite, less maintenance
Operators guide, instructional video aod booklet
wea1 nng and maximum th1ust
OPTIONS Dual automatic vacuum....... Continuously removes water ente1ing lhe
Removable dry bag tor front storage siphon pumps engine compartment.
3-posilion retractable ski pylon
Removable wakelxlard rack Safety kit Large diameter d rive shalt ... Maintains engine and pump alignment at all
Depth finder Sandbag ancho1 with crowned spline design operating speeds.
Ski mode Speed lie'" Stainless steel . ..........._..... .Delivers imp1oved acceleration. higher top
lime/distance to empty Glovebox 01ganiser impeller speed and less cavitation.
Attitude Protective cove1
Topfaverage speed/RPM Advanced TEC trailer
Lap timer fire exlin�ulsher
Engine temperature
WARRANTY
BRP limited warranty covers the watercratt tor ooe year.•• �

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GTXtLIMITED iS™ 260
iBR iTC iS S:J CLCS
Specifications
DIMENSIONS
length............... ........ .. ................ 139' / 354 cm
Width.................... ............... .48" / 122 cm
Height.. ...................... .................. 43.9' / l l l .4cm
l'le1 g hl (dryl...................................980 lb. / 446 kg
Rider capacity ............................... 3
fuelcapacti y......................... -.... 18.6 US gal/ 70 I
Storagecapacity ........................... 16.4 US gal/ 62 I
ENGINE
Type ...............................................1503 XHO RotaX- 4-TEC.,engine
Intake system................................S uperch arged with external inte rcooler,
60 mmlhrottle b o dy
Bore x stroke..................................100 mmx 63.4 mm
Oispla c e menl................................ 1,494cc
Till tmlni wll
l l 1 olo11 01l1Dn oen b e R1bo1rdin& pliUorm w1lll1lorag1 Compression ratto .........................8.4:1
Cool i n g ..........................................Clos ed-loop cooling system (ClCS)
fueltype........................................ 87 octane- minimum
91 octane -recommended
DRIVE UNIT
Propulsion system .........................Sea·Ooo* Di1ect Drive
Jet µump ..........................-.......... Aluminium, axial now, s n
i gle stage.
larg e hub wt
i h lO·vane stator
Trans mis�ion.................................iBR
lmpe11e1 ......................................... Stainless steel
Tourin& seal 1BR" (h1ltlhge11l 811k1 l RovorseJ brah leve1
ELECTRICAL
tg nltion..........................................Dlgltallnductlon
Starter...........................................Electrlc
Battery.......................................... 12 v
HULL AND COMPONENTS

Type ...............................................$' Hull'"
Colour ............... .............................PearlWli11e
Glave box ari;imstr

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Standard Features GTX LIMITED iS 260

HULL ANO COMPONENTS ENGINE
!Control*.............................. The "Brain" that integrates and controls all Supercharged, i11tercooled....Supercha1ged. lnteicooled 1503 XHO Rotax 4·T£C engine
systems to create the best possible nde. 1,494 cc lour-stroke, provides reliable ultra-high peiiormance in fresh or
rS" ....................................... Allows the hull to move independently ol the upper Rotax with lour valves saltwater, increased torqtre al low RPM, optimi�ed
deck, isolating ridei and passenger from the Impact of per cylinder power at all RPM levels and throttle positions.
rough waler. Electronic adjustment, manual or auto
Multi-port fuel injection ... .... Better contiol of exhaust emission and power at all
matic mode. Auto docking position, Touring calibration.
S' Hull ...................... .......... Stepped, stable & strong. Lightweight material, ribbed
RPM ranges to reduce emissions and reduce fuel
and stepped. Creates a low·1iressure zone to reduce consumption.
drag for nimble handling and rail-tight cornering. ITC'" (Intelligent............... ..... Operating electroofc:ally, this advanced throttle system
Touring I Sport mode...... ........ Otters a choice between two throttle responses tor rhottle Control) system starts you In neut.rat tor easier dockside starts. II also
different riding styles. Touring mode is the default features an actrvrty-specrfrc cruise COlllrol, Tourrng I
setting offering a more progressive acceleration Sport mode and Variable Trim System that can all be set
i
curve tor a more e-0nfidenl ride - Ideal for cruising
and 2-up rding. Sport mode can be easily activated
using the Se\ button. It provides all acceleration
to accom modate your rrdirrg style. The result 1s a more
responsive. more intuitive ride.
iControl leaming Key'".. ....... The programmable learning Key allows you to limit
perfounance for a more aggressive thwtlle response
the performance of the PWC based on rider skill level.
Hinged seal... ........... ........... Easy-open seat wllh convenient stay-open support
Each of the two settings can be fine-tuned using the
struts. Provides easy access to the engine compartment
while remaining attached to the watercraft. mode/set buttons.
Touring seat ....................... Ergonomie<illy designed for comfort and great looks D-Sea-Bel� system ........ ...... Combines a senes of resonators and vrbratron·
providing ultra-plush sealing for three. absorbing components to make Sea-Ooo watercraft
High-performance electric ... Provides pre-set positions for quick settings some of the quietest on the water.
VTS'�{Variable Trim System) when adjusting boat trim. maximises acceleration Closed-loop cooling system.. Uses coolant to keep the engine running al the ideal
and high-speed stabihty. temperature, much like a car's radlalrir. Also keeps
Bow and stern eyes . ........ ..... Designed for lowing 01 secunng the craft to a out corrosive saltwater and debris.
trailer or dock.
Watcrfalr separator .............. Provrdes maximum airflow to engine and re<luces
Carpeted tootwens ............... Otter extra comfort, non-skid surface and
water Intrusion.
and deck pads great looks.
Reboardlng platform............ Easy access to battery, fuses and storage. Watertight drgrtat ignition .... Provides optimal energy for a consistent spark.
with rear storage ensuring maximum performance.
Fold-down re boarding step....Makes reboarding from the water easier and quicker RPM limiter .......................... Protects engine from ove1-revving
Ski tow eye.... _,,,......... ... For easy and secure attachment of ski rope. Warnin� device..................... Warns operator of engine and exhaust overheating,
Watffiighl, rem011able ........... Provides dry storage for luggage and necessities with engine management and system failure.
storage bin easy access Handlebar-mounted ............. Engine starts and stops IVlth single,
Tilt steering .......................... 4 adjustable steeriug and information centre startlstop button user-friendly control button.
angles for maxrmum ease and comfort.
Tip Over Protection ............... Protects engine m case of tum over.
Interactive Mullrfunclion ...... Reports 34 key operating functions:
System (T.0.P.S.")
Digital Information Centre Fuel level, Tachometer, Spee<lometer, Hour meter1
Compass, Clock, Fuel consumption meter, ITmet
Distance to empty, Altitude. Water temperature,
PROPULSION SYSTEM
Depth finder, Touring I Sport mode. Cruise control, IBR (Intelligent Brake .......... The wllrfd's only on-water braking system, iBR lets
Stow mode, VTS, VTS preset. Suspension settings:
& Reverse} system you stop up to 100 feet sooner than any other
auto and manual mode, Suspension dock mode
watercraft'. All with the squeeze of a lever. And
ON_OFF. F-N-R indicator. low fuel level, low oll
level. low oil pressure, Low V1lflage, Overheat, with its electronic 1eve1se, it gives you a level or
Hi voltage, Check engine, Sensor check, Battery manoeuvrability that makes docking easier.
protection, Key (wrong key), L-Key IR-Key, Sea-Ooo Direct Drive . .... ...... Delivers optimum performance with the Rotax
Maintenar1ce info, Error codes. propulsion system engine.
Digitally EncO<led Security.... Industry's first digitally encoded lh eft-deterren t Replaceable UHMW"' .......... Provides long Impeller life, less maintenance
System (O,E.S.S.�) system wear ring and maximum thrust.
Foam flotation ...................... Ride with securrty and peace of nund. Meets or Dual automatic vacuum ....... Continuously removes water enlenng the engr ne
siphon pumps compartment.
Off-Throttle /\ssrsted ........ .... Provides the operator with a dd1tronal s\eerrng
large diam el er drive shaft... Maintains engine and pump alignment at all
Steenng (0.T.A.S.'"J effect m off-throttle situations for greatei
manoeuvrability. with crowned spline design operating speed s.
Stainless steel impeller.... .... Delivers Improved ar.celeration, higher top Impeller
Quick latch fuel mtei design &temat exhaust coo ling flush at\<1ehment
Sponsons speed and less cavttation.
Special comfort hand grips
Burnpers Wide handlebars Aluminium stator vanes ....... Handles the high-performance engine without erosion.
Adjustable mirrors Emergency floating lanyard (peimanent)
Reboardmg handles on rear platform Cut & sew seal with 2 colours llMITEO PACKAGE
Rear grab handle Seat strap
Additional gauge functions ... Depth finder, lime/Distance lo empty, Altitude.
Front splash deflector Operator's guide, instructional video
Dual dram plugs Speed lie*.................. .......... Automatlc retractable mooring lrnes eliminate the
and booklet
Engine access cover (removable) hassles of t1adilional docking lines.
Removable dry bag .............. Keeps contents dry and converts to backpack when
OPTIONS rem oved.
Removable wakeboard rack Lip timer Sandbag anchor............. -... Easy way to hold your boat in one position.
Ski mode Engine teml)flrature Safety kit.............................. Contarns all the essential safety equipment.
Topfaverage speed/RPM Fire extinguisher Glove box organiser .............. Ideal to keep gear or cell pho ne dry; removable and
watertight.
WARRANTY Custom boat cover ............... Protect your PWC.
BRP hmrted warranty covers the watercraft for one year.•
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CLCS
Specifications
DIMENSIONS
Length ... ........................................121" J 307 cm
Width.......................... ...................48' I 1l2 cm
Height ........... ...... ...................... ....45.8" 1116 cm
Weight (diy)... .............. ............. .....774 lb. / 351 kg
Rider capac1ty ...............................2
Fuel capacity.................................15.9 US gal I 60 I
Storage capacity ...........-.............10.7 US gal 140.31
ENGINE
Type ........ ...... ....... ....... .......- ...1503 HO Rotax 4-TEC engine
... .
Intake system ...... .- .... ...... . . ...Supercharged wilh external lnlercooter,

. . _
52 mm throttle b ndy
Bore x stroke.. ..... .........................100 mm x 63.4 mm
Displ acement ..... ..........................1,494 cc
Compres.sion ratio .................. -......8.4:I
X-llandleba11 H11h·parlormance m'" Cooling ................................. ........Closed-loop cooling system {ClCS)
.
Fuel type............. ..........................87 octane - minimum

9 1 octane - recomme n de Oirett Drive

Racing pump with high ..... ....... ....Aluminium, axial llow, single stage.
pe1 fo1mance intake g1ale large hub with 10-vane stato1
Transmission ............................ ... Direct drive, forwardlneullal/reverse
and high-per1onnance elettric
VTS (Variable Trim System)
X·Rac1na seal l�lr1 lntchon carpel
Impeller ....................................... .Stainless steel
ELECTRICAL
lgmtion..........................................Dig1tal induction
Starter...........................................Electric
Batteiy ................. ............ .............12 v
HULL AND COMPONENTS

Type.............. ..................... .... ....FRP, composite
.
Colour.......... ........................... ... Black and Dragon Red

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S ecifications
Standard Features RXP-X 255 RS

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FRP. composite-.... ................. Strong, light and easy to mainl�i11. Designed lo enable
your craft to cut through the water witl l 1aror p1ecision
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and corner more aggressively than the oompetition. 2
Elevated fuel filler................... Easy access and prevents water inlrosion while 0
refueling. rn
Bow and �ern eyes ..... ............ Designed for towing or securing the craft to a trailer
N
or dock.
0
Carpeted tootwells .................. Otter extra comfort, non-skid surtace and an I-'
,_.
and deck pads aggressive diamond;ilate pattern tor additional
traction.
Reo1ovable engine hatch........ Easily 1�moved to allowelpanded access during
rootine engine maintenance. ENGINE
Multifunction Digital.............. Re.ports 20 key opera ting functions: Supercharged, tntercooled....Supercharge<f, lntercooled 1503 HO Rotax 4·TEC engine
l11fo1mation Cen\ie Fuel level,Tachometer, Speedometer, Hour 111ete1, 1.494 cc tour-stroke, pro\11des reliable ultra-high performance rn fresh 01
Maintenance info. Compass, Water temperature. Rotax with lour valves saltwater, rncreased torq ue at low RPM, optimised
VTS, VTS preset, low fuel level, Lnw oil pressure, per cylinder powe1 at all RPM levels and throttle positions.
Lem volta ge, Overheat. HI voltage,Check engine, Multi-port fuel ln1ect1on....... Better control of exhaust emission and power at all
Sensor check, Battery protection, Key (wrong key), RPM ranges to reduce em1ss1ons and reduce tuel
L-Key, Error codes. consum pti on.
High-performance electric......Provides pre-set pooitions tor quick settings Sea-Ooo t eaming Key�... .... . LKl - limits engrne RPM and top sp<led io about
Variable Trim System (VTS) when adjus ting boat trim, maximises acceleration 35 mph (56 km/h).
and high-speed stability. LK2 limits engine RPM and lop speed to about
Digitally Encoded security ...... lndustiy's first d igitally encoded thell-detenenl 45 mph (72 km/h). Options are programmable by dealer.
System (0.ESS.") system. 0-Sea-BP.I'" system.. ..Combines a seriPsot resonators and vlbra!ion-
roam flotation ......................... Ride with security and peace of mmd. Meets or absorblog components to make Sea-Doo watercrafl
exceeds USCG standards. some ot lhe quietest on the water.
Oft.J>owerAssisted.................. Assists steering during ott-power, as well as Water-cooled exhaust pipe ... Regulates exhaust temperature.
Steering (0.P.A.S."') ott-throltle situations. Closed-loop cooling system.. Uses coolant to keep the engine runnrng at the ideal
X-Tra traction carpet with d1amood plate pattern temperature. much like a car's radiator. Also �eepsout
Removable storage bm couosiVI! saltwater and debris.
Sponsons Waterta1r separator .............. Provides maximum airtfow to engine and reduces
Bumpers water rntrusion.
Reboarding platform Watertight digital Ignition .... Provides optimal energy for a consistent spark,
Ski tow hook ensuring maximum performance.
Rear grab handle
RPM limiter .._. ... ..... .. ...._.•. Protects eng ine from ovei·revving.
Dual drain plugs
Warning device.... .. ....... ........ Warns operator ot en gine and exhaust overheating,
Knee pad
engine management aud syslem fa�ure.
E'Aernal exhaust cooling !lush attachment
Handlebar-mounted ............. Engine starts and stops with sing le,
Double density comfort hand grips
starf/stop butlon user-friendly control button.
Aluminium finger throttle with braided steel cable
lip Over Protection ............... Protects engine in case of tum oll1lr.
Emergency !loafing lanyard
System (lO.P.S.'")
Seal strap
Operator's guide, mslsuctiooat video and booklet
PROPULSION SYSTEM
X-PACKAGE Sea-Ooo Direct Drive ........... Oehvers optimum perlormance with the Rotax
propulsion system engme.
X-Handlcbars .......................... Keep you In complete control In tough wale! conditions.
Racing pump wilh high- ..... Ensures that the inlet stays hooked up and fills
X-Racing seat ......................... low-profile seat allows rider to adjust body position
performance Intake grate the pump tor maxlmum thrust even fn lhe roughest
for maximum leverage.
conditions.
X-Tra tractioncarpet.................With diamond plate pattern
Fo1ward/neulrallreve1se ....... Located on lhe left side !or maximum convenience and
manoeuvrnblllty especially around docks and !miler
OPTIONS
ramps.
Fold-down reboarding step Aluminium stator vanes.-... Handles the high-performance engine wilhoul erosion.
Removable dry bag for front storage Replaceable UHMW*• ..........Provides long Impeller lite. less maintena nce
Safety kit wear nng and maximum thrusL
Mooring rope Dual automatic vacuum ....... Continuously remo\/1ls water entering the
Sandbag anchor siphon pumps engine compartment
Protective cover large diameter drive shalt... Maintains engine and pump alignment al all
Advanced TEC trailer with crowned spline design operating spee<fs.
Fire extingui sher Stainless steel ..................... Oehvers improved acceleration, higher top
impeller speed and less cavitation .
WARRANTY
BRP limited warranty covers the watercraft for one year.•
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Specifications
DIMENSIONS
len�lh ...................................... ...139. /354 crn

Width............ .. ..48. /122 cm
Heigllt ..................................... ....45.9. /I 16.6 cn1
Weight {dry).. ..............................845 lb./383 kg
Ridef capacity . .... .. .... .. . ..3
. ... . .. .. . . ..
Fuel capacity ......................... ....15.9 US gal/60 I

Storage capacity ......... . .. ... ....13.7 US gal I 52 I
.... . .. .
ENGINE
Type .... ............. .............................. 1503 XHO Rotax· 4 IEC engine•

Intake system ................................Supercharged with 1ntercooler,
60 mm throttle body
Bore xstroke..................................100 mm x 63.4 mm
Tiii steermP. & mlonnalion canlra R•lloardmg plalfonn Displacement ......................... ...... . 1,494 cc
Cooling .......................................... Closed-loop cooling system !ClCS)
Fuel type........................................87 octane - minimum
91 oct ne - recornmendeda
DRIVE UNIT
e
Propulsion syst m .........................Sea-Doo" Direct Drive
Jet pump ..
.............. . .......... .. ...... . . ..Aluminium, axial flow, single stage,
Transmission...... ... iBR'"
Impeller ......Stainless steel
ELECTRICAL
lgmt1on..........................................Oig1tal inducti on
Starter ...........................................Elect11c
Battery .......................................... 12 v
HULL AND COMPONENTS

Type...... .........................S1 Hull..
Colour ................. ......................... Bright Yellow
Ski tow t1 ook Ouick l•tch fuel ftUer d•Sll\11 How for 2011
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Standard Features RXT 260 RS

HULL AND COMPONENTS
iConliol'"..............................The "Brain" that integrates and conlrols all
systems to create the best pos sible ride.
s• Hull .._...............-............Stepped, stable & strong. lightweight material, ribbed
and stepped, Creates a low-pressure zone lo reduoe
drag for nimble handling and rail-tight cornering.
Touring/Sport mode............... Offers a choice between two Wottle responses for
dillerent riding styles. Touring mode Is the default
en
setting offering a more pwgressive acceleration
curve for a more confi d t ride- ideal for cruising
and 2-up riding. Sport mode can be easily acbvated
using the Set button. It provides all acceleration ENGINE
performance for a more aggressive th1otlle response.
Hinged seat ........ .................Easy--0pe11 seal with convenient stay-open support Supercharged, intercooled .... Supercharged, lntcrcoofed 1503 XHO Hotax 4-TEC engine
struts. Provides easy access to the engine compartment 1,494 cc four-stroke, provides reliable ultra-high perlorm·ance rn tresh o r
while remaining attached to the watercraft. Rotax with fow valves saltwater, increased torque at low RPM. optimised
Watertight. removable..........Provides d1y storage for luggage and necessities pe r cylinder power at all RPM levels and throtUe positions.
storage bin wrth easy access. ITC� (lntelligent...................... Opcratlng electronically, this advanced throttle system
Till steerlng. ...... ......... ..........4 adjustable steering and Information centre l hrotue Control) system starts you 1n neutral for easier dockside starts. It also
angles for maxirnum ease and comfort. features an act1vity-speciftc cruise control, Touring I
Fold-down reboardrng step....Makes reboarding trom the water easier and quicker. Sport mode and Variable Trim System that can all be
Bow and stern eyes ............. Oesiene>J for towing 01 securing the cratt to a set to accommodate your riding style. The result is a
trailer or dock. more responsive, more intuitive ride.
Carpeted lootwells .............. Offer extra comfort, non-skid surface and 1Control Learning Key'".........The programmable Learning Key allows you to hmit
and deck pads great looks. the performance of the PVIC based on rider skill-level.
Ski tow eye ........................... for easy and secure attachment ot ski rope. Each of the two set tings can be fine-tuned using the
co
Multifunction Digital ........... Reports 26 key operating functions: mode/set buttons
Information Centre Fuel level, Tachometer, Speedometer, Mour meter, Mulb-port luel ln1ecbon .......Better n trol ot exhaust em1ss1on and power at all
Compass, Clock. Fuel consumption meter, Water RPM ranges lo reduce emissions and reduce fuel
temperature, Touring ISport mode, Cruise contro l, consumption.
Slow mode, VTS'", F·N-R indicator. Low fuel level, D·Sea-Bel'" system.............. Combines a series ot resonators and vibration·
Low olt level, Low on pressure, Low voltage,
absorbing components to make Sea-Ooo watercraft
i
Overheat. Hi voltage, Check engine. Sensor check.
Battery p rote c t on, Key ( wrong key), L-Key IR-Key,
Maintenance info, Error codes.
some ol the quietest on the water.
Water-cooled exhaust pipe ... Regulates exhaust temperature,
Digitally Encoded Security ... Industry's lirst digitally encoded Closed-loop coolmc system . Uses coolant to keep the e11gine running at the ideal
System (0.E.S.S.�) theft·deterrent system. temperature, much like a car's radiator. Also keeps
Electric Variable Trim ........... Provides boat trim adjustments, maximises
System IVTSl acceleration and higlJ-Speed stability. Water/air separator .............. Provides maximum airflow to engrne and reduces
Foam ffotallon ......................Ride with security and peace of mind. Meets or water intrusion.
exceeds USCG standards. Watertight digital 1gn1hon.... Provides optimal energy for a consistent spark,
011-Thro ttle Assisted ............ Provides the operator with additional steering ensuring malimum performance.
Steering (0.T.A.S.") eflect in off -throttle situations !or greater RPM limiter .......................... Protects engine from over-rcwing.
manoeuvrability. Warning device............. ....... Warns operato1 of engine and exhaust overheating.
01.Jick latch fuel tiller design Oual drain plugs engine management and system failure.
SPonsons External e<haust�'OGiing flush attachmer1t Handlebar-mounted.............E.ngine starts and stops with single,
Bumpers Special coo1fort hand grips start/stop button use1·friendly control button.
Adjustable minors Ell\llfgency floating lanyard TIP Over Protection ............... Protects englne in case ot turn over.
Reboarding plattllfm Cut & sew seat with multi colours System (T.0.P.S.")
Reboarding handles on rear platlorm Scat strap
Rear giab handle Operato(s guide, instructional video PROPULSION SYSTEM
Front splash deflectllf and booklet IBR (lntelllgent Brake .......... The world's only on-water braking system. iBR lets you
& Reverse) system stop up to JOO feet sooner than any other watercraft'.
OPTIONS
All w l th the squeeze ot a levCI. And with its etectromc
3-positlon retractable ski pylon Removable dry bag for front storage reverse, 1t glves you a level ol maneuverability thal
Removable wakeboard rack Glove box organiser makes docking easier.
Depth finde r Satety kit Sea--Ooo Direct Drive ......... .. Delivers optimum performance WJth the Rotax
Ski mode Sandbag anchor propulsion system engine.
Time/distance to empty Speed Tie'" Aluminium stator vanes ....... Handres the high-pe11ormance engine wilhout erosion
Altitude ProteC1ive cover
Replaceable UHMW*' .......... Provides long impeller tile, less mamtenance
Top/average speed/RPM Advanced TEC trailer
wear nng and maximum thrust.
Lap timer Fire extinguisher
Oual automatic vacuum ....... Continuously removes water entering the
Engine temperature
siphon pumps engine compartment.
WARRANTY Large diameter drive shai1... Maintains engine and pump alignment at all
wilh crowned spline design operating speeds.
BRP limited warranty covers the watercraft for one year.• Stainless steel ..................... Delivers improved acceleration. higher top
impeller speed and less cavitation.
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Specifications
DIMENSIONS
Length.......................................... .139• I 354 cm
Width............................................48' / 122 cm
Height .... ..............
. .... .......... ........46.5' I 118.1 cm
..
Weight (dry)........... ......................855lb.1388 kg

..
Rider capacity ............................... 3

Fuel capacity.................................15.9 US gal/ 60 I
Storage capacity ...........................13.7 us gal/ 52 I
ENGINE
Type...............................................1503 XHO Rota� 4-TEC• engine
Intake system ................................Supercharged with external lntercooter.
60 mm throttle body
Bore x stroke..................................100 mm x 63.4 mm
l·Steeno & with A . E . S :" X0lnlorm1Uon c1nlr11 Displacement ................................1,494 cc

Coohng..........................................Ctosed-toop cooling system (ClCS)
Fuel type........................................87 octane - minimum
DRIVE UNIT
Propulsion system .........................Sea-Doo• Dirett Drive

Racing pump with .........................Aluminium, axial flow. single stage.
high-performance intake grate large hub with 10-vane stator
Transmission.................................iBR�
Impeller .........................................Stainless steel
ELECTRICAL
Ignition.........................................Digital induction
Starter................. ........................ Electric
Battery ................ ........................12 V
HULL AND COMPONENTS

Type ................... ...................... ...$1 Mull'"
Colour.................. ..Black and Dragon Red
X - Calourobon teat Hinged •oat
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Standard Features RXT-X 260 RS ;:g :::0
HUU ANO COMPONENTS cg

Hlgh-pei!O!mance electnc ........Provldes pre-set posillons tor quick s c tling s :::0
VTS'" (Vari able Tlim System) when adjusting bO!ll trim, maximises Rctele1atlon s::
i
and high-speed stability. )>
iCOlllTOI"'.... ............... ....... .... .... ..The "Bran" that rntegrates and cootlols all systems to z
create the best possible ri de. ()
rn
s• HulL..... ...... ............ ..-........ ...Step ped, stable & stroog. lightweight material, ribbed
and stepped. Creates a low-p ressure zone to reduce N
drag for mmblehandhng and rail-t igh t comermg. 0
Touring/Sport rnode ..... -... ... Offers a c hoice between two throttle responses for .......
......
drfferent riding styles. Touring m od e 1s the delautt

selting otfenng a more p rogressiv e acceleration
cu1Ve lor a more confirlenl ride- Ideal for cruising ENGINE
a nd 2-up riding. Sport mrxle can be easily aclivaled
Supercharged, intercooled ...Supercharged, in ter cooled 1503 XHO Rotax 4-TEC engine
usmg the Set button. It provrdes all ac c e leration
performance tor a more aggress!Ve lhrottle response.
1,494 cc tour-slloke. provides reliable Ollra-hlgh performance in fresh or
lhnged seat.............. ...............Easy-wen seat with C011ve11ient stay- open supporl
Rotax wrth four valves saltwater. increased torque at low RPM, optimised
st.ruts. Provrdcs easy access to the engine compartment per cylinder powef al all RPM levels and throl11e position s.
while remaining attached to the watercraft. rrc·· {Intelligent ................ ..... Operating eleclr011ically. lhfs advan<:ed throttle syst em
Wateitighl, r em Olla b le .. ........ .... .Provides dry storage fOi luggage and necessities Thrott le Contlol) system starts y ou in neutral tor easier dockside starts. It also
slorage bin wi1h eagy access. features an act1v1ty-specrlrc Tounng I Sport mode and
Tilt stee!lng................................4 adjustable steering and lnlormahon centre angles f or Vanable Trim Syst em that can be set to accommodate
maximum ease aoo comfort your ndrng style. The result is a more responsive. more
Bow and stem eyes ...... ........... Designed lor towing Ol securing the craft to a lrailei intuitive ride.
IXdock. 1Contiol Leaming Key'•......... The programmable Learning Key a llows you lo limit
Carpeted tootwells and.............Offer extra comfort, non-skid surface and a n
the performance of the PWC b ased on nder sklll level.
reboardlng deck pads .............. aggressive diamond-plate patternt r:radditional tractioo.
ln1eractive Mullilunclion...........R eports 30 key operating functions, Each of the two settings can be fine - tuned using the
Digital Inform ation Cenlle Fuel level. Tachometer. Speedometer, Hour mele1. mode/s et bu ttons.
Compass, Clock, Fu el consumption meter, lime I MuIll-port fuel injeclion . ... ........Betterconlrol of exhaust emissio n and p&•'8r a t all RPM
Dis t a nc e l o empty, Top/average speed/RPM, Lap rangesto reduce emissions a nd reducefuel consumption.
timer, Engine temperature, Water temp er atu re , D-Sea-Bel • system .. .................Combines a secies ol resooalors and vibration-absorbing
T ou ring I Sport mode, VTS, VTS preset F-N·R components to make Sea-Doo watercraf t some o t the
rndicator, low fuel level, tow Ori level. Low orl quietest on the water.
pressure, low voltage, Overheat, Hr volt ag e, Check Water-cooled exhaust prpe........Regulates exhaust temperature.
e ngine, Sensor check, Battery protection, Key (wrong Closed-loop cooling sys1em ......Uses coolanl to kfep tire e11girre run ning a l the ideal
keyl. L-Key I R·Key. Mainler1aoce i nfo, Error crxles. temperatu re. much like a car's radiator Also keeps 001
Digilatly EncodeO Secunty .... . .Industry's first digitally encoded theft-deter rent
corrosive saltwaterand oobris
System (D.E.S.S.'") system.
Water/air �parator ......_ ........Provides maximum airtlow lo engine and reduces water
Foam llotalfon........-...............Ride wtth security a nd peaceolmind. Meets or exceeds
USCG standards. inlruslo n.
Oft-ThrottleAssisted .. ..-.....f>lovides the operatorwith addttional steering elfect
.. ..
Water tigh\digrtal igmflou... .....Provides optima l energy1ora consrsle11l spark, �nsu1rng
Steering (0.T.A.S.") io off-throttle situations f0t g1eater manoeuvrability. maximum performance.
Ski tow eye......... ............... .........For eagy and secure attachment of sk i rope. RPM limiter ................................Protects en gine from over-revving.
Sponsons Dual drarn plu gs Warning devfce ................ _....... Ya \ ms opeiatorol en gin e and exhaustoverheating. engine
Bumpers External exhaust cooling flush atta chment management and system failure.
Adjustable mirrors Special comfort hand grips Han dlebar-mounted. .... .............Eng ine starts and stops wilh srngle,
Reboardirrg platform Emeigency floating lanyard (permanent) start/stop button user-friendlycontrol button.
Reboarding handles on rear platform Seal strap lip Over f>lolection........_..... ......Protects engine i n case of tum over.
Rear grab handle Operator's guide, rnstruct1onal video and Systern !T.O.P.S.")
Front splash <letfector boolllet
PROPULSION SYSTEM
X-PACKAGE
X-Sleering wilh A.E.S ............ ...The only fully adjustable harnilebar ln !he industry. With IBR ( ln tellrg enl Brake...........The world's only on-water br akrng system, IBR lets you
(Allj11Stable ErgonomicSteering) AE.S. the rider can adjust !he handlebar widlh and grip & Reverse) system stop up to 100 teet sooner th an any other watercra ft'.
All w ilh the squeeze of a lever. And with its electronic
for a fully customised ride.
reverse. ft gives y o u a level of manoeuvrability that
X-Colouration seat..................... Race-lnsprred designed for comfort and great looks
prrl'lidlng seating for three.
Sea-Ooo Direct D1ive ........ ... . Delivers Ojltimum peiforrnance with th e R otax
.... .
X-Tra tracilon carpet ......... ... .... .Wrth diamond plate pattern
pmpulsior1 system engine.
OPTIONS Alumlruum stator vanes............Handlesthe htgh·pertormance engi ne without erosion.
3-positlon retrac t a ble ski pylon Glove box organiser Replaceahle UHMW*'.......... .. ...Provides tong impeller life, less mainleilance
wear ring arid maximum fhrusl
Removable wakeboard rack Safety kit
Depth fi11de1 Sa ndbag ancho1 Uual automabo vacuum ...........Continuouslyremoves water entering the
Cruise control Speed lieN siphon pumps cngrnc compartment.
Ski mode Fold-down reboarding step Large diameter drive shall ...... Maintai ns e ngine and pump alignme nt at all
Slow mode Protec1ive cover wilh crowned spline design ope1ating speed s.
All ilude Advanced TEC trailer Starnlcss steel ........................ ...Oelrvers improved acceleration, hrghertop
Removable dry bag for front storage flre extingui sher Impeller speed and less cavitation.
WARRANTY
BRP l im �ed wananty covers the watercratt for one year.•
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Rxr·:.x� aS� 260 RS
iBR iTC 5:1 CLCS

Specifications
DIMENSIONS
length ...... ...... ...•• - •.-....•- ........... 139' / 354 cm

\Yldth ...... ..... .....
.. . . .... ... ..... .... ..48' / 122 cm
.. ... ..
Height ... ....... .... . . ..... ..... ..4S.5' / l 18 cm

. ... . . ... ... . .
Weight (dry)...................................960 lb./ 436 kg

Rider capacity...............................3
Fuel capacity................................. 18.G US gal/ 70 I
Storage capacity ... ... .. .... .... ....
... .... 13.7 US gal/ 521
ENGINE
Type............................ ...... .......1503 XHO Rolal\9 4-TEC* engine

Intake system.............. ................Supe1charged with external in\ercooler.
60 mm throttle b<>dy
Bore x stroke... ............ ..... ......... 100 mm x 63.4 mm
. ... .
Oisplacement ................................ 1,494 cc

X·HaJ!dlebarf with A.LS:' R1bo11d101 pllUorm with1to111e
11
Compression ratio.........................8.4:I
Cooling.............................-..........Closed-loop tooling system (CLCS)
fuel lype........................................87 octane- minimum
91 octane-recommended
DRIVE UNIT
Propulsion system...........-..........Sea·Doo" Direct Drive

Jet pump ....... ..................... ........l\lumlnium, axral flow. single stage,
large hub witll 10-vane stator
Transmrssion................................. iBR
HEW as mp•Mlon 18R" lh11elU1enl Brah l RevmeJ brake lcv01 lmpcller.........................................Stainless steel
ELECTRICAL
Ignition... ................................ ....Digital induction

Starter............ ........Electric
Battery......... ........... t2 V
HULL ANO COMPONENTS
Type ............................................... S' Hull'"

Colour . .
........... ..... .............. .... . .. ..... Black and Dragon Red
X - Ca1ourabo11 seat X·1nform11Jon centrt
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Standard Features RXT-X aS 260 RS

HULt AtlO COMPONENTS ENGINE
iControl'" ...............................The "Brain" that integrates and contiots all systems to Sup erchargeil, in tercooled ....Supercharged, intercooled 1503 XHO Rota1 4-lEC engine
cre ate the best P-OSsible ride. I ,494 c c tour-stroke. provides reliable ultra-high pertormance In fresh 01
as . ..._........... ........... ... ..........Allows the hull to move independently ol the upper deck, Rota1 wilh lour valves sallwater. increased torque al low RPM, optimised
(Adjustable Suspension) isolatinr, rider and passenger lrom the impact of rough per cylinder powe1 at all RPM levels and throttle pos1ttons.
water. Manual compression damping adjustment via the Multi-port fuel injection ....... Better control ol exhaust emission and power at a ll
nitrogen remote rcsC1Volr Into the glove box. Suspension RPM ranges to reduce emissions and reduce tuel
spring r.an •lso Ile easily adjusted with fools 1rndes the seal consumption .
S1 Mull ....................................Stepped, Slable & Slrong. lightweighl mateiial. ribbed ITC'" {tntell1gent ...................... Ope1ahng electromcally. this advalltCd throttle system
and stepped. Creates a low-pressure zone to reduce Throttle Control ) system starts you m neutral for easier dockside starts. It also
drag lnr nimble handllng and rail-Hg ht cornering. features an activity-specit11: Touring /Sjiort mode and
Touring/Sport mode....... .......Olfers a choice between two t llrottre responses for Variable Tnm System that can be set to accommodate
different riding styles. Touring m�e s i !tie default
rour riding style. The iesull is a more responsive, mol3
settmg offering a more progress i ve acceleration curve intuitive ride.
tor a more cont1dent 11de- ideal lor cruising and 2-up
1Control Learning Key�......... The programmable learning Key a llows you to hmrt
riding. Sport mode can be easily activated using the
the pertomiance ol lhe PWC base<! on rider skill level.
Set liutton. It provides all acceleration performance
Each of 111e two set tings can be fine-tuned using the
for a more aggressive throttle response .
mode/set buttons.
Hmged seat ....._ .... ... ..... ..... .Easy--0pen seat with conven1enl stay-open support
D-Sea-Bel'" system ..............Combines a series of resona tors and vibration
struts. Provides easy access to the engine compartment
absorbing components to make Sea-Doo watercraft
while remaining attached to the watereratt.
some of th e Quietest on the water.
tligh-perfonnance etectnc ..... Provides pre-set po.sit ions for quick settings
Waler-cooled exhaust pipe .. . Regulates ex hau st temper ature.
Variable Trim System (VfS�) when adjusting boat trim, maximises acceleration
and high-sJIBed stability. Closed-loop cooling system Uses coolant l o keep the en gine running al the ideal
temperature, much hke a car's radiator. Also keeps
Bow and stern e yes ................Oesrgned tor towmg or securing the e1aft to a t iader
or dock.
Water/air separalor .............. Provides matimum airflow to engine and reduces
Carpete<l lootwells..._,_...... Otter�ra cornfOfl. non-skid surface and great looks
wa ter int rusion.
and deck pads
Watertight digital 1gnrtion.... Provides optimal energy for a cons1slent spark,
ReboardJng platt01m ............. Easy access to batteiv. !uses and st01age.
ensuring m aximu m performan ce.
with rear storage
RPM limiter ......................... Protects e11gine from over-revving.
Watertight. removable ...... .. ...Provides dry st111age for luggage and necessities
Warnin� device......-............. Warns operator of engine and e1haust overheating,
Slorage bin with easy access.
Tilt steering......... .... .......� adjustabl e steering and i nlorma11on centre augles
Handlebar-mounted ..... ........ Engine starts and stops with sing le ,
for maximum ease and comfort.
start/stop button user-lrlendly control button.
Interactive Multifunction .. .....Reports 30 key operating tuocfions,
lip Over Protectlon ............... Protects engine In case ot turn over.
Digital lnfonnalion Centre Fuel level. Tachometer. Spee<lometer. Hour meter.
Syslern IT.O.P.S.'")
Compm, Clock. Fuel consumption meter. lime /Distance
to empty. Top/average speed/RPM, Lap timer, Engine
PROPULSION SYSTEM
temperature, Water temperature, Touring I Sport mode,
VTS, VTS preset, F-N-R Indicator, Low fuel level , low oil IBR {Intelligent Brake ...... ....The world's only on-water braking system, IBR lets
level, Low oil pressure, Low voltage.OverheaL HI vol tage, & Reverse) system you stop up lo 100 feet sooner than any other
Check engine. Sensor check. Batteiy protect io n, Key watercraf1'. All with the squeeze of a lever. And
(wrong key), l-Key IR-Key, Maintenance into, Error codes. with its electronic reverse, it gives you a level ol
Dreitally Encoded Security .....Industry's first digitally encoded theft-dete rrent manoeuvrability that makes docking easier
System (O.E.S.S.�) system.
Sea·Doo Direct Drive ...........Oellvers optimum performance with the Rotax
Foam tlotatron........................ Ride with secu11ty and peace of mind, Meets or e!Cttds propulsion system eoglne .
USCG standards .
Replaceable UHMW*' .. .... .... Provides tong impeller life. less maintenance
Off-Throttle Assisted ............. Provides the operator with add1bonal steering eflecl wear ring and ma�irnum thrust.
Steering {0.l.A.S.") In oft-throttle situations for greater manoeuvrability.
Dual automatic vacuum .......Continuously removes water entering the
Quick �itch luel filler design Exlernal exhaust cooling nu sh
siphon pumps engine compartm ent.
SJX)nsons attachment
aumpers Special comfort hand grips Large diameter drive shalt .. Maintains engine and pump alig nment at all
Adjustable mnrors Wide handlebars wilh crowned spline design operating speeds.
Ski tow eye Emergencyfloat r ng lanyard Stainless sleet Impeller ...... Delivers improved acceleration, higher top
Reb-Oarding hand les 0111331 plalf0<m (permanent CO!lfacl) impeller speed and less cavitation,
Rear grab handle Seat strap Aluminium stator vanes .. , .... Handles the hig h-performance engin e with oul erosion.
Front spl ash deftecfct Operator's guide, Instructional video
D11al drain plugs and booklet OPTIONS
Engine access oovei {removable)
Fold-down reboardlng step Clove box organiser
X-PACKAGE Removable wakeboard rack Safety kit
Depth finder Sandbag anchor
X- steering with A.E.S...,...,...... .The only fully adjustable handlebar in the induStl'/. With
Cruise control Speed liew
(Adjustable ug(W'll)lll ic Stwing) A.E .S . the rider can adjust lhe handlebar width and
Ski mode Protectrve cover
g ri p f or a fully customised ride.
Slow mode Fire extinguisher
X-ColouraUon seat.......-..... ...Race-inspired designed tor comtort and great looli.s
Altit ude
providing seating 1111 three.
Removable dry bag 101 front storage
X·Tra traction carpet .................Vflth diamond plate pattern
WARRANTY
BRP limited wa11anty covers I he watercraft for one year.•
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WAKC:155
/BR ITC CLCS EC�

Specifications
DIMENSIONS
Length ....... ........ ... ........... .........132.6'/ 336.8 cm

. . .. .
Widlh .............................................48.5'/ 123.I cm

Height ...........................................44' I 111.8 cm
Weight (dry)...................................748 lb.1339 kg
Rider capacity ............................... 3
Fuel capacity ................................. 15.9 US gal/ 60 I
Storage capacity ...........................30.8 US gall t16.6 I
ENGINE
Type ...............................................1503 NA Rotai(ll 4-TEC8 engine

Intake system ................................Naturally aspuated with
60 mm throttle body
3·111>sihon reu1c1able >�I pylon folsHSuwn rttburdm11t1p Bore x stroke..................................100 mm x 63.4 mm
Oisplacement ................. .... . ... .......1,494 cc
Cooling..... .... ..............-........ ... Closed-loop cooJing syStem (ClCS)
fuel type ........................................87 octane
DRIVE UNIT
Propulsion system . . .._..................Sea-Ooo"' DirectDrive

let pump ...... ......................... .....Aluminium, axial now, single stage,
Transmission .......................... ....iBR
Removable board tack 1BR· 11111elllgtnl B,.k• l R"'meJ bnl!e lmr
Impeller......... ........................ ....Stainless steel
ELECTRICAL
lgmtton .......................................... Dig1tal inductive

Starter ........................................... Electric
Battery ..........................................12 V
HULL AND COMPONENTS

Type... ... ..... ... ... ......... .......LFI, composite
.. ... . ... .. ...
Colour ........................................... Wake Red

Wide·ng� mirrors 0121121 1nro1m31Jon centre with S�l mode
sdd2011.002.eo 1_en_21
S ecifications
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Standard Features WAKE155 -u
0
HULL AND COMPONENTS ;a
-;
Touring I Sp0rt mode.......... ... Offers a choice belween two throtlle resl)-Onses for
d1t1erent riding styles. Touring mode 1s the default N
setting offering a more progressive acceleration 0
1--'
curve for a moie confident rid e- ideal for cruising 1--'
c
and 2-up riding. $1)1)11 mode cao be easily ativ�te�
using the Set button. I t provides all acceleration
performance for a more aggressive throttle response.
ECO mode ...-.................. .... ECO mode is the newest ITC'" function that
automati cally determines the most economic-di
power deliveiy and sets the optimal speed tor
c1eatest fuet economy. ENGINE
Bow and stem eyes ........... .. Designed tor towing or securing the eraIt to a
tiaiJe1 01 dock. t,494 cc four-stroke,. 1503 NA Rotax 4-TEC engine provides reliable
Carpeted footwells ... ........... Offer extra comfort, non-skid surtace and Rotax with four valves performance in fresh 01 saltwater, inc1eased torque
and deck pads great looks_ per cylinder at low RPM, optimised power at all RPM levels and
throttle positions.
3-up seat ... ..... .. ... .. . ... ...... .. .Comfortable room for three- permits
1ea1·faci11g spotter for watersports. iTC� (Intelligent.. ....................Operating electronically. this advanced throttle system
Throttle Control) system starts you in neutral tor easier dockside starts. It also
Efevafed fuel lltler ................ Easy access and prevents water intrusion Whife
le<ttures an activity-sp ecific cruise control, Touring I
refueling.
Sport mode, ECO mode and Variable Trim System that
Fold-down reboardlng step .••.Makes reboarding from the water easier and quicker. Clln all be set to accon1modate rou1 rfdin� style. The
Multifunction Digital .... Reports 26 key operating functions: result is a more responsive, more intuitive ride.
Information Centre Fuel level, Tachometer, Speedometer, Hour meter, !Control Leaming Key'".. .......The programmable Leaming Key allows ynu fo limit
Compass, Clock, Cruise conhol, Ski mode. Slow the perlormance of lhe NIC based on rider skill-level.
mode, Fuel consumption metCI, New ECO mode, Each of the two settings can be fine-tuned using the
Touring I Sport mode. VTS'", F-N-R indicator, mode/set bultons.
Low fuel level, Low 011 pressure, Low voltage,
D-Sea-Be1•• system .............. Combines a senes ot resonators and Vlbrat.1on
Ove!heat, Hi voltage, Check engine, Sensor check,
abso1bing components to make Sea.l)oo watercraft
Battery protection, Key (wrong key), L-Key I R·Key.
some of the quietest on the water.
Maintenance lnto, Error codes.
Multi-port fuel injection .......Better conhol of exhaust emission and power at all
01g1tatly Encoded Secunty.... tndustry's first drg1tafly encoded theft·detenent
RPM ranges to reduce emissions and reduce tuel
System (D.E.S.S.") system.
consumptiou.
Foam flolahon ..................... .Ride with secu11ty and peace of mmd. Meets or
Closed-loop cooling system.. Uses coolant to keep the engine running at the Ideal
temperature. much like a car's radiator. Alw keeps
Oii-Throttie Ass1sted ............ Prov1des the ope1ator with additional stee11ng out corrosive saltwater and debris .
Steering (0.T.A.s:·) effect In off-throttle situMions for greater
Water/air separator .............. Provides ma!lmum airflow to engrne and reduces
manoeuvrability .
water intrusion.
Spoosons Double density comfort hand grips
Watertight d1g1tal 1gml1on.... Provrdes optimal energy for a consistent spark,
Bumpers Emergency floating lanyard
ensuring maximum pert01mancc.
Re boardfng platform C11t & sew seat with three colours
RPM limiter ........ .................. Protects engine from over-revving.
Wide-angle mirrors Seat strap
Warning devir.li... . ....... ._.... .IVarns operator of engine and exhaust overheating,
Rear grab handle Operator's guide, instructional
External exhaust coolmg flush attachment video and booklet
Handlebar-mounted ............. Engine storts and stqps with single, user-friendly
WAKE PACKAGE start/stop button control button.
lip Over Protection ............... Protects engine in case of turn over
Ski mode .............................. This advanced iControl'" feature allows the driver
System (T.0.P.S.�)
to adjust the intensity ol the launch for d1ffe1ent
rider skill levels and tow sports while mamtaining a PROPULSION SYSTEM
constant speed. You get highly repeatable runs lor
Sea-Doo Direct Drive ............ Oelivers optimum performance with the Rotax
the best possible tow sports experience .
propulsion system engine.
3-position retractable.......-..Retractahfe. so it's theie when you're pulling someone
IBR (lnlelhgent Brake ........... lhe world's only on-water braking system. tBR lets Y1JU
ski pylon and out of the way when )'<lu're not Also features
& Reverse) system slop up to 100 feet sooner than any other watercraft'.
spotter hand grips �nd rope storage All with the squeeze of a lever. And with its electronic
Removable wakeboard rack...Provldes easy transport ot a wakeboard to the ride sfte. reverse, ii gives you a level ot manoeuvrab ility that
OPTIONS Aluminium stator vanes....... Handles the high-pe;formance engine without erosion
Depth finder Speed Tie� Dual automatic vacuum ....... Conlrnuously removes water entenng the
lime/distance to empty Safety kit siphon pumps engine compartment.
Top/average speed/RPM Additional wakeboard rack Large diameter drive shaft ...Marntains engine and pump alignment at all
lap timer Sandbag anchor with crowned spline design operating speeds
Engine temperature Protective cover Replaceable UHMW" .......... Provides long Impeller lite, less maintenance
High Performance VTS fire extinguisher weaning aud maximum thrust.
Removable dry �ag for front storage Stainless sfeel .. Delivers improved acceleration, higher top
impeller speed and less cavitation.
WARRANTY
llRP limited warranty covers the watercraft 101 one year.•
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6
WAKE�PRO 215 CJ)

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iBR iTC s:s CLCS
Specifications
DIMENSIONS
Length.. ...........................139'/ 354 cm
.
l'l1dlh. .
..... .._...... . . ... 48' / !22 •111
....... ....... .. ....
Heighl ...........................................45.9' f 116.6 cm

l'leighl (dry)...................................855 lb./ 388 kg
Rider capacity ...............................3
Fuel capacily ••...•......•...................• 15.9 US gal/ 60 I
Storage capacity •. ...•••..........•••... .. .13.7 US gal/ 521
ENGINE
Type............... ..... ..... ............. .....1503 SC Rotatt 4-TEC• engme

. . . .
Intake system ................................Supercharged with mtercoole1.

60 mm throttle body
Bore x stroke ... .. ............ .. ..... ....100 mm x 63.4 mm
... ...
Ski mode 3·poubon relmtlbl• 1k1 pylon Oisplacemenl ................................ 1,494 cc

Cooling................ ...Closed-loop coollng system (CLCS)
........................................87 octane - minirnum
Fuel lype
DRIVE UNIT
Propulsion system ......................... Sea-Ooo"' Direct Drive

lei pump ...... ......................... .....Aluminium. axial now, single stage.
large hub with JO-vane stator
ow
fold-4 n reboard1na stop Rumo¥JWe bo1td rnk
Transm1ssion..................... . ...........iBR'"
Impeller .........................................Stainless steel
ELECTRICAL
Ignition......... .............................. Digital induction
Slarle1 ............. ..................... .. .... Electric
Ba ttery: ...... .. . ....... .. .... .. . .
.. ... .. J2 V
...
HUU AND COMPONENTS

Type..............................................$'Hull'"
Colour.............. .............................Wake Red
nowmg 1dg1 d1mp,n W3tert12h� remov3ble stor•ge bin
r-""""'l' l
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Standard Features WAKE PRO 215

HULLAND COMPONENTS
1Contror·....................................The ''Brain" that Integrates and cootrols all systems to
create the best possible ride.
S1 HutL..................-.................Slepped, stable & stroog. Lightweight mateiial, nbbe<I
and stepped. Creates a low·pressure zone to reduce
drag for mmble handlmg and rail-tight comenng.
Touring I Sport mode .......... .... Offers a choice between two t hrottle responses for
different riding styles. Touring mode Is the default
setting ottering a more progres�lve acceleration
curve for a more confirlenl ride- Ideal for cruising
and 2-up ridiog. Sport mode ca n be ea sily activated
using lhe Set button. It provides a ll acceleration
ENGINE
performance !or a more aggressive throtUe response.
811.Y and stem flJf!L........... , ..Designed for tO\\ing or securlng the craftt o a trailer or Supercharged, mtercooled ....Supercharged, mte�led 15-03 SC Rotax 4-TEC engme
d<X:k. 1,494 cc four-stroke, provides reliable ultra-high performance in fresh 01
carpeted tootwells.....................Offer e:dla comfor t, non·sktd surface and Rotax with lour valves saltwater. increased torque at low RPM. opt im is ed
and deck pads llJeallooks. pei cylinder power al all RPM levels and fh1ottle posihons.
3-up seal .....Comfortable mom for three- permtts spotter tor ITC'" (lnlelllgenl .................... Operating electronicalty, this advanced throttle system
watersports. Tbroltle Control) system starts you in neutral for easier dockside starts. It also
Hinged scat...............................Easy-<ipen seat with convement stay-<ipen support features an activity-specific cruise control. Toming I
struts. Ptovides easy access to lhe engine compartment Sport mode and Vanabfe Trim System thal can all be
while remaining at tached to the walea:ralt. set to accommodate your riding style. The result Is a
Fold·down reboardmg step ....Makes reboa rdmg from the water easier and quicker, more responsive, more intuilive ride.
Watertight. rem011abJe.__,.......Provides diy storage f01 luggage and n<ieessities iConl!ol learning Key'"......... The prog1ainmable Learning Key allows yuu to limit
storage bin with easy access. the performance of the PWC based on rider skill·levef.
Each of the lwo settings can be fine-tuned using the
lilt sleeling ................................M1usls !he steering aJld mfi.matioo centleangle Ii.
maXJmum ease and comfort. mode/set buttons.
MulLifunclion Digital-......._,Reports 28 � operating functions: D·Sea-Bei'" system ... ..........Combines a se1ies of re$onators and vibration
absorbing components to make Sca-Doo watercraft
lnformallon Cenlre Fuel level, Tachometer. Speedometer, Hour meter,
Compass, Clock, Cruise control. Ski mode, Slow some ol lhe qtJletest on lhe water.
mode, Fuel consumption meter. Water temperature, Mulli·po1t luel injection .......Bette1 control of exhaust emission and powe1 al all
Touring I Sporl mode, VTS'", VTS preset, f·N·R RPM ranges to reduce emissions and reduce fuel
indicator, Low luel level, Low oil level, Low oil consumption.
pressure, Low voltage, Overheat. Hi voltage, Check Closed-loop c oolin g system. .Uses coolant to keep the engine running a l the Ideal
engine, Sensor check. Baltel)' protection, Key (wrong temperatu1e, much like a car's radiator. Also keeps
key), l-Key I R·Key, Maintenance info, Error codes. out corrosive saltwater and debns.
Digital� Encoded Security........lndusby's first digitally encoded lheft-<leterrenl Water/air separator ..............Provides maximum airtlow to engine and reduces
System (0.E.S.S.'") system. water intrusion,
Walertight d1g1tal 1gnition ....P1ov1des optimal energy for a consistent spark.
Foam flolalion.. ........... ... ....... .....Ride wiU1 security and peace o l mind. Meets or exceeds
ensuring maximum performance.
USCG standards.
RPM l imiter ,_.... .. .. .. ....... ..... .Protects engine from over-revving.
Off-Throttle Assisted ..... ............Provides the operator wilh additional steering effect In
Warning device .....................Warns operator of engi ne and ex haust overheaifng,
Steering (OJ.AS.�) off-throttle situations ror greatei manoeuvrability.
engine manageme11t and system failme.
Quick latch fuel ftller des1Rn External exhaust cooling flush Handlebar-mounted .............Engine starts and stops with single, user·fnendly
Sponsons attachment start/stop button control button.
Bumpers Spedal comfort hand grips lip Over Protection ...............Protects engine in ca se of turn over.
Adjus table minors Emergency tloalmg lanyard System (tO P.S.'")
Reboarding plallorm Cut & sew seat with multi colours
Reboardlng handles on rear platform Seat stJap PROPULSION SYSTEM
Rear grab handle Operato r's guide, instructional video iBR (lntelligenl B1aka ........... The world's only on-waler braking system, IBR lets y(JU
Front splash deflector and booklet
Dual drain plugs
& Reverse! system stop up to 100 feet sooner than any otller watercraft'.
All with the squeeze of a lever. And with ifs electronic
WAKE PRO PACKAGE reverse. it gives you a level of rnanOiluvrabilily that
•nakes d01;king easier.
Ski mode ..............................This advanced iControl leature allows the driver Sea·O-Oo Direct Dnve ..............Oellveis optimum performance with the Rotax engine.
to adjust the Intensity of the launch lor different propulsion sy stem
nder skill levels and tow sports while mamtaming a Aluminium stator vanes ....,...Handles the high-performance engine without erosion.
constant speed. You get highly repeatable runs for Dual automatic vacuum ........Continuously removes water entering the
lhe best possible tow sports experience. siphon pumps engine compartment.
Hlgh-performance electr 1c ...... Pr011ides pre-set positions tOf quick set1 1 ngs when large die meter drive s haft ....Maintains engine and pump alignment at all
VTS (Variable Trim System) adjusting boat lnm, maximises acceleration and
with crowned spline design ope1ating speeils.
Replaceable UHMW"*... .. .......Provides long impeller life, Im maintenance
high-speed slabilily
wear ring and maximum thrust.
3·posit1on retractable ............ Retractable, so it's there when yoo're pullmg someone Stainless steel ....................... Delivers improved acceleration, higher top
ski pylon and out of lheway when )'Qu're nol. Also features impeller spee<l and less cavitation.
spotter hand grips and rope storage.
Removable wa�eboard rack. Provides easy tiauspo.t of a wakeboa1d to the ride site. OPTIONS
Wide-angle convex mirrors ..... Increase held of view by 32% over standard mirrors. Depth tinder Glove box organiser
Time/distance to empty Satety kif
WARRANTY Altitude Sandbag anchor
BRP liniited warranty coveis the watercrart fo r one year.• Top/ave1�ge speed/RPM Speed Tie'"
Lap ltmer Protective cover
Engine iemperature fire extinguisher
Removable dry bag lor fronl sto1age
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6
150 Speedster"
CLCS
Specifications
DIMENSIONS
length . . . . . . . . . . . •. ..• • . • . . . . •• . . . • . • • .• •• . . . 15' 4' I 4.67 m
Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7' l'/2.16m
Yellow
Orafl. . .. ..• . • .. • . . . . . . .. • . . . • .. .. . . . .. . . ... . . 12' / 30.5 cm
Ory weigh( . . , • • • • .1 ,4 54 lb. I 659 kg
� ,, Staling capacity
Fuel capacity.
. .
.
.. . . . . .. . . . . . .. . . .. , ..................... 4
. . . . . . . . . . . . . . ... . . . ... . . . 21 US gal 179.4 I
I '- • ..
-- •
_. ENGINE
___..._
Model. .................................... 1503 Rotax'94-1EC..
Type . . • . • .. • . . • • •• • .. • • • . . . .• • . • .. • • .. 1.51 high output
Highlights
• 1.51 high output Rotax4·11C engine
• Oigital Information Centre with 18 functions

Including depth finder, compas.s, water temperature, hour meter
• Sate llite-re d ..a

y stereo with MP3 port and 2 speakers
• Chrome cleats (4)
• Hon-slip grab handles (8)

Driver console
Di11iil lnlormabon •••Ile
•
• Front and stern lockable storage
• Ski pylon - pull-up
• Swim platlorm with ladder
sdd2011.002.eo2.en.1
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6
150 Speedster �
Overall Specifications d
DIMENSIONS
lenglh
Beam
. . • • , • • • , • • • , • • . • • , • • • .• • • • • . . • • , • • . . • • • •• .
. . .. • • .• . 7' I' f 2.16m

. l!i' 4' 14.67 m �.IJl � �
�I j
(')
• . • . • . . . . .. . • . • • , . .. .. • . .
Draft..... ..................... , ..................... 1 2 ' / 30.5 crn

rn
Dry werght .........................................1,454 lb.f 6 5 9 kg
Storage capacity . • • . 14.5 cu. tt. / .44c u m N
0
. . . • • . • • • • . • • . • • • . . • • .. . . • .
Seating capacity •. . . • .• . . . . • • . . • .• ., . • . . 4 .....

.....
Weight capacity . . • . . • . . . . • , . • . . • . . • • . .. . . . . • . • . . • . . . . 715 lb./32 4 kg
Fuel capacity • • . . .• . • • . . . • . . • . . • • • • • . • • • • . . . . • • • • . , . 2.1 US gal/79.4 I ELECTRICAL
GeneralOI . • • 30 ampf380W
DIMENSIONS (ON TRAIURJ Satteiy 12V
length . . . • . . • . . • • . . • . . . • . • • . . • • , ..................... 18' !i'/5.6 m HULL & DECK

Width , .. ..... ............. ........ .. 1' l'/2.16m
Material . . .. . Composite FRP
• • . • ••
, , . . . . . . . . . . . . . . . . . . . . . . . . . . , •. . .
, ............. ........ , ... 4' 11' / 1 . 5 0 m

. . . . •
Heiglrl: No lower .... .

Vinylester barrier I ayes .. .• .. .. • .. • Std
. ••
• • .. • ..
Tower down .................................... 6' 10' f 2.08m
. . •
Full fiberglass stringer. . • • .. .. • . . .. • • . •.. •• . . • Std

.. •
Tower up .......................................8' 6" 12.59 m Graphics.. . . . . . . . . • .. . .• • •. .. . .. . . . .. • • • • • . . • . . . • . .. • Std

. . . . . . . •
Cross weight . . •. .. .. .. . .. • • • . . • . .. . .. .. • .. "2.1 00 lb.19 52 kg Deadrrse . . . .. ..

. . . . . . . . . . . . . . ... . . . . . . . . . . . . .
. . . . . .. .. .
. . . 2 0'
. , .•
Colours • . • • . . • . . . • • . • . . • . • . • . . . • • . • . . • • • . • . . • • . . . . . • • . .. . . . , Yellow
ENGINE • • . • • • . • . . • • • . • • . • • • • • . . • • . . • • . • • . . • . • • • • . • . •• • • • • . • • • • • Re<!
Model , .• Fuel injecte<J, 1503 Rotax 4-TEC PROPULSION
Displacement........................ ............ 1.494 ct
Jet pump type:
fype: .............................................. 1.5 I high output
Axial llow............................................Single stage
Cylinders .., ............. , .......................... ,.......... 3
Pump diameter: . . . . . . , ...........6 lf4'/15.63 cm
. . . . .. .. . . . . . , ••
Max RPM . . . • .. . . .. . . . • .• . . 8,000 .. . . • . . • • •

Impeller:
0-tane: Recommended .......................................... 91 i
Materal... • • .. • • ,• .. .. • .. Stainless steel
• • . • . .. • . . . • .. • • . . .
Emission level . . . . .. . . CARB 3-Star

. . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . ,•
Outside diameter(mm) .. . . • 1 5 9 ± .0 7
. . . • • . . .. . . • . . . . • • • . . . • • • • .
Cooling system . • .• • . • .. . • • . • • . . • • . • • . . • • . • . . Closed-Loop Cooling System Reverse ssy tem . . •• . .• . . . . . . Std

• . . . . . . • • .. . . • . . .. .. . . . .. • .. . . . • .
Equipment Options
HULL & DECK CONTROL STATION (Cont'd) COCKPIT • Wakeboard tower &racks
(red model only}
Cleats-chrome (4) INSTRUMENTATION Dashboard timsh- Black
CalJ)et-snap-in
• •
•
Cup holders (4) • Outlel-12 volt accessoiy (I)
Mirror· with tower only
•
• Fuel level •
Rub rail - Black • Cooler-integraled
(red model)
•
• Tachometer
Grab handles ( 8 )
STEREO & SOUND Mooring cover
•
• Speedometer •
• Non·skid decking Bimini lop
Hour meter •
Navigation lights Stereo system -satellite-ready ..
•
(Incl.tower: red model only)

• •
Maintenance info
Ski pylon - pull-up Speakers - cockpit( 2 )
•
•
Compass
•
• Fire extinguisher
• Tow hooks-stainless steel how •
• M P 3 port
Anchor
Waler temperature
•
&stem •
Depth finder CANVAS & MISCELLANEOUS

• Walk·through - bow •
• Reboardrng ladder - stern (I·step) • low fuel level • Sunpad

Engine access - sunpad low orf level
• •
CERTIFICATIONS
• Engine blower • low oll pressure
NMMA
Auto bil�e purnp Low voltage
•
• •
• CMMA
• Overheat
STORAGE
• HI voltage TRAILER
• In-floor. lockable
• Check engine Single a)Je
• Sunpad, lockable •
• Sensor check Galvanised tralle1

• Console.lockable- starboard •
• Battery protection • EC versions available

CONTROL STATION • Key(Wrong Key)
HELM
• Steering- standard
• Separated shill & llrroUle leve1
• Neutral lnck
• Ballecy switch
• Fuse hox
• Security system D.E.s.s:· magnetic
lanyard key
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6
CLCS
Specifications
DIMENSIONS
--��-��-
-
-__
- _
--
_
-_
�- __
_, �� Length . . . • .. • . . • • . • . . . .. . . • •. • • ••• .. .. 19' 9' / 6.02 m
BriptWhlta Beam .............. ..... , ......................... 8' / 2.44 m
Draft.......................................... 12' / 30.5 cm
Ory weight: No tower .. . • •• • .. • • .. 2.770 lb./ 1.256 kg
With tower•. . . . . . . . • . . . . . . . , ....... 2,830 lb./ l,284 kg
Seating capacity .. .• • . ••• .. • .. • .. • .. . • • .. • 1
Fuel capacity .. .......... .. . ... .. . ... .... . ... 44 us gal/ 166.51
ENGINE
Model .......... , ................ , ..... 1503 Rolax'!' 4·TEC3 (x 2)
Type ........ ......... ...... . ... . ... .. . ... Twin l.51 high outpul
Highlights
• Twin 1.51 high output Rotax 4-TEC engine
• Swim platfomt with 2·step ladder
• D ual stern storage compartment
• Sundeck pad
• Pop-up ski pylon
• Cockpit courtesy lights
see
• Ski storage
Twin Rolu 1nau1e1 Larae cockpit are3 • Satellite-ready.. AM/FM/CO t r o with MP3 port and 4 speakers
• Depth finder
• 12 voll jack
• Windscreen with pop-up wind dellector and helm stora2e
• Built-in cooler
• Multi-function aluminium black rails
• Grab handles
• On-board storage
Full lnsltllrne��Uon dashboard Slim rtoraga 1cc11ts
sdd2011-002.eo2_en_3
.---... ,�-·��- SECTION
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6
200 Speedster�
Overall Specifications 0
,,
;o
DIMENSIONS
�
Length . .. 19' 9'/ 6.02 m
, . . . . • . • • • . . . • , . . . . • • • •• . . •• , • . . . • . )>
Beam ................... , . . ., . . . 8' 12.44 m
. . . . . . . ....... . , ..•••. z
Draft...... ,............. , ............................ 12' / 3 0.5 cm 0
rn
Dry weight: No tower............................... 2.770 lb.11.256 kg
With tower+ 2,830lb.11.284 kg
• . . • . . • . . . • • • • • . . • . • • . . • • • . • • N
Storage capacity 46 cu fl / 1.3 cu rn
. . . . ,. . . . . , • • . • • . . • • , . . • • • • • • • • . • • .
BriefitWhi1e 0
Seating capacity . • .. . . • . •
. . •• . • . .1
. .. • .. . • . • .
�
Weighlcapacity ......... ................. , .l,3651b.1619kg
Fuel capacity , 44 US gal I 166.51
ELECTRICAL
. • . . • • . . • . . . • . . • . . • • • • • . . • . • . . • . • • . • •
DIMENSIONS (ON TRMLERJ Generator ... ,.............,......................... 30 amp I 380VI

length {tongue folded) 22' 7' I 6.88 m (20' 6' I 6.25 mI
. • . . . • . • • . . • . . . • . . . • Battery .... . ,...................................... .. 12V
• . . • • ,
Width . .. .. .. , .. 8' 6' 12.59m

HULL & DECK
. • .
Height: No tower . • . .. 6' 6' 11.98 m

• .. • ..
Tower down+ .............., .................... , 7' l' 12.16 m Material , ........., .............................. Composite FRP
. . • .
lower up• ..................................... 9' 11' I 3.02 m Vrnylester bamer laye; ,

. • . . . . .
• • • • • . . •• , . . . . • • , Std
. . . .. . . .. . . .. .. . . .
Gross weight: No tower 4,095 lb./ l,857 kg

• . . . . . . • • . • • • . • . . • . , . . . . • . . • .
Full fiberglass stringer........................................... Std
With tower+ ........................... 4,115 fb./ 1,885 kg Graphics. . .. . . . .. . •
. . . . . . . . . . . . .. • . • . .. . Std
• . . . .. . .. • . .. . . . .
Deadrise....... .. . . .• .
. . ..• . . .. . . • . , . 21'
. . • . . . . . . . . .
ENGINE Colour..... , . .• .
. . . . • .. •
.. • • . .. .. Bright White
. . • • .• • . .
Model .. , .. .. .... .Fuel injected, 1503 Rotax 4-TE C (2)

Oispl�cemenl.. , .. • .. . .... .... l.494 cc
.
PROPULSION
Type ...........................................Twin 1.5 I hl�h output Jet pump type:
Cylinders (/engine) 3
• • . • . . . . • • . • . . • • • • • . . • . • • . . . • . . • . , . . . . . . . . • . . • . . Axial llow.. . . .. .. . • . .. . .. . .. . • . .. .. , Single stage
.. . .
Max RPM (!engine) ................................ ,.......... 8.000 Pump diameter ............ ....... ..... , ... 6 114'/15.63 cm
O.tane: Minimum . .............................................. 87 Impeller:
Recommended .. ...................... ................. 91 Material........................................... Stainless steel
Emission level . . ..
. •. .. • .. .. .• CARS 3-Star
, , •. Outside diameter (mmJ................. ,.................1 5 9 ± .07
Coolmg system . • , • • • • • . . • . • • . . . • • .•• . . • . • • . . Closed-Loop Coolmg System Reverse system ................................... ,......... ,.. Std
Equipment Options
HULL & DECK CONTROL STATION STEREO & SOUND • Wakeboa1d tower & racks
Carpet- snap-in
Stereo system - satellite-ready<'
•
Cleats - chrome (6) HELM •
Mirror - with tower ooly
•
Speakers - cockpit (4)

•
Cup hotders (6) Steering-custom •
Mooring cover
• •
MP3porl
•
Rub rail -Bla ck Steering - rack & pmion •
Bimini top
• •
•
Grab handles (8) Horn
Fire extinguisher
•
CANVAS & MlSCEllANEOUS
•
Separated shift & dual throttle levers

•
Non-skid decking •
Anchor
•
Battery switch
•
• Navigation lights- bow side • • Sunpad
• Courtesy llghls (3) • Heulral tock • Wind deflector
• Ski pylon -pull-up • Fuse box
• Towlloolls-sta1nlesssteel bow & stem • Security system D.E.S.S.'" magnetic CERTIFICATIONS
Reboarding ladder -stern ( 2-step) lanyard key
•
• NMMA
• Engine access INSTRUMENTATION • CMMA
• Engine blower (2) • Gauges - backlight & anti-fog
• Auto bilge pump • Fuel level TRAILER
Tachometer
STORAGE •
• Single axle
Speedometer
Anchor
•
• Swing-away tongue
Oepth finder
•
ln-Ooor, lockable
•
• EC version available
Overheat
•
•
• Under seal
• Sunpad, lockable COCKPIT
• Glove box, lockable
• Dashboard finish-Peallstone
• Outtel -1 2 volt accessory (I)
• Cooler - mtcgrated
SEATING
Driver Seat
• lrack & sw ivel
Passenger Seat
• Track & swivel
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Specifications
DIMENSIONS
Length • , , • .. . , ,•. , .. , . .. . • .. • • . .. , • •• ..• .. .. 20' 6'/ 6.25 m
Beam . • . . • . . . • • • • • . . • • . . . . . • • . • . . . • • . . . • • . . . • . . •8' 6' I 2.59 m
Draft. ........•.......•. . ..•••. • , ...•....•...••..12' /30.5 cm
Oryweigh1 . .... ...... ........... .. 3.1001b./1.406kg
Seating capacity . . .. . .. . .. . .. . . .. .. .. . .. . .. . . .. .. .. . .. . .. . 10
Fuel capacity ............................ .... 44 US gal/ 166.51
ENGINE
Model ............. , ....................... 1503 Rotax• 4-TEC"
Type... . . . • • . . .. .. • • • .. .. • • • .. • • Twin 1.51 supercharged
Highlights
• Twin 1.51 supercharged Rotax 4-TEC engine
• ITC'" (lntelllgenl Throttle Control)-Drive by wire
• Swim platform storage accessible from inside and outside the boat
• Salellite-ready**• stereo AM/FM with USS Direct Control (MP3).

4 speakers, LCD remote on sundeck
• Complele premium instrumenlation dashboard
• Innovative Transat seats on sundeck
trinsat se�ls Pre-nm

u n helm • Reboarding ladders - bow & stern
• Stainless steel rub rail
• Stainless steel cup holders
• Oeplh finder
• Cruise control
• Bimini top
• Ski mode
• ECO mode
Stereo remote & table mouqt oqsundec� Bowladdu
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DIMENSIONS �
Length •..•. • •. .••• .•..•• • •..••. . • •..••• ...••..••. .. 20' 6' / 6.25 m 0
Beam ••.••.... .••.••..•••••..••• ••..•• , •..•••.••...•. 8' 6' /2.59 m z
Draft .• •• .. • •..• , , .... ..... ....... . .. 12' / 30.5cm
N
D1y weight •.•..••..•.••• , ••..• ..••..•• • . ... .. • 3,100 lb./ l,406 kg 0
Storage capacity 56.GS cu.ft./ 1.6 cu m
................................ f-'
Seating capacity ................................................IO f-'
Weight capacity . • ..• • • • . .. •• ..• • • . .1.525 lb./ 692 kg

Fuel capacity ...................................... 44 US gal / 166.51 ELECTRICAL
Generator ........................................... 30 amp / 380 VI
DIMENSIONS (ON TRAILER) Battery........ . • . •• •
. • .... • . 12 V•.
Length [tongue folded! .••.• .•.••••.•...•• 23'6" /7J6 m120' l' /6.43 ml HULL & DECK
Width ................................................8' 6' / 2.59 Ill Material • •. .. . .•.. .• • ...• • . .• .. • •••..•• ••.. • Composite FRP
Merght 7' 3' / 2.20 m

..•..•...••• •..•••••..•••.•..••• ••..•..••..•• • Vinyleste1 barrier laye1 .. .•
• .••.... ..• .• . • . . •.
.• • .• . .. • .
• . Std
Gross weight ..................................... 4,070 lb./ l,846 kg Full frberglass stnnger ........................................... Std
Deadrlse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . 21'
Colour. . • ••..... •.•• . .••. •• ..•. • •...••. .•. •• •.. . . Black
ENGINE
.• • • • •
Model .•.••. •••..••• .....• ••..••.••.. Fuel 1n1ected, 1503 Rotax 4-TIC (2) PROPULSION
Displacement .•..••..•..••.••.•••.••..••.•.•.•..••.....•.•• 1, 494 cc Jet pump type:
Type • .. ••. •..• •.... .• • .. .. • • •• • •• Twin 1.51 supercharged Axial Oow. .. ....• .
.. . .. .. • • , ....Single stage
•• •..... ..
Cylinders Vengine).. .••...•.•• ..•..••.

..• 3 ... . •..•••..•••. .••..••.
Pump diameter ..............
. G 114' / tS.63 cm
....................
iTC-electronic throtlle control . .. ....

. . . .. ....
. .. . , • Std
...... . .......
Max RPM (/engine) ........................................... 8,000
Impeller:
Octane: Recommended............ , ............................... 91 Material.. . . • . . . . .
.. . ..
. . ...
. .. . ....
. ... . Stainless steel
. ... ... ..
Emissioo level • • • •• .•• .• CARS 3-Star Outside diametei (mm}, ..................................159 ± .07
C-Ooling system •..•..•.•..•..•..••.• .. .•• ••.. Closed-Loop Cooling System Reverse system ....• .. , ............ , .•
•• • . • . • . . .. . •
.•.. •Std •• . .•
Equipment Options
HULL & DECK CONTROL STATION (Cont'd) COCKPIT (Cont'd) • Are extinguisher
Anchor
Cleats-stainless steel, pull-up (6) Electronic throttle control SEATING
•
• •
• Cup holders-stainless steel (1Ol • Batteiy switc� Driver Seat

• Rub rail - stainless steel • Circuit breakers • lrack & swivel
Grab handles (7 lotal)-stainless Engine synchronisation
• Bolster
• •
steel (Sl Neutlal lock

Passenger Seat
•
• Non-skid decking INSTRUMENTATION • Track & swivel

Navigation lights
Gauges backilght & anti fog
•
• Bolster
•
Courtesy lights (4)
Cruise control
•
Sundeek
•
Tow hooks-slainles.s steel bow & stem
Fuel level
•
• Transat seats
•
Ski pylon - pull-up
•
Fuel consumption
Ski eye - stem
•
ECO mode�· STEREO & SOUND

o
•
•
Walk-through-stern
Tachometer
•
•
Walk-through bow S tere system - satellitHeady.. *
Speedometer
• •
•
Rcboarding ladder bow (3·stcp) Speakers - bow (2)
Hour meter
• •
•
Reboarding ladder - stern (2-step) Speakers- cockpit (2)
Compass
• •
•
• Engine access Water temperature • MP3 - USS direct control
En gine blower (2)
•
•
• Dep th finder • Stereo remote with LCD dlsplay
Auto bilge pump
Docking mode sundeck
•
•
Swim platform mat
Ski mode
•
or
•
STORAGE • Low l uel level CANVAS & MISCELLANEOUS
• Anch locker • Low oil level • B1mm1 lop
ln-Ooor, lockable Low oil pressure Bo w cover
•
• •
Under seat Low voltage Cockpit cover
•
•
Giove box
•
•
Overheat
Door -see-through
•
• Console - port & starboard bow Hi voltage
•
Windshield-fixed
•
backrest • Check engine
•
• Cargo net • Sensor check CERTIFICATIONS

• Swim platform. lockable Balter/ protection
NMMA
•
•
Maintenance info
CONTROL STATION
•
• CMMA
COCKPIT
HELM TRAILER.
• Steering - standard • Outlet -12 volt accessory (2)
Ccoier - removable Tandem axles
• Steering - rack & pinion
•
•
Snap.Jn carpet Single disc brakes

• Steerrng - till
•
•
Swing-away tongue
• Horn Table
•
•
• Shilt & throttle lever-chrome • Table mount-bow, cockpit and • EC version available
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Specifications
DIMENSIONS
Length . . . . . . . . . . . . ....... . . . . . ..... . ... .. . . . .. 23' 6' /7.16 m
Beam . . . . . . . . . . . . . . . . . . . . . . . , . • . . . . . . . . • . . .. . ..
8' 9• /2.67 m
Draft. . . . . •. • • . . . . . . . . . .. . . . .. . . . .. , • . .• . . . . • . . 12' / 30.5 cm
RMera Blue
Ort weight • • . . • • . • . . • • • . • . . . • . . • . . • • . . . . . • . 3,435 lb./ l,558 kg
Sealing capacity . . • • . . . . .• . .. • . . . .. .. . .. 12
Fuel capacity . . • . . • . . • • • • • . . • • • . • . . • • . • . . . • . . 53 US gal/ 200.6 I
ENGINE
Mo<lel.... ........................ .. Rotax" 1503 4-TEC" (12)
Type .....................................twin 1.51 high output
- -.-
l .... -
"J
·=· Highlights
• Tw in 1.51 high output Rotax 4-TEC engines
• l.at1est Sea-Ooo" ever with 12 passeniter capacity
• Huge cockpit and bow area
• ITC'" (Intelligent Throttle Control)- Drive by wire
• ECO mode
• Snap-in carpet
• Stainless steel rub-rail
• St ainless steel cup holders
nip-up hal•ter coc�plt uats HEW premium dasbbo�rd wllb tCO made
• Stainless steel pull-up cleats
• Cockpit & bow covers
• Table mount - bow & cockpit
• Stereo remote with LCD display at transom
• 6 stereo speakers
• Backlit depth finder
• Bimini top
Bow l coc�pll co"rs Stainle1s >loel cup holders
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Overall Specifications
DIMENSIONS
length . . • . . . . . . . • . 23' 6· / 7.16111
Beam . . • . • . • • . • • • . .8' 9' /2.67 m
Diaft. . • • . . • . • . . • • . 12' / 30.5 cm
DJ)'weighl . ....................... . 3.435 lb. / 1,558 kg
Slorage capacity . • • . • • . • . . • • ..... . 60cu.fl./ l.69cu m
Seating capacity . • • . • .. • • • • • . • • . • • • • •
•• . . .. . 12
Weight capacity . . • . • • .• •. • .• • . • • . • • . • • • • • . . 2.383 lb./ 1.081kg ELECTRICAL
Fuel capacity . . • . • .• • •• • •• • . • . . . . . . ..... . . 53 US gall 200.61 Generator .• • • • . . . • • . • • • . • , .......................... 30amp/ 380 W
Baltery .. . • . .. . . . ... . • . • • . • • . ••••• .. . . . • • • • . .• • .• 12V
DIMENSIONS (ON TRAILER!
HULL & DECK
Length {tongue fofdcdJ . 25' 10' 17.87m124' 7" 17.49 mJ
Composite F RP
. . . . . . . . . . . . . . . . . .
Material
Width 8' 9' I Z.67 m
. . • . . • . . • • . . • . . . • • . • . . • • • . • . . • • . • • . .• • • . . . . • .
Vlnylester barrier layer. .. . Std

• .. • • . • • • . . • . . • .. • • • • • • . • • . • • . . • • . • • . . • . . • • . . • • .
.
Heigh! .............................................. 7' 4' /3.15 m
• .• . • • . • . • •• . • . . • • • • . •
Full �bergtass stringer Std

Gross weight ..................................... 5,168 lb / 2,344 kg
. • . . . • • . • . . • • • . • • •• . . • • . . • • • . . . . • • . • • . . • • • •
Graphics. . Std
.
. • . .• ..• . . • • .. • • .. • . • • •. • • • • . • • .. • • • •• • • • . • •. • . • .
Oeadrise......... . . • • • .. • . .• •• . • • •• • . • • . .• • • . •. •• . . • 21'
. . • .
ENGINE
•
Colour. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Riviera Blue

Model • . . . • . • • • . • . • . • • . • • • • • • . • • . • • . . Fuel m1ected, 1503 Rotax 4-TI:C 12) PROPULSION
Displacement l,494 cc
Jet pump type:
. • • . • • . . • . . • . • • • . . • • . • • . . • • .• • . . • . . • • . . . . • • . . •
Type Twin 1 5I high output

Axial now. • • • Single stage
.• • . . • . . • • . • • . • • . . . • • . • . . • • . • • . . • • . • . . . • . . • .
• .•
• . •. • •.. . •• . • • . • •• • • • . . • .. .. • .
Cylinders (/engine) 3
• • . • • . . • • • . • • . • . . • • . . • • • • • . . • . .• • . . . . .• . • • • . . • . .
Pump diamete1 6 l /4" / 15.63 cm
. • • . • . . • • . . • . . • • • . • . . . • • • • . . • • . . • . .
Max RPM Venginel. 8.000

• . • • . . • • • . • . . • . . • • . . • • . • • . . • . • • • . . • • .• . . . • •
ITC -electronic throttle oonlrol ............................... Dual
Octane: M1mmum • 87
• . • • . . • • • • • • . • • • • • . . . • •• • . . • • •• • . . . . . • . .• • . . • .
lmpellei:
Recommended 91
. • . . • • • • • . . • • • • • . . • . • • • . .• . . • • . . . . .• . . • • . . • . Material .. . .
. . . . . . . . . Stainlesssteel
. . . . . . .......... , •• . . • • • • • •.• •
Em1ss1on level CARB 3-Star

• . . • • . • • . . • . • • • • . • • • • • . . • • . • . . .• . . • • . . . . . • Outside diameter(mml........ 1 5 9± .07
• . . . . . . . ........... . .
Cooling system • • . • • . • • . . • . • . . • . • • . • • . . • . •• . . Closed-Loop Cooling System Reverse system Std

. . • • • . • . . • • . • • . .• • • . • • . . • . • • . . • • • . • . . • • . • • . . • • . .
Equipment
HULL & DECK CONTROL STATION (Cont'd) COCKPIT TRAILER'
• Cleats -stainless steel.pull- up ( 6) HELM • Cacpet - snap-in • Ta ndem axles
• Cup holde<s-stainfess steel (IQ) • Dashboard finish • Single disc brakes
• Separated shift & throttle lever -
• Rub rail-stamless steel • Dashboard mat • Swmii-away lon&ue•·
chrome
•
•
Bow 1ails- stainless sleet
Grab handle.s (10 total)-
• Electronic throttle conlrol ·
• Batte1y switch r
• Outlet 12 volt accessOl}' ( 2 )
• Cooler - emovable
• Galvanised trailer
• n
stalnless steel ( 6 }
Coami g boJ ( 5 )
• Clrouit breakers•
• Engine srnchronisalion..
• Table
• Table mounl - bow
•
•
Non-skid decking
Navigation lights INSTRUMENTATION
• Table mount - cockpit Options
SEATING
• Courtesy lights (7) • Gauges - backtlght & a nti-log • Moorin� cover
Driver Seat • Fire ext111guishe1
• TowhOQks-staintess steel bow& stern • Clock
• Track & swivel • Anchor
• Ski eye- stern • Fuel level
• Alp-up bolster
• Walk-through -stem • fuel consumpuon" • Height adjustable
• Walk-through - bow • ECO modo' Passenger S eat
• Reboarding ladder -stern (2-step ) Tachometer
•
• Track & swivel
• Engine access • Speedometer • flip-up bolster
• Engine blower ( 2 ) • Hour 111ete1
• Auto bilge pump • Maintenance inlormation STEREO & SOUND
STORAGE • Compass • S ter eo system - sat
ellite-ready< "
• Anchor • Vlatertemperature • Speakers - bow (2)
• ln-Hoor, lockable • Depth finder • Speakers - cockpit (4)
• Under seat • CruJse control • MP3porl
• Side compaitment • Dnckln2 mode • USB direct control
• Sunpad • Ski mode' • Stereo remotP. with LCD dls111ay
• Glove box (2) • low Iuel level sw1111 platform"
• Cargo nets (3) • Low oil level CANVAS & MISCELLANEOUS
CONTROL STATION • low oil pressure
• Cock pi t cover
• Low voltage
HELM • Bow cove1
• Overheat
• Steering- custom • Bimini top
• High voltage
Door-see-through
• Steering - till •
• Check engine
• Sunpad
• Steering - 1a1:k & pinion • Sensor check
• Horn • Windshield- fixed
• B attery protection
• Neutral lock
CERTIFICATIONS
• NMMA
� • CMMA
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Specifications
DIMENSIONS
Length. .. .............. ......... .. . 23'6'/7.16m
Beam . .. . . . .. . . . . . . . . .. . . .. .. ..
. . . . , . . . .. . . . • .. 8' 9' t 2.67 m
Draft . . , . . . , . . . . . . . . . . . . . , •• ,
, . ,... ,.........,. 12" / 30.S cm
Dry w�lght • . . . . . . . • . • • • • . . • • • • • . , . • . • . .. . 3,842 lb./ l,742 kg
While ' Btao� witll Reu aooenr
Seating capacity . . . . . . • . .• . .. ..• . . . . •• .. . .. 1.2
fuel capacity ..••.••..•••..•..•.••..• ,......, 53 US gal/200.6 I
ENGINE
Model.., . .. . . . .. .. . . . . . . . . . . . . .. . . .. . . 1503 Rotai- 4-TEC" (� 2J
Type . . . . . . .
. . . . . . . . . . . . . . . .. . . . . . . . . , . • . . .Twin 1.5 I lligh output
Highlights
• Twin 1,5 I high oulput Rotax 4-TEC engines
• Satellite·ready** stereo with USB Direct control, MP3 port.
wilh 125 walls/channel amp., 6 speakers, 2 lower speakers
and LCD remote
• Walk·through - stern & bow
• Wakeboard tower
• Wakeboard racks (2)
• Cockpit-controlled WakeBoost l1,000 lb./ 454 kgJ system
• Heater
• Walk-through door - transparent
HEW Premium dnllhoard wUh Ski mode NEW tonr 1puken • Bimini top
• Snap-in carpet
• Cockpit & bow covers
• Stainless steel cup holders
• Stainless steel rub rail
• Depth finder
• Cruise control
• Docking mode
• Ski mode
• ECO mode
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DIMENSIONS
:::0
Length . ... . . . . . . ... ..
. . . , • • •. ••• • • . . •• , • • . • • • • • • • . . • 23' 6" 17.16 m -I
Beam . , . ....8' 9' / 2.67 m
i
• • • . • . . • • • • • . .• . . . . . • . • . . • . . . . . . .. •
D1afl................................................. 12' / 30.5 cm N

Ory we g ht ....................................... 3,842 lb./ l,742kg 0
t--'
Storage capacity .. . . .. .. .. .. 67 cu fl I 1.90 cu m
.• .• • • • . . • • • • . . .
t--'
Se at ing ca pacity . . . . . . . . . . .. . . .. . . . . . . . . • . . . . . . . . . • . • . 12
Weight capacity • . • • . • • . .•• , ............., ......... 2,260 lb./ l,Q25 kg
Fuel capacity ........ . . . . ..... ... .. ., ........... 53 us Rall 200.6 I
. . .
DIMENSIONS (ON TRAIURJ

Length (tongue folded)................... 25' JO' 17.87 m124' 7' 17.49 mJ Wl1lle l 81aek w1U1 Red accent
Width ................................................8' 9' 12.&7 m
Height: Tower down . .... . . . . .. 7' 6' / 2.29 n1
. .• . • • . . . .• . • . . . . . • .
HULL & DECK
Tower up ..................................... 10· I0' / 3.30 m
Gross weight ..... . ...... . . . ..... .. ... 5,57 5 lb./ 2,529 kg
. . . . . . . . . . . .
Mate rial ... . . . .. . .
. . . .. .. .
. . . .. .. .. . Compo site FRP
. . . . . . . . . . . . .. . ..
Vinylester bamer layer. .......................................... Std

EtlGINE Full fiberglass stnnger ........................................... Std
Model ............. , ..... , ...........Fuel Injected, 150 3 Rotax 4 -TEC (2)
Graphics . .. ... ... .. .. ......... .... . . .. .. .. WAKE graphics
. . . . . . . . . . .
Displacement .. . . . .... , . 1.494 cc Deadrise 21'

. . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
White & Black with Red aetent

• • • • • .. .• . • .
Type ...........................................Twin 1.5 f high output Colour....... .. . . . . . . . . . . • • •
Cylinders Vengine)................................................ 3
PROPULSION
Max RPM (/engine) ........................................... 11,000
Oetane: Minimum . . . . .. .. . . .. . .
. .
... . .87
. .. . . . . . . . . . . . . , . • . Jet pump t�pe:
Recom mended , ......................., .............91
. • . . • • Axial How. . • .. . . • . . .. . Single stage
. ..• • . . .. •• • . . • . • . . . •
Emission level ......... .. ... . .... ... .. .... . .CAAB 3·Sfar

. . . . . . . . . . . .
Pump diameter , ........ ................... 6 l/4' / 15.63 cm
• . . . • .
Cooling system . . . . . • . . , ..Closed-loop Cooling System

• • • . • .• •• • • •
rrc� el ectronic throttle control .............................. , Dual
Impeller:
ELECTRICAL Material.. , ..... .. .. . . . , .. . , ...... ... . Staml ess steel
. . . . . .. . .. . . .
Ge ner ator . ., .. . ... ... . ,

. . , .. 30 amp 1380 W
. . . • .• .. • . .• Outside di ameter (mm). . . . . .. . . . 159 ± 07
. . . . . . . . . . . . . . . . . . . . ... . . .
Battery......... . ...................................... 12 Y Re verse sy�tem . . . . . . . . . • .•. , . Sld

. . • . . . • . • . . • • .
Equipment
HULL & DECK CONTROL STATION COCKPIT CERTIFICATIONS
• Cleat s - stainless steel, pulf·up (6) HELM • Carpel -snap-in • NMMA
• Cup l1old01s- stainless steel ( 10) • Steering-rack & p1n1on • Dashboard f1msh- Silver I chrome • CMMI\
• Rub rail - stainless steel • Horn • Dashboard mat
• Mirro1 TRAILER'
• Bow 1 ail -stainless sleel • Separated shift & thr ottle lever-
Grab handles (9 total)- stainless chrome • Outlet- 12 volt accessol)' (2)
• • Tandem axles
steel (4) • Neutral lock fleater
• Single disc brakes
•
• Coammg box (4) • Electrontc throttle con tr o l Cooler - removable

• Swtnit·away ton21JJ1'
•
Non-skid decking • Battery switch SEATING

•
• Galvanised trailer
• Navigation lights • Circuit breakers· Driver Seat
• Engine syochrontsatron
• Cou1tesy lights (6) • T1 ack & swivel
• Wakcboard towor & racks' INSTRUMENTATION • Flip·UP bolster
• WakeBoosl system
(twin 1,000 lb total)
• Gau ge$-backflght & anti-fog
• Clock'
Passenger Seat Options
Rear-lacing bench
Mooi ing cove1
•
• Tow hooks-stainless steel bow & stern • Fuel level •
• Ski eye- stern • fuel COOSll'll1PllOn" STEREO & SOUND • Fire extmgu1sher
• Walk·lhrough - stern • ECO mode • Anchor
• S tereo system - sale!Jite ·ready••
• Walk·lllrough - b ow • Tachometer • Speakers - bow (2)
• Rcboarding l adder - stern (2-slep) • Speedometer • Speakers -cockpit (4)
• Swim platfom1 mat • Hour meter • Tower speakers <2r
• Engine access • Maintenance information • USS direct control IMP3l
• Compass • St ereo remote with LCD display
Engine blower <2l
• Wate1 temperatuie
•
• Auto bilge pump swim platform•

• Depth tinder • MP3 port
STORAGE • Cruise control" • Amplifier
• Anchor locker • Oockini mode
• fn.floor. lockable • S k r mod8' CANVAS & MISCELLANEOUS
• Under seat • Low fuel level • Cock pit cover
• Sunpad • Low 01! level • Bllw cover
• Low oil pressure • Bimini top
• Con sol e - port side
• low voltage • Oom-see·llll�ll&h
• Glove f)ox
• Overheat Sun pad
• Cargo nets (3)
• High voltage
•
Windshield- fixed
HELM • Check engine
•
• Steering- custom (Silver) • Seosor check

• Steering - til l • Battery protection
·HflwVt.lll 0011r ZOl I

C?OIO Bomll.lififletPraiwk�1t\ tBWJ «- fousdroct.\I�"' ·� lebgi:IBRPSORI 0tsm�de:ccmat1U!MiomhJrMProollll( �t�111t.
11 nlcti:al PC111lli
oue1t111sWXJe:!M"!5itett. •\\lit'Kl1i.<.OOttS.s1011a 1 S;fQ\lllllltL £11tonu:ICfliltlam6itoir�*1pmiutssoid4idnbuispa1�P£�
Olst!JCW)bSA.w us Int.,fJRPAus.tr.aaa ftyU� OU�f'toolllll *4.MlflID(.GAPItrGeM It ll!iiltll:• ttm� dlllt.11�mttt1U liemodM"Sil
6clltl:o:MIQliM.�(OCQ{lllOIO&,ear.KWisiJGuu,modtld116G11�t1a11J a11m1tfl11Vti0n0t1;1!Wt.c.ru.as mMtlll.J«tS$0!RS.011oph;M•�
1tpn61ttllt190n1bltdaiu-.o1tcpa)'I.
sdd 201 1-00 2-602..•l\.10
162 2011 Technical Update Book - Sea·Doo PWC and Sport Boats
------ '1--
Annexes
.,
··I
,�
..
.....
we do not <".OmPQm wrth our draler ne1wor'r< by sollino d1rocll
• 1:.. ••
Tliere e � rehulid1ng steps -' ' .
01 03
04
a baller y of teStS, l11cludl11g pressure te:sU111,1
� Shnply reu �1 to the cor� nd you II bt!
the cenHH or easy 11on�
Cylinders $50.tlO $75011
Crankshafts $200.00 $200.00
Short blocks $300.00 $700.00
I 11 lrmll
Cylinders $0.00 $50.00
Crankshafts $0.00 $100.00
Short blocl<s $0.00 $300.00
.. Credit amounts may bf rtitJuced or altogether retust:d if anv ieturned tore cas ing ar0·
Broken, cracl<ed or damaged-Modified in any way e,veldlng of crankshaft, porting of cylinder or crank.case, etc )-With brok.en bolts inside the threads
- Sl1owlng wear around the mounting ba!ts to the frame - Damaged during bansportaHon due to poor packing - Dfsassen'bled or Incomplete
The better shape your cores are in, the more we pay out
lcondltlon ICylinder ICrankshatt Sh<>rt bock

itl'ftuctiorJ 1led11ctio11 deduction
Broken or cracked casting S75/5o• NA $200
Welding NA $200/100' NA
Porting of cylinder & crankcase $75/50' NA $200
Broken bolts inside threads S75/50� NA Up to $200 -depending

on location & quantity
ot broken bolts
Incomplete core NA NA Vallie of missing pars

t
Wear around the mounting NA NA $200

bolts to the frame
Damaged during transportation $75150" $200/100" Value of damaged parts

due to poor packing Damaged parts
'$7S represeom vaiue vAth Rell.rn Cote Fonn,ood $50 represents value'WfthoU! Retum core FOftll,
Whether placing an order or returning a core, it's a simple procedure
Ira do Iwhat to do
Place an order Simply use BOSSWeb"'.
Return a core without a •RebuiH Credit Form" • Identify each core as much as possible. Tag them
and indicate the engine type as reference.
• Fill out and endose a copy of the endosed 'Universal' BRP Rebuild
Center Core Credit Request Form with the cores in your shipping box
(for additional forms go on BOSSWeb™.)
Return a core with a "Rebuild Credit Form" • Return the white copy of the "Rebuild Credit Form", included with
every rebuilt part shipped by the Rebuild Center, along with the core.
• Cores received with the yellow copy or with a photocopy will be con
sidered as core returns without the Rebuilt Credit Form. The white copy
is, therefore, required in order to receive the proper credit amount
Shipping core returns: Must be freight prepaid
I who/What I where
US Dealers BRP
7575 Bombardier Court
Wausau WI, 54401
(Please use Rebuild I Warranty Return Label# 480901601)
Canadian Dealers BRP

75 J.A. Bombardier Street
Sherbrooke, QC J1 L 1 W3
(Please use Rebuild I Warranty Return Label # 480901500)
For defective parts replaced with rebuiH parts BRP

and In connection with a warranty claim Warranty Part Inspection Center
(Canadian dealers only) 565 de la Montagne
Valcourt, QC CANADA, JOE 2LO
(Please use Rebuild I Warranty Return Label# 484500001, and
indude copy of daim and core credit form)
btu e_rebuilL7
--
REBUILT PRICE LIST
COOLING
PRODUCT REBUILT PART PART ENGINE SYST M
E AMOUNT YE AR OESCRJPTION ORIGINAL PA RT
TYPE F/C · UC CVL •
421000635 REP GCARtlOX RCPAJR RCOUtST NIA Odlcn:runplclt.-. ((l(nl (mm OOs� wtb NIA
4210000 3 1 277 FIC I 1993 IO 2005 420095301
421000639 277 F IC I 2006 IO 2009 420995'.!01
4210001 54 311 . 443 FIC 2 1991 to 2006 420889630
421000151 1
·� UC 2 1990 to 2000 420B8G933
421000S67 493 UC 2 2 000 ll > 2002 4208&8462

•21000599 4'J3 UC 2 2003 420888' 65
421 000011 503 FIC 2 1990IO1 996 K•..,.
.,.., e1 3- o'
doc k 420996«5
1i210001ss 503 FC
/ 2 1997 to2003 420888390 / 4 2()8a8391
421000601 552- FIC 2 ?003 to 2<>09 •20 839 062

421000673 552 ric 2 2()10 42\l 889 061
f-
421000553 LL 593 UC 2 1999 420SSS250
421000563 <( 593 L/C 2 2000 10 2002 420888252142()868751

421000011
I 593 UC 2 2003102010 420ea&151
2 4208800rnl / 4200001l SC / 890951
421000064 (/) 593SOJ UC
2004 to2010
f>9(1 ETEC 4208W91i6 t •208909 S t 890954
� LIC 2 5
421000574 693 L/C 2 2000 to 2002 OIECAST ENG INE ONLY 4 W 8&!286
z
693
421000600 2003 to 2007 893 AND 593 HOONLY
421000152
� S93HO
599
UC
UC
2
3 \996& 1997
420889091
420887970
•21000310 () 599- S99CK3 UC 3 19981<>2000 New mQdif.ad001"$ for 1999-2000 4�0888030 I 420881l(J3'
421000153 699 L/C 3 1997 6 05

420887
21000573
4 79J UC 2 2000 IO2002 420 8884ll 2
.1nO OOGOR 7 93 UC 2 20 0 3 ;10()30,.LV 420669101
4 21000607 7 93HO UC 2 2 00 3to2007 HO ONtY 42088967 1
421000606 793$01 L/C 2 2003 & 2004 SO I ONLY • 20869106
4?1000 665 7fll UC 2 2000 to 2008 2006 & 2007 REV/ 2008 REV-XP 1:120892562
•210005SS W
T L/C 2 2009&2010 R EV-XP •208956
2 7
420867861/4208676&1
421000156 809 IJC 3 Ul97 lo 2 00 3 New mtXf.f.e<t p.'tn tor 199 9-2002
42088 76112
421000634 995501 UC 2 2005 &2006 420869211
•21000200 211 FIC 1 1993 to 2009 •209132181420913219 1 6
2 3180
•21000559 Jn FIC 2 1999 to200• P io •2
9
0 23<03
421000500 317 FIC 2 1999 to 2004 Mao 420923408
a:::
0 • 2100056tl
421000500
w
0
• 93
503
IC
L
FIC
2
2
200 1 10 200�t
1983 IO2003
11 20923855 ' 42061360 5
420923
41 7
0 421000600 z
- 552 FIC 2
2003 IO 2006
4 209239751420923978
0 ....J 2007 to 2009 Model MX2. Summit el GTXIGSX

I >- 2001 FREESTYLE otExpeelruon 420623141I420623,42
-
4210 00G51 () 552 FIC 2 2006 & 2009 E =ol MXZ. &Imm� oocl GTXIGSX _.,H6Xi07T.tltJlld•&iat.
�
lnwPari
2010 All model•
(./) 421000578
·'21000605
593
593HO
UC
UC
2
2
1 999 to 2010
200 3 to 2006
All models
H.O. ONLV
420613620 /420613625
420813711
I G13G27
2004 to 2008 5 $01 ONI. Y

•21000824 593 501 UC 2 93 4206 13940142()613944
421000687 _j 593 ETEC UC 2 2008 to 2010 420623250 /420623252
4 210000 64 >- 699 L/C 3 19971<>2000 •20923-020
42100057-9 () 793 UC 2 2000to 200.. WITH OUT D EKO S LOTS 4209238111<20923817

42100060<1 793HO L/C 2 2003 102006 H . 0 . 0 NLY 420613852
421 000666 0
- 797 L/C 2 2007 to 2009 4 20823240 I 42062324 1
1121000675 z 797 Li
e 2 2010 • 20823242
•210000 68 8 09 UC 3 199710 2003 420613852

iS21000G3G � UC 2 2005 &2000 C Y LINDER B
LOCK 420013746
•21000025 371 >IC 2 2004 to 2006 N e w 377 w iin oil ch&ct i.i;i f\<e6
•121000617 493 UC 2 2003
•21000410 503 flC 2 1994 lo 1999 NIA
552 FIC 2 2003 to 2007 E'""' Pl REV, RF, Exp00 4200552<1114200552()4

421000638 2005 & 2.006 Model RCV & Exr>ed•lioo
552 FIC 2 420055206
200710 2009 Model MXZ. Summll 11 GT'X/GSX
421000663 � 5 52 FIC 2
2007 FREEST'i'LE ec E-icoedrt i o n
420055207
2'006 8 2000 C,,.p1 MXZ. Summll and G TX/ G
() SX
42 1000674
0 552 F/C 2 201 0 42005520&
4210000 16 _J 593 UC 2 2001 t02007
1210006 00
• co S9 3XP LIC 2 2008 to 2010 XP500 SS 4200fi9310 1 U2
.' 420059
42100061 5 f- 593HO UC 2 2003 to 2007 H.O , ONLY
421000623 a::: 593SDI L/C 2 2004 lo 2007 S93SDIONLY
•21000659 0 5 93 S Dl·XP UC 3 2008 I02010 59JSDl·X P model& 4200593 13
42100066 2 I 593ETEC UC 2 2008 10 2010 593 SDI E -l'EC 42<1053

9 50 I 9352
59351 / 5
� 2100001 3 (/) 793 UC 2 2001to2003
421000612 79' JHO UC 2 200 3 lo 2007 HO ONL Y
•21000645 7 97 UC 2 2008&2007 NOT FO

R XP MO DEL 420079103 1 420070704
421000
6
50 797 UC 2 2008 REV·XP 42079105142019107
421000661 791 UC 2 2009 REV-XP 420079706

421000676 77
9 UC 2 2010 REV-XP 1 20079708
•
4210006:,\7 995$0 1 UC 2 ?005 8 200!! 420099602
421000678- long block 1203oc: UC 3 2009& 2010 420120302
sdd 2 011-002-701_1
COOLING
PRODUCT REBUILT PART PART ENGINE SYSTEM AMOUNT YEAF! DESCRIPTION ORIGINAL PART
TYPE FIC • LIC CYL. #

d2 1000.6 20 175 L/C l 2003 102005 RAl.L Y -17 5 •20296420
CRANKSHAFT
� 421000157 611 UC 1 •II T 1 axtet 4 2029589�
12.1 000577 711295192
<{ 65• l/C , all DS650
I 42:100oo72 longblock llflDO llC 2. 20011 Ttnooa oiJnANOEF! eo 1 999 C<1rt1, 2110M8103
.,,
4�100071� &; 76 71'!F I L/C � t 9$18 \O 4!005 RH 2.904!87.t!lJl J 42.081!74!gl
"'
42100057• -"" !'4 701 L/C 2 �II Cl 2:90887767
<:
421000711 "' 94 7 UC 2 t99810 2003 Exc®lD.L 220087762
...
42 1 000670 0 1003 UC 3 420810077
20U2lo2005
d2 l0001571 CS03 UC 3 2006 ., 2009 "206'R346
421000056 717 UC 2 i
995 lo2003 291J�23805
.;;110ooosa Ct'. 787 UC 2 19116lo 1 999 Carl> 290913!.03
w
42100081� 0 787 FlF I UC 2 1��8l<> 200� RFI WW2.3846
1,210000 Zlj z 787RFI L/C 2 200•!Jo2005 R�I 420623-086
-
4210005;; 1 :'.j 947 UC 2 19118 10 2002 E.x.cep t OJ . 29!}1;1356 1
>-
421000610 UC 2 D.I. 290923718
(.) 94701 2001
• 21000205 UC 2 01 "2061l.�76
0
9<1701 2002 & 2003
421000097 717 rJC 2 1995 IU 2005 290071703
0 •2tooooee .:.c
(,J
787 UC 2 19.95 USE 421 000100 + 290 9 68057 290881527 J 290881628
0
421000100 787 UC 2 1 90010 1999 cam. 290078704
0
42\000913 :a 787RFI UC 2 1998lo 200:! RFI 2900787ll S
I 't: 787 RFI
d21Qll0 1i.?7 LiC 2 ;>()1).1 & 2005 RFI •20010101
<( 42100056i
0
.s=
en
947 UC '1 1911<1 10 2002 Excapl 0 .1. W009470J
w 421000572 94701 UC 2 2001 0.1 290094705
CJ)
421000416 9<1701 UC 2 200210 2005 OJ. "20094706
42 '1 000;;17 1503 N/A UC 3 2002 1 0 2005 I $1 OV

&rsl lo lol1!l Bloc!< 27000 0645
0
421 0006<10 "'
.. 1 50J BN UC 3 1003102005 1 st Overolze; LongB loci< 27000il&l4
; i1000649 .... 1 503 1/C 20<l4 & 2005
UC 3 1 SI Ovellll>B Lang Bl<>d. 2.70000643
""
isl O�r&.llc Long Blc;ol(
u
421000640 0 1503 IJT UC 3 20061r.>2009 420150345
42 1 000 6'1 ·1 :a 1503 NIA UC :) 2000102 009 161 O ver$lte LMg Blor-� 4201SO:l1S
O>
c
421000d42
..5! 1 503 UC L/C 3 2006 !0 200 � &..110 Long BIOd\
I Si Ov 42015(1335
42100005B 1503 H O UC 3 2009 & 200 9 1 st Over!llte Lnfl!l lllocl< 420150355
421000 652 ... 1503 NIA LJC 3 2005 11. pnor Bo.,c Long Block 2 7 0000645
0
421000653 0 1 503 BN 3 2005& on or 270000044

L/C Basic L<>ng llloo �
j5
Cl>
421000$').I c: t 5ll3 l
l C L/C 3 2004 8.. �005 6"'1c Lona Bio ;�
• 2 7000004:.1
E.
421000055 0
1 W3 DT UC 3 200 6 1
020
0 0 B�
S1C l.o nw BIOCI< 42016034�420150347
�/100065fi ·:a 15(1� NA UC 3 2006l<> ?OOR B • s lc l.nng Blnck �201�0335/�201!\03.17
IXI
4�1000657 llC& !<O &ETC I.J
C 3 200tilo2009 lioitc .Long lilack 42015033 714W 15035.514:l0150365
42100064 4 Head 1503 L/C 3 200210 2009 H�3\1 with valves 1 n s1alled 42061397614 20513978
"lot�. 010 e>?re will be completely relundod only If LEGEND
-Coia is telU!ned w1thin 30 IJ1rys w111t 11ie folle.J-out rebulll oor 1ti1t11a1n>n lu1111 CR CRANKSHAFT
• Core is sa1'!le model as U1e one shipped CY CYLINDER
• Core casting ls nol broken CV N CYLINDERINICASILI
• Core is con1plete and fully assembled . REP REPAIR O NLY

• C o re '� shipped preps1d lo BRP se SH ORT BL OCK
- Core is retumed In original packaging to avolJ lroight aa111age�
No1!ffipec i
tnqtho
se requlrem&ntscould result l ng 1 efused
r or reduQ!tdcore· c.cedll
sdd2011.002-701_2
QUICK REFERENCE CARD
IMPORTANT INFORMATION
Practice and become proficient with the different features
and controls of your Sea·Doo PWC before riding. This quick
reference card is provided as a reminder of the main
functions available.
Refer to the O perator s Guide for complete instructions
'
and available functi ons .
Sarne features shown may differ rrom the ones

available on your PWC.
''™"odttif't BRP to9011,o-tni011m1�..-of Bon\n.erdlerfl�t16Atioll"I PrQ�1.1�ulno. O• its atfi�al"S

� 2010 Sc11nbarU1u1 lh:criii1brmt1il P·rodutu fne.tnd SRtl OSInc;. Alt nght')i ruJi1Jrved.
CONTROLS IDENTIFICATION
iBR'M LEVER
/ THROTTLE
LEVER
ENGINE CUT-OFF SWITCH U P/D O WN

START/STOP
STARTING THE ENGINE
TO ENTER;
... Briefly press � Hold SET u ntil W>#•l;JW appears

START/STOP
Message displayed: ENTERING SPORT MODE·
Note: Ensure tether
INCREASED ACCELERATION - INSTR UCT
cord is at least
PASSENGERS TO HOLD
15 cm (6 in) away
from e11gine cut-of! � Press SET to confirm
switch TO EXIT:
� Hold SET for 3 seconds

or shutdown engine
..,_ Firmly insert tetlier
Note: When engine rs stopped,
cord cap on
PWC resumes to default Touring Mode
e ngine cut-off
switch
CHANGING GAUGE DISPLAY
.... Press MODE repeatedly until DI S PLAY

� After dou ble message appears
1• beep » press again
..,_ Press SET
START/STOP
� Press UP/DOWN until prefe rred indic ation
setting is displayed
.,.. Press SET to select
sdd2011.002-708_e n.1
QUICK REFERENCE CARD (CONTINUED)
SKIMODE @)
TO ENTER:
..,_ Press MODE repeatedly up

to SKI MODE
... Press SET
..,_
..,_
Press UP/DOWN to choose tamp
Press SET
ECO MODE FCO�
..,. Press UP/DOWN to set TO ENTER:
target speed
..... Press MODE repeatedly up to
... Press SET @) {blinking) FUEL ECONOMY MODE
..,. Press SET
..,. Press SET again @ ..,_ Press and hol\i SET
..,_ Fully apply throttle levet until Eco� appears

when ready
TO EXIT;
TO CANCEL: Press MODE ..,. Press MODE repeatedly until ECO MODE appears
TO RESUME: Press SET ..,_ Press SET
TO EXIT: Press MODE twice ..,. Press SET to disengage ECO MOOE
CRUISEMODE 8
TO ENTER: TO ENTER:
• Maintain a constant speed .... Engage NEUTRAL
..,. Hold CRUISE until 8 appears ..,. Hold CRUISE until 8 appears
..,. Fully apply throttle lever .... Press UP/DOWN

to adjust speed
... Press UP/DOWN
to adjust maximum speed TO EXIT:
TO EXIT: ..,_ Prnss CRUISE, iBR lever

or t hrottle lever
... Press CRUISE
THE WORLD IS OUR PLAYGROUND ..

From snow and water to on· and off-road fun, BRP's passion for adventure fuels the
innovations that deliver the ultimate experience in powersports. Because your free time
should always be your best time.
SKl-000® LVNX'M SEA-000® EVIN�UOE® JOHNSON ROTAX® CAN-AM™
sdd 201 1-002-1os_en_2
BRP Oils and Lubricants I Huiles et lubrifiants BRP
0 0
0 0
Part# PTt>duc� De$cription Size 0 q ii:

i:
I/)
«I
Cl> <
"'
Synthetic jet pump oil 75W90 177ml

293 600 011 - x -
Huile synthetique 75W90 pour tu r bine (6oz).
Synthetic gear oil 75W90 946ml - Same as 293 600 011
293 600 043 - x
HU ile svnthetloue 75W90pour e norenade (32oz) but 946 ml (32 ozl
XP-S chaincase oil 250 ml
413 801 900 x - x
Huile XP-S pour carter de chalne (8.4 oz)
XP-S synthetic chaincase oil 3 55 ml
413 803 300 x x
Huile svnthetlque XP-S pour carter de chaine (�2oz)
spray473 ml
413 711 600 XP-S st orage oil / Huile de remi
sage XP-S x x x
(16 oz)
Spray 473 ml Ge neral u se
293 600 016 XP-S lu bricant I Lubriflant XP-S x x x
(16 oz) Usaqe !lenerale
XP-S synthetic grease 400 g tube - High rev ma rine appllca tto n
293 550 010 x
Gr;1 iss e syn.thetiqu e XP-S (14 o.z) Utilisation marine, revolution elevee
XP-'S synthetlogrease 400g ut be for suspension
293 550 033 x - x
Graisse synthetique XP-S (14 oz} Pour su spensio n
413408 600 Fuel stabilizer I Siabiltsateur de carburant 236 ml (8 oz) x x x
500ml For carbureted 2-slroke

413 803 100 XP-S premix oil I Hude pr emela ngee XP-S x X
17 oz Pour moteur deUX-i.em s a carburateur.
XP-S 2-stroke mineral iniectfon oil 1 U.S. Quart I For carbureted 2-stroke a nd ATV: Mlnl OS
413 802 900 x x x
Huile mineral XP-S pour mo eur deuxAemps 946ml 2-stroke ony
l
l
XP-S 2-stroke mineral in]ectlof'l'oll 1 U.S. Galol n Pour moteur deux-temps DI, SDI et a
4�3 803 000 x x x
Huile mineral XP-S pour moteut deux·temps / 3.785 L carburateur.
VTT.: MiniOS a rnoteu1' deux-ternps
·-
Xl"'-t: 2-31Iokc mlni;rol injection oil Drum 205 LI

413 803 200 x x x seulenwnt VTI: MiniOS a mote ur deux-
Huile mineral XP-S pour moteur deux-ternps 54 US gallons
temps seulement
� .semi-Synthelic 2-srt oke oil
XPs 1 U.S. Quart I For DI, SDI and Carbureted2-stroke.
293 600 071 x x x
Hui le Semi-Synthetlque XP-S pour moteur deux-temps 946 ml ATV: Mini DS 2-stroke o;ily
XP-S Semi-Synh
t e!ic 2-stroke oil 1 U.S. Ga llon Pour moteur deux-4emps DI, SDI et a
293 600 072 x x x
l Semi-Synthetique XP-S pour moteur deux -e
Huie t mps / 3.785 L carbu rateur.
XP-S Semi-Synthetic 2-srt oke 011 Drum205 LI VTT: Min iOS a moteur deux-temps
293 600 073 x x x
le Semi-Svnthetlque XP-S oour moteur deliX-temos
Hui 54US oallons seulement
XP-S Synthetic 2-s rt ok e oi
l 1 U.S. Quart I For DI. SDI and Carbureted 2-slroke.
293600 045 x x x
Huile Synth etique XP-S pour moteur deux-temps 9 46 ml ATV: Mini OS·z-stroke o nly
XP,S Synthetic 2-stroke oil 1 U.S. Gallon P0ur moteur deux-temps 01. SDI el a
293600 046 x x x c<irt:>urateur .
Huile Synthetique XP-S pour moteur deux-temps / 3.785 L
XP-S Synthetic 2-stroke oil Drum 205 LI vn: Minios a moteur deux t-etn ps
2.9360P 047 x x x seuterneot
Huile Synthetique XP-Spour moteur deux-temps 54 US gallon s
XP-S 4-stroke S ynthetic oif OW40 1 U.S. Quart/ - Recommended for V-1000
293 600 054 x -
Huile XP-S Svnthetioue OW40 oour moteurQUatre- ternos 946ml Recommande oour V-1000
XP-S 4-stroke Synthetic oil 5W40 1 U.S . Quart/ - Not recommended for t he supercharged
293 600 039 x x
Huile XP-S Synthetlque 5W40 pour moteur Qllatre- temps 946ml e ngines.
XP-S 4-strqke Syntheticoil 5W40 Drum 205LI Non r ecornmande pour moteur a
219700 359 - x x
Huile XP-S SvnlhBtiQue 5W40 pour moteur auatre-temps 54 US oallons surrompresseur.
XP-S 4-slroke Mineral oil 5W30 1 U.S. Quart/
219700 706 x New
HUile m ineral XP-S 5W30 pour rnoteur quatte-temps 946 ml
XP-S 4-stroke Mineral oil 5W30 Drum 205LI
219700702 x New
Huile mineral XP-S 5W30 oour moteur auatte-temos 54 US oallons
XP-S 4-stroke Mineral oil 10W40 1 U.S. Quart I - See Oil ApplicationChart in Operator's
2197003.46 x -
Huile mineral XP-S 10W40 pour moteur Quatre-temps 946ml Guide for ATV's I Recomm e nded forthe
-
supercharged engines, Sea-Doo
Pout VTI, se referrer a la charte
XP-S 4-sltoke oil 10W40 Drum 205 LI -
219700433 x - d'utli t on des huiles du Guide de
l sai
Huile mineral XP-S�10W40pour moteur q u atr�te mps -54 US gallons
l'operateur. I Recommande pour moteur a
surcompresseur1 Sea-Doo

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2011

RING GEAR.............................................................................................. 105

GENERAL .......................................... ............................. ............................ 112

ENGINE OIL.............................................................................................. 112

ENGINE OIL PRESSURE ................................................................................. 115

SUPERCHARGER OIL SPRAY NOZZLE.................................................................. 127

CYLINDER HEAD COVER................................................................................ 156

ROCKER ARMS.......................................................................................... 157

CYLINDER HEAD........................................................................................ 163

VALVE GUIDE............................................................................................ 170

PISTON RINGS........................................................................................... 182

03 ELECTRONIC MANAGEMENT SYSTEMS

DIAGNOSTIC TIPS....................................................................................... 204

MONITORING SYSTEM ................................................................................. 215

PROCEDURES..................... ......... ........................ ........................................ 280

SYSTEM DESCRIPTION ................................................................................. 288

ENGINE CONTROL MODULE (ECM).................................................................... 290

MANIFOLD AIR TEMPERATURE SENSOR (MATS) .. .......... ....... .................................. 314

04 FUEL SYSTEM {cont'd)

MANIFOLD ABSOLUTE PRESSURE SENSOR (MAPS).................................................. 317

KNOCK SENSOR (KS) ................................... ....... .................. ............... . ...... 319

03 - FUEL TANK AND FUEL PUMP .............................................................................. 323

POWER DISTRIBUTION DIAGRAM ............ ......................................................... 351

GROUNDS ............................................................................................... 354

IGNITION SYSTEM TESTING......................................................... . ......... ......... 356

TROUBLESHOOTING ........... .................................................... ............. ......... 365

BASIC STARTING SYSTEM OPERATION................................................................ 383

ENGINE START/STOP SWITCH.......................................................................... 384

05 ELECTRICAL SYSTEM (cont'd)

05 - DIGITALLY ENCODED SECURITY SYSTEM ID.E.S.S.) ............................................. .... 395 .

06 STEERING AND PROPULSION

DIAGNOSTIC TIPS....................................................................................... 458

HANDLEBAR GRIP ...................................................................................... 458

06 STEERING AND PROPULSION (cont'd)

PROCEDURES ........ ........................................................ ..... ....................... 487

iBR LEVER SENSOR (BRLS)............................................................................. 487

U-ARM ................. ................................................................................. 505

iBR GATE SUPPORT PLATES............................................................................ 506

VTS CONTROL BUTION ................................................................................ 512

IMPELLER SHAFT RADIAL PLAY........................................................................ 518

VENTURI ................................................................................................. 525

GENERAL ................................................................................................... 541

DRIVE SHAFT ....................... . .............. ..................................................... 541

DRIVE SHAFT B O O T..... .................................................... .......................... 548

CARBON RING........................................................................................... 548

07 BODY AND HULL

GENERAL ................................................................................................... 553

07 BODY AND HULL (cont d) '

01 - SUSPENSION (aS) (cont'd)

CARPETS .......... .. .................................... ................................................ 610

MIRROR SUPPORT................................................................................... ... 615

GLOVE BOX COVER.............................. ....................................................... 617

VENTILATION DUCT..................................................................................... 619

07 BODY AND HULL (cont'd)

HULL ..................................................................................................... 678

HULL ..................................................................................................... 692

WIRING DI AGRAM LOCATION.......................................................................... 735

iBR AND iS POWER CONNECTORS (DELPHI).......................................................... 743

INFORMATION CENTER CONNECTOR (DELPHI)....................................................... 744

out after manufacturing of the product, whether

The use of BRP parts is most strongly recom­

The engines and the corresponding components

A CAUTION Indicates a hazardous situation

The use of BRP parts is most strongly recom

The information and component/system descrip