2002 Seadoo

www.SeaDooManuals.
net
2002
Shop Manual
Volume 2
GTX DI, GTX 4-TEC
www.SeaDooManuals.net
Legal deposit:
National Library of Quebec

2nd trimester 2002
National Library of Canada
All rights reserved. No parts of this manual may be reproduced in any

form without the prior written permission of Bombardier Inc.
©Bombardier Inc. 2002
Technical Publications
Bombardier Inc.
Valcourt (Quebec) Canada
Printed in Canada
®*Registered trademarks of Bombardier Inc.
Loctite® is a trademark of Loctite Corporation

Snap-on® is a trademark of Snap-on Tools Corporation
Gelcote® is a trademark of Gelcote International Limited
TABLE OF CONTENTS
SECTION SUBSECTION PAGE
SAFETY NOTICE .................................................................................................................................. III
INTRODUCTION ................................................................................................................................... IV
01 SERVICE TOOLS 01 - Table of contents ...................................................................... 01-01-1

AND PRODUCTS 02 - Mandatory service tools............................................................ 01-02-1
03 - Optional service tools................................................................ 01-03-1
04 - Service products ....................................................................... 01-04-1
02 MAINTENANCE 01 - Table of contents ...................................................................... 02-01-1
02 - Periodic inspection chart ........................................................... 02-02-1
03 - Flushing and lubrication............................................................. 02-03-1
04 - Water-flooded engine................................................................ 02-04-1
05 - Storage...................................................................................... 02-05-1
03 TROUBLESHOOTING 01 - Troubleshooting chart ............................................................... 03-01-1
04 ENGINE (DI) 01 - Table of contents ...................................................................... 04-01-1

02 - Leak test ................................................................................... 04-02-1
03 - Removal and installation ........................................................... 04-03-1
04 - Magneto system ....................................................................... 04-04-1
05 - Top end ..................................................................................... 04-05-1
06 - Bottom end ............................................................................... 04-06-1
07 - Exhaust system......................................................................... 04-07-1
05 ENGINE (4-TEC) 01 - Table of contents ...................................................................... 05-01-1

02 - Leak test ................................................................................... 05-02-1
03 - Intake system............................................................................ 05-03-1
04 - Exhaust system......................................................................... 05-04-1
05 - Removal and installation ........................................................... 05-05-1
06 - PTO housing/Magneto .............................................................. 05-06-1
07 - Lubrication................................................................................. 05-07-1
08 - Cylinder head and valves........................................................... 05-08-1
09 - Engine block.............................................................................. 05-09-1
06 ENGINE 01 - Table of contents ...................................................................... 06-01-1
MANAGEMENT (DI) 02 - Overview................................................................................... 06-02-1
03 - Component inspection and adjustment .................................... 06-03-1
04 - Diagnostic procedures .............................................................. 06-04-1
07 ENGINE 01 - Table of contents ...................................................................... 07-01-1

MANAGEMENT 02 - Overview................................................................................... 07-02-1
(4-TEC) 03 - Component inspection and adjustment .................................... 07-03-1
04 - Diagnostic procedures .............................................................. 07-04-1
08 COOLING SYSTEM 01 - Table of contents ...................................................................... 08-01-1

02 - Circuit, components and care ................................................... 08-02-1
09 FUEL SYSTEM 01 - Table of contents ...................................................................... 09-01-1

02 - Fuel circuit................................................................................. 09-02-1
03 - Air intake (DI)............................................................................. 09-03-1
10 LUBRICATION 01 - Table of contents ...................................................................... 10-01-1

SYSTEM (DI) 02 - Oil injection system................................................................... 10-02-1
03 - Oil injection pump ..................................................................... 10-03-1
SMR2002-053_00A2.FM I
TABLE OF CONTENTS
11 ELECTRICAL 01 - Table of contents ...................................................................... 11-01-1

SYSTEM 02 - Charging system....................................................................... 11-02-1
03 - Starting system......................................................................... 11-03-1
04 - Instruments and accessories.................................................... 11-04-1
12 PROPULSION 01 - Table of contents ...................................................................... 12-01-1

SYSTEM 02 - Jet pump................................................................................... 12-02-1
03 - Drive system............................................................................. 12-03-1
04 - Reverse system........................................................................ 12-04-1
13 STEERING 01 - Table of contents ...................................................................... 13-01-1

SYSTEM 02 - Steering system........................................................................ 13-02-1
03 - Alignment ................................................................................. 13-03-1
14 HULL/BODY 01 - Table of contents ...................................................................... 14-01-1

02 - Adjustment and repair .............................................................. 14-02-1
15 TECHNICAL DATA 01 - GTX DI model ........................................................................... 15-01-1

02 - GTX 4-TEC model ..................................................................... 15-02-1
16 WIRING DIAGRAMS 01 - Wiring diagrams........................................................................ 16-01-1
II SMR2002-053_00A2.FM
SAFETY NOTICE
SAFETY NOTICE 0
This manual has been prepared as a guide to correctly service and repair 2002 SEA-DOO watercraft. See
model list below.
This edition was primarily published to be used by watercraft mechanical technicians who are already
familiar with all service procedures relating to Bombardier made watercraft. Mechanical technicians
should attend training courses given by Bombardier Training Dept.
Please note that the instructions will apply only if proper hand tools and special service tools are used.
This Shop Manual uses technical terms which may be slightly different from the ones used in the Parts
Catalog.
It is understood that this manual may be translated into another language. In the event of any discrepancy,
the English version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at time of writing. Service
and Warranty Bulletins may be published to update the content of this manual. Make sure to read and
understand these.
In addition, 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 exact replicas
of the parts.
The use of Bombardier parts is most strongly recommended when considering replacement of any com-
ponent. 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.
Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking tab,
self-locking fasteners, etc.) must be installed or replaced with new ones. If the efficiency of a locking
device is impaired, it must be renewed.
This manual emphasizes particular information denoted by the wording and symbols:
 WARNING
Identifies an instruction which, if not followed, could cause serious personal injury including
possibility of death.
CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle components.
NOTE: Indicates supplementary information needed to fully complete an instruction.
Although the mere reading of such information does not eliminate the hazard, your understanding of the
information will promote its correct use. Always use common shop safety practice.
Bombardier Inc. disclaims liability for all damages and/or injuries resulting from the improper use of the
contents. We strongly recommend that any services be carried out and/or verified by a highly skilled
professional mechanic. It is understood that certain modifications may render use of the vehicle illegal
under existing federal, provincial and state regulations.
SMR2002-053_00A2.FM III
INTRODUCTION
INTRODUCTION 0
This Shop Manual covers the following BOMBAR- HULL IDENTIFICATION NUMBER
DIER made SEA-DOO® 2002 watercraft models.
(H.I.N.)
ENGINE MODEL It is located on footboard at the rear of watercraft.
MODELS
TYPE NUMBER
GTX DI and GTX 4-TEC
GTX DI International
947 DI 5563
(green)
GTX DI (green) 947 DI 5564
GTX 4-TEC International
1503 5573
(red)
GTX 4-TEC (red) 1503 5574
GTX 4-TEC International
1503 5593
(blue)
GTX 4-TEC (blue) 1503 5594
GTX DI International
947 DI 5595
(blue)
GTX DI (blue) 947 DI 5596
1
F18L0ZA
1. Hull Identification Number (H.I.N.)
The Hull Identification Number is composed of 12

digits:
ZZN12345L495
Model year
Serial
number* Year of production
Month of production
Manufacturer
F00A0CB
*A letter may also be used as a digit.
IV SMR2002-053_00A2.FM
INTRODUCTION
ENGINE IDENTIFICATION ARRANGEMENT OF THIS

NUMBER (E.I.N.) MANUAL
947 DI Engine The manual is divided into 16 major sections:
The Engine Identification Number is located on the 01 SERVICE TOOLS AND PRODUCTS
upper side of the magneto housing. 02 MAINTENANCE
03 TROUBLESHOOTING
04 ENGINE (DI)
1
05 ENGINE (4-TEC)
06 ENGINE MANAGEMENT (DI)
07 ENGINE MANAGEMENT (4-TEC)
08 COOLING SYSTEM
09 FUEL SYSTEM
10 LUBRICATION SYSTEM (DI)
11 ELECTRICAL SYSTEM
12 PROPULSION SYSTEM
F01D01A
13 STEERING SYSTEM
TYPICAL
14 HULL/BODY
1. Engine Identification Number (E.I.N.) 15 TECHNICAL DATA
1503 Engine 16 WIRING DIAGRAMS
The Engine Identification Number is located be- Several sections are divided in various subsections.
side the oil separator. There is a table of contents at the beginning of
many sections.
F18A04A 1
1. Engine Identification Number (E.I.N.)
SMR2002-053_00A2.FM V
INTRODUCTION
TYPICAL PAGE
Page heading
indicates section
and subsection
detailed.
Subsection title
indicates
beginning of the
subsection. Subsection 04 (MAGNETO SYSTEM)
Italic sub-title
above exploded
view indicate
pertaining models.
Drop represents
a liquid product
to be applied to a
surface. In this case
Loctite 243 to
screw threads.
Loctite
243
Loctite
243
Dotted box
contains parts of
a particular
Exploded view assits Loctite model or an
243
you in identifying exploded view.
parts and related
positions. Loctite
243
Loctite
243
Bold face number

indicates special
procedure
concerning this part.
Loctite
648
145 Nm
(107 lbfft)
Anti-seize
lubricant
F01D4WS
Illustration number
for publishing
process.
03-04-1
Page numbering system:

03: ENGINE section
04: MAGNETO SYSTEM subsection
1: First page of this subsection
F01A0CS
VI SMR2002-053_00A2.FM
INTRODUCTION
TYPICAL PAGE
Sub-title with part

name(s) from
exploded view.
Section 06 FUEL SYSTEM

Subsection 03 (CARBURETORS)
Title indicates main

procedure to be CARBURETOR REMOVAL DISASSEMBLY AND INSPECTION
carried-out. To remove carburetors from engine, proceed as fol- Inspect parts for corrosion dammage (shaft, butterfly,
lows: spring screw, check valve housing, etc.).
Remove air vent tube support.
Sub-sub-title in
Unlock retaining slides holding air intake silencer base.
Diaphragm capital indicates a
Remove air intake silencer base from watercraft. PUMP DIAPHRAGM LEAK TEST particular testing,
Remove screws holding flame arrester base support Using a suitable pump gauge tester, perform the fol- adjustment or
lowing test proceeding as follows:
to cylinder head cover.
- Install pump gauge tester (P/N 295 000 083) on pulse
repair procedure.
Unscrew base retaining screws then remove base from
Service tool to be carburetors and move to front of watercraft. nipple.
used to perform a Turn the valve to OFF position. - Pump tester until it reaches 28 kPa (4 PSI).
certain procedure. NOTE: For fuel line removal, use pliers (P/N 295
000 054). 1 A
Disconnect pulse line from fuel pump.
Disconnect fuel fuel supply line from fuel pump. Illustration
Disconnect fuel return line. always follows
Title in italic indicates a Disconnect oil injection pump cable, throttle cable and text it is
particular procedure choke cable.
pertained to.
concerning a model. XP Model Only
Remove screws no. 6 and lock washers no. 7 retaining
carburetors.
Sub-sub-title in this All Others Models

case indicates that Remove 4 bolts no. 8 and lock washers no. 12 from
rotary valve cover then move carburetors and rotary 2 1 2 TYPICAL mention
particular procedure valve cover on top of engine.
F01F0XB
indicates a general
for XP is finished, so NOTE: When removing rotary valve cover , pay
TYPICAL
view which does not
from this point, all
1
attention that the rotary valve stay in place, other-wise
represent full detail.
2
it must be timed.
others models are
concerned. Remove carburetors from intake manifold.
Diaphragm must stand pressure for 10 seconds. If
Disconnect fuel bypass line between carburetors (twin
carburetors). pressure drops, replace diaphragm. Numbers in a frame
Remove carburetor(s) from rotary valve cover. are used to give a
sequence to be
perfomed.
Letters are used for

any measures.
06-03-4
Bold numbers in the

text refer to the parts Numbers are used
shown in the exploded for description of
view at the beginning components.
of the subsection.
F01A0BS
SMR2002-053_00A2.FM VII
INTRODUCTION
LIST OF ABBREVIATIONS USED OPS Oil Pressure Sensor

IN THIS MANUAL OPT Optional
DESCRIPTION OSPS Oil Separator Pressure Sensor
AC Alternate Current P/N Part Number
ADC Analog to Digital Conversion PFD Personal Flotation Device
APS Air Pressure Sensor PSI Pound Per Square Inch
ATS Air Temperature Sensor PTO Power Take Off
Bombardier Utility and Diagnostic RAVE Rotax Adjustable Variable Exhaust
B.U.D.S.
Software
RFI Rotax Fuel Injection
CAPS Camshaft Position Sensor
RPM Revolution Per Minute
CDI Capacitor Discharge Ignition
STD Standard
CPS Crankshaft Position Sensor
TBD To Be Determined
CSI Cooling System Indicator
TDC Top Dead Center
CTS Coolant Temperature Sensor
TOPS Tip-Over Protection System
DC Direct Current
TPS Throttle Position Sensor
DESS Digitally Encoded Security System
VCK Vehicle Communication Kit
DI Direct Injection
VDC Volt Direct Current
DLA Digital Linear Actuator
VTS Variable Trim System
E.I.N. Engine Identification Number
WTS Water Temperature Sensor
ECU Electronic Control Unit
EGT Exhaust Gas Temperature
EMS Engine Management System
EPA Environmental Protection Agency (USA)
HP Horse Power
KS Knock Sensor
LED Light Emitting Diode
MAG Magneto
MAPS Manifold Air Pressure Sensor
MATS Manifold Air Temperature Sensor
MPEM Multi-Purpose Electronic Module
MPH Mile Per Hour
MPI Multi Protocol Interface
N.A. Not Applicable
OPAS Off-Power Assisted Steering
VIII SMR2002-053_00A2.FM
INTRODUCTION
GENERAL INFORMATION As many of the procedures in this manual are in-

terrelated, we suggest, that before undertaking
The use of LEFT (port) and RIGHT (starboard) indi- any task, you read and thoroughly understand the
cations in the text, always refers to driving position entire section or subsection in which the proce-
(when sitting on watercraft). dure is contained.
Besides, in the marine industry, FRONT is called A number of procedures throughout the book re-
BOW and REAR is called STERN. quire the use of special tools. Before undertaking
any procedure, be sure that you have on hand all
the tools required, or approved equivalents.
1 2
ENGINE EMISSIONS
INFORMATION
Manufacturer’s Responsibility
Beginning with 1999 model year engines, PWC
manufacturers of marine engines must determine
the exhaust emission levels for each engine horse-
power family and certify these engines with the
F01L45B
United States of America Environmental Protec-
tion Agency (EPA). An emissions control informa-
1. Left (port)
2. Right (starboard) tion label, showing emission levels and engine
specifications, must be placed on each vehicle at
The information and component/system descrip- the time of manufacture.
tions contained in this manual are correct at time
of writing. Bombardier Inc. however, maintains a Dealer Responsibility
policy of continuous improvement of its products
without imposing upon itself any obligation to in- When performing service on all 1999 and more re-
stall them on products previously manufactured. cent Sea-Doo watercrafts that carry an emissions
control information label, adjustments must be
Bombardier Inc. reserves the right at any time to kept within published factory specifications.
discontinue or change specifications, designs,
features, models or equipment without incurring Replacement or repair of any emission related
obligation. component must be executed in a manner that
maintains emission levels within the prescribed
This Shop Manual uses technical terms which certification standards.
may be different from the ones of the Parts Cata-
logs. Dealers are not to modify the engine in any man-
ner that would alter the horsepower or allow emis-
When ordering parts always refer to the specific sion levels to exceed their predetermined factory
model Parts Catalogs. specifications.
Exceptions include manufacturer’s prescribed
ILLUSTRATIONS AND changes, such as altitude adjustments for exam-
PROCEDURES ple.
The illustrations show the typical construction of
the different assemblies and, in all cases, may not Owner Responsibility
reproduce the full detail or exact shape of the parts The owner/operator is required to have engine
shown, however, they represent parts which have maintenance performed to maintain emission lev-
the same or a similar function. els within prescribed certification standards.
CAUTION: These watercraft are designed with The owner/operator is not to, and should not allow
parts dimensioned mostly in the metric system. anyone to modify the engine in any manner that
However some components may be from the impe- would alter the horsepower or allow emissions
rial system. When replacing fasteners, make sure to levels to exceed their predetermined factory spec-
use only those recommended by Bombardier. ifications.
SMR2002-053_00A2.FM IX
INTRODUCTION
EPA Emission Regulations LOCTITE APPLICATION

All new 1999 and more recent Sea-Doo water- PROCEDURE
crafts manufactured by Bombardier are certified
to the EPA as conforming to the requirements of The following describes the most common appli-
the regulations for the control of air pollution from cation procedures when working with Loctite
new watercraft engines. This certification is con- products.
tingent on certain adjustments being set to factory NOTE: Always use proper strength Loctite prod-
standards. For this reason, the factory procedure uct as recommended in this Shop Manual.
for servicing the product must be strictly followed
and, whenever practicable, returned to the original THREADLOCKER
intent of the design.
The responsibilities listed above are general and in no Uncovered Holes (bolts and nuts)
way a complete listing of the rules and regulations
pertaining to the EPA requirements on exhaust emis-
sions for marine products. For more detailed informa-
tion on this subject, you may contact the following
locations:
1
VIA U.S. POSTAL SERVICE:

Office of Mobile Sources
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J)
401 M St. NW
Washington, DC 20460
2
A00A3LA
VIA EXPRESS or COURIER MAIL:
Office of Mobile Sources 1. Apply here
2. Do not apply
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J) 1. Clean threads (bolt and nut) with solvent.
501 3rd St. NW 2. Apply Loctite Primer N (P/N 293 800 041) on
Washington, DC 20001 threads and allow to dry.
3. Choose proper strength Loctite threadlocker.
EPA INTERNET WEB SITE: 4. Fit bolt in the hole.
http:/www.epa.gov/omswww
5. Apply a few drops of threadlocker at proposed
tightened nut engagement area.
SELF-LOCKING FASTENERS 6. Position nut and tighten as required.
PROCEDURE
The following describes the most common appli-
cation procedures when working with self-locking
fasteners.
Use a metal brush or a screwtap to clean the hole
properly then use a solvent (Methyl-Chloride), let
act during 30 minutes and wipe off. The solvent
utilization is to ensure the adhesive works properly.
X SMR2002-053_00A2.FM
INTRODUCTION
Blind Holes 1. Clean threads (stud and hole) with solvent.

2. Apply Loctite Primer N (P/N 293 800 041) on
threads and allow to dry.
1 3. Put several drops of proper strength Loctite
threadlocker on female threads and in hole.
2 4. Apply several drops of proper strength Loctite
on stud threads.
5. Install stud.
6. Install cover, etc.
7. Apply drops of proper strength Loctite on un-
covered threads.
8. Tighten nuts as required.
A00A3MA
1. On threads
Preassembled Parts
2. On threads and at the bottom of hole
1. Clean threads (bolt and hole) with solvent.

2. Apply Loctite Primer N (P/N 293 800 041) on
threads (bolt and nut) and allow to dry for 30
1
seconds.
3. Choose proper strength Loctite threadlocker.
4. Apply several drops along the threaded hole and
at the bottom of the hole.
5. Apply several drops on bolt threads.
6. Tighten as required.
Stud in Blind Holes 2

A00A3OA
1. Apply here
2. Do not apply
1 3
1. Clean bolts and nuts with solvent.
2. Assemble components.
2
3. Tighten nuts.
4. Apply drops of proper strength Loctite on bolt/nut
contact surfaces.
5. Avoid touching metal with tip of flask.
A00A5RA NOTE: For preventive maintenance on existing
1. On threads
equipment, retighten nuts and apply proper strength
2. On threads and in the hole Loctite on bolt/nut contact surfaces.
3. Onto nut threads
SMR2002-053_00A2.FM XI
INTRODUCTION
Adjusting Screw Standard Thread Repair

1. Follow instructions on Loctite FORM-A-THREAD
81668 package.
2 2. If a plate is used to align bolt:
1
a. Apply release agent on mating surfaces.
b. Put waxed paper or similar film on the surfaces.
3. Twist bolt when inserting it to improve thread
conformation.
NOTE: NOT intended for engine stud repairs.
Repair of Small Holes/Fine Threads
Option 1: Enlarge damaged hole, then follow Stan-
dard Thread Repair procedure.
A00A3PA
Option 2: Apply FORM-A-THREAD on the screw
1. Apply here and insert in damaged hole.
2. Plunger
Permanent Stud Installation (light duty)
1. Adjust screw to proper setting.
1. Use a stud or thread on desired length.
2. Apply drops of proper strength Loctite thread-
locker on screw/body contact surfaces. 2. DO NOT apply release agent on stud.
3. Avoid touching metal with tip of flask. 3. Do a Standard Thread Repair.
NOTE: If it is difficult to readjust, heat screw with 4. Allow to cure for 30 minutes.
a soldering iron (232°C (450°F)). 5. Assemble.
STRIPPED THREAD REPAIR GASKET COMPOUND

Stripped Threads All Parts
5 1 2
1
6
8
2
3 1
A00A3QA 4 7
1. Release agent
2. Stripped threads
3. Form-A-Thread
4. Tape
5. Cleaned bolt
6. Plate A00A3SA 1 3
7. New threads
8. Threadlocker 1. Proper strength Loctite
2. Loctite Primer N (P/N 293 800 041) and Gasket Eliminator 518
(P/N 293 800 038) on both sides of gasket
3. Loctite Primer N only
1. Remove old gasket and other contaminants

with Loctite Chisel remover (P/N 413 708 500).
Use a mechanical mean if necessary.
XII SMR2002-053_00A2.FM
INTRODUCTION
NOTE: Avoid grinding. Mounting in Tandem

2. Clean both mating surfaces with solvent. 1. Apply retaining compound on internal element
3. Spray Loctite Primer N on both mating surfaces bore.
and on both sides of gasket. Allow to dry 1 or 2 2. Continue to assemble as shown above.
minutes.
4. Apply GASKET ELIMINATOR 518 (P/N 293 800 CASE-IN COMPONENTS
038) on both sides of gasket, using a clean ap-
plicator. Metallic Gaskets
5. Place gasket on mating surfaces and assemble
immediately.
NOTE: If the cover is bolted to blind holes (above),
apply proper strength Loctite in the hole and on
threads. Tighten.
If holes are sunken, apply proper strength Loctite
on bolt threads.
6. Tighten as usual.
MOUNTING ON SHAFT
Mounting with a Press
A00A3VA 1
1. Proper strength Loctite
1. Clean inner housing diameter and outer gasket

diameter.
2. Spray housing and gasket with Loctite Primer N
(P/N 293 800 041).
1
3. Apply a strip of proper strength Loctite on lead-
ing edge of outer metallic gasket diameter.
2
NOTE: Any Loctite product can be used here. A
3
low strength liquid is recommended as normal
strength and gap are required.
A00A3UA
4. Install according to standard procedure.
5. Wipe off surplus.
1. Bearing
2. Proper strength Loctite 6. Allow it to cure for 30 minutes.
3. Shaft
NOTE: Normally used on worn-out housings to
Standard prevent leaking or sliding.
1. Clean shaft external part and element internal It is generally not necessary to remove gasket
part. compound applied on outer gasket diameter.
2. Apply a strip of proper strength Loctite on shaft
circumference at insert or engagement point.
NOTE: Retaining compound is always forced out
when applied on shaft.
3. DO NOT use anti-seize Loctite or any similar
product.
4. No curing period is required.
SMR2002-053_00A2.FM XIII
INTRODUCTION
TIGHTENING TORQUES N•m

FASTENER SIZE
Lbf•ft
(8.8 grade)
Tighten fasteners to torque mentioned in explod-
37 27
ed views and text. When they are not specified
refer to following table.The table also gives the 38 28
metric conversion. 39 29
40 30
FASTENER SIZE
N•m Lbf•in 41 30
(8.8 grade)
42 31
1 9
43 32
2 M4 18
44 32
3 27
45 33
4 M5 35
46 34
5 44
47 35
6 53
48 M10 35
7 62
49 36
8 71 50 37
9 80 51 38
10 M6 89 52 38
11 97 53 39
12 106 54 40
13 115 55 41
14 124 56 41
15 133 57 42
16 142 58 43
17 150 59 44
18 159 60 44
19 168 61 45
62 46
FASTENER SIZE 63 46
N•m Lbf•ft
(8.8 grade)
64 47
20 15
65 48
21 15
66 49
22 16
67 49
23 M8 17
68 50
24 18
69 51
25 18
70 52
26 19
71 52
27 20
72 53
28 21
73 54
29 21
74 55
30 22
75 55
31 23
76 56
32 24
77 57
33 24
78 58
34 25
79 58
35 26
80 M12 59
36 27
XIV SMR2002-053_00A2.FM
INTRODUCTION
FASTENER SIZE FASTENER SIZE

N•m Lbf•ft N•m Lbf•ft
(8.8 grade) (8.8 grade)
81 60 116 86
82 60 117 86
83 61 118 87
84 62 119 88
85 63 120 89
86 63 121 89
87 64 122 90
88 65 123 91
89 66 124 91
90 66 125 92
91 67 126 93
92 68 127 94
93 69 128 94
94 69 129 95
95 70 130 96
96 71 131 97
97 72 132 97
98 72 133 98
99 73 134 99
100 74 135 M14 100
101 74 136 100
102 75 137 101
103 76 138 102
104 77 139 103
105 77 140 103
106 78 141 104
107 79 142 105
108 80 143 105
109 80 144 106
110 81 145 107
111 82 146 108
112 83 147 108
113 83 148 109
114 84 149 110
115 85 150 111
TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTS
Technical Publications
Bombardier Inc.
Valcourt (Quebec), Canada
SMR2002-053_00A2.FM XV
Section 01 SERVICE TOOLS AND PRODUCTS
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS 0
MANDATORY SERVICE TOOLS ........................................................................................... 01-02-1
ENGINE .............................................................................................................................. 01-02-1
COOLING/FUEL/OIL SYSTEMS ........................................................................................ 01-02-4
PROPULSION SYSTEM..................................................................................................... 01-02-5
STEERING SYSTEM .......................................................................................................... 01-02-7
OPTIONAL SERVICE TOOLS ................................................................................................ 01-03-1

ENGINE .............................................................................................................................. 01-03-1
COOLING/FUEL/OIL SYSTEMS ........................................................................................ 01-03-4
WATERCRAFT HANDLING................................................................................................ 01-03-5
SERVICE PRODUCTS ............................................................................................................ 01-04-1
SMR2002-095_01-01ATOC.FM 01-01-1
Subsection 02 (MANDATORY SERVICE TOOLS)
MANDATORY SERVICE TOOLS 0

ENGINE
Piston circlip installer Air compressor ring compressor Starter drive bearing pusher
P/N 529 035 563 P/N 529 035 713 P/N 290 876 502
F06B054
APPLICATION
F06B014
F12B0L4
All engines.
APPLICATION
947 DI engine. APPLICATION
947 DI engine. Piston pin puller
P/N 529 035 503
NEW
Carbon dam guide
Piston circlip installer P/N 529 035 715
P/N 529 035 765
F12B0M4
F00B0T4
V04B0B4
APPLICATION APPLICATION
APPLICATION
947 DI engine. 947 DI engine.
4 -TEC engine.
Carbon dam compressor
Sleeve set
P/N 529 035 716
P/N 529 035 543
(21 mm sleeve)
F00B0U4
F12B0N4
947 DI engine. 947 DI engine.
SMR2002-054_01_02A.FM 01-02-1
Puller Alignment support plate kit VCK (Vehicle Communication Kit)

P/N 529 035 547 P/N 529 035 506 P/N 529 035 844
1) Alignment plates Individual B.U.D.S. diskettes v1.1
P/N 529 035 507 P/N 529 035 845
2) Support Individual CD-Rom
P/N 529 035 511
P/N 529 035 886
A00C1A4 3) Screw (2)
P/N 207 182 544
Puller plate
P/N 420 876 080 4) Lock washer (2)
P/N 234 181 601
5) Flat washer (2)
P/N 234 081 410
A00C1R4
Extension handle
P/N 295 000 125
F01D164
F00B0F4
Screw M8 x 35 (3) APPLICATION

P/N 420 841 591 All models. F12H0A4
155.6 mm jet pump. APPLICATION

F00A094 All models.
Sleeve (3) Alignment shaft
P/N 295 000 141 Engine leak tester kit
P/N 290 847 220
P/N 295 500 352
Pump only
P/N 529 021 800
F00B0G4
F00A0A4
APPLICATION
APPLICATION
All models.
PTO flywheel on 947 DI engine.
NEW
Alignment adaptor
P/N 529 035 719
F01B2Q5
APPLICATION
947 DI engine.
F18B0C4
APPLICATION
GTX 4-TEC models.
01-02-2 SMR2002-054_01_02A.FM
Supplementary engine leak test kit Crankshaft protective cap Engine oil pressure adapter
P/N 295 500 780 P/N 290 877 414 P/N 529 035 652
1) 947 DI Intake plate
P/N 296 000 025
2) 947 DI Rave plate
P/N 296 000 026
3) 947 DI Exhaust plate
P/N 296 000 027
APPLICATION
F00B1R4
947 DI engine.
APPLICATION
NOTE: This kit is supplementary
to P/N 295 500 352. 947 DI engine.
V00B074
Handle Polygonal wrench APPLICATION

P/N 420 877 650 P/N 529 035 505 4-TEC engine.
NEW
Crankshaft looking tool

A00C3V4
F00B0Y4 P/N 529 035 821
APPLICATION
APPLICATION
Use with pushers
(P/N 290 876 609 and 290 877 740). Exhaust system of the 947 DI en-
gine. F18B064
APPLICATION
Ring gear puller tool
Intake plug 4-TEC engine.
P/N 420 976 235 (puller ass’y)
P/N 529 035 708
P/N 529 035 549 (puller bolt)
NEW
APPLICATION
Camshaft looking tool
947 DI engine.
P/N 529 035 839
Oil pressure gauge (1 to 8 bars)

F18B074
P/N 529 035 709
APPLICATION
F01B294 4-TEC engine.
APPLICATION
947 DI engine.
V00B064
APPLICATION
4-TEC engine.
SMR2002-054_01_02A.FM 01-02-3
COOLING/FUEL/OIL SYSTEMS
Pliers Fuel line disconnect tool NEW
P/N 295 000 070 P/N 529 035 714

Oetiker 1099 Oil seal guide
P/N 529 035 822
F01D174
F12B0G4
APPLICATION
APPLICATION F18B094
All models. 947 DI engine. APPLICATION

4-TEC engine.
Pliers 1. Fuel pressure gauge
P/N 295 000 054
P/N 529 035 709 NEW
Caillau
2. Fuel pressure gauge T-fitting
P/N 529 035 710 Coolant pump seal pusher
P/N 529 035 823
3. Fuel pressure gauge pressure
relief valve
F01B1T4 P/N 529 035 711
APPLICATION 4. Fuel pressure gauge air com-
All models. pressor adapter
NOTE: This tool is also used for P/N 529 035 712
the propulsion system.
F18B084
Fuel pressure gauge 1 APPLICATION

P/N 529 035 591 4-TEC engine.
3 2 4
F12R014
APPLICATION
947 DI engine.
F02B0B4
APPLICATION
4-TEC engine.
01-02-4 SMR2002-054_01_02A.FM
PROPULSION SYSTEM
Impeller remover/installer Bearing/seal installer Pliers
A) P/N 295 000 001 P/N 295 000 107 P/N 295 000 054
B) P/N 529 035 820 Caillau
F01J0T4 F01B1T4
A) GTX DI models. F01J4K4
All models.
B) GTX 4-TEC models. APPLICATION NOTE: This tool is also used for
the fuel system.
NOTE: This tool is also used for GTX DI models.
the PTO flywheel.
NEW
Inner seal installer
Pliers
P/N 529 035 609 PTO seal support
P/N 295 000 069
Oetiker 1090 P/N 529 035 842
F01D184
APPLICATION
All models.
F18B0F4
Impeller shaft holder F08B014

APPLICATION
P/N 295 000 082 APPLICATION GTX 4-TEC models.
GTX DI models.
NEW
Impeller shaft guide

Drive shaft holder
P/N 295 000 002
P/N 529 035 871
F01B0W4
APPLICATION
GTX DI models.
F01J1O4
Jet pump bearing remover APPLICATION

P/N 295 000 144 GTX DI models.
F18B0G4
F01J114
APPLICATION
APPLICATION GTX 4-TEC models.
GTX DI models.
SMR2002-054_01_02A.FM 01-02-5
NEW NEW NEW
Drive shaft/floating ring Shaft pusher Pressure cap

P/N 529 035 841 P/N 529 035 818 P/N 529 035 843
F18B054
F18B044
APPLICATION
APPLICATION
GTX 4-TEC models.
GTX 4-TEC models.
NEW
F18B0E4
Seal/bearing pusher APPLICATION

P/N 529 035 819 GTX 4-TEC models.
F18B0D4
APPLICATION
GTX 4-TEC models.
01-02-6 SMR2002-054_01_02A.FM
STEERING SYSTEM
NEW
OPAS cylinder nut wrench

P/N 529 035 840
F18B0A4
APPLICATION
All models.
SMR2002-054_01_02A.FM 01-02-7
Subsection 03 (OPTIONAL SERVICE TOOLS)
OPTIONAL SERVICE TOOLS 0

ENGINE
Distance gauge Dial indicator (TDC gauge) Crimping tool
A) P/N 529 035 100 P/N 295 000 143 P/N 295 100 164
11.5 mm (.453 in)
B) P/N 529 035 000
7.5 mm (.295 in)
A00B4E4
APPLICATION
947 DI engine. F00B0E4
APPLICATION
Digital/induction type
Contacts of AMP plug connectors.
F01B0H4
tachometer
APPLICATION P/N 529 014 500
A) 947 DI engine (MAG). Terminal (Packard) remover
B) 947 DI engine (PTO). Not sold by Bombardier
Snap-on
TT 600-4
Stroboscopic timing light
P/N 529 031 900
F01B1J4
APPLICATION
F01B1G4
All models.
APPLICATION
All models.
Joint connector tool
Not sold by Bombardier
Timing mark pointer
A00B4F4 Deutsch
APPLICATION P/N 295 000 135 114010
947 DI engine.
Six-pin magneto harness

P/N 295 000 136
F01H544
F01B284 APPLICATION
APPLICATION 947 DI engine.
F12B0C4
947 DI engine.
APPLICATION
947 DI models.
SMR2002-054_01_03A.FM 01-03-1
Safety lanyard switch tool Exhaust outlet tool MPEM programmer

P/N 529 034 600 P/N 295 000 132 P/N 529 035 878
F01B2A4
F01B244
APPLICATION
APPLICATION A01B5B4
All models. APPLICATION

All models.
947 DI models.
Engine lifting device
Protective mat
Not sold by Bombardier Piston ring compressor (2)
P/N 295 000 128
Do it yourself P/N 290 876 965 (88 mm)
Refer to REMOVAL AND INSTAL-
LATION section of engine.
F01B1T4
APPLICATION
F02B0A4
947 DI engine.
APPLICATION
All models. NEW
F01D0A4
APPLICATION
NEW Digital multimeter
947 DI engine.
P/N 529 035 868
Spring installer/remover
Steering cable tool
P/N 529 035 559
P/N 295 000 145
F01B2P4
APPLICATION
A00C3S4 All models.
APPLICATION
GTX 4-TEC models. Rubber pad
P/N 290 877 032
V00B0H4
APPLICATION
F06B064
All models.
APPLICATION
947 DI engine.
01-03-2 SMR2002-054_01_03A.FM
NEW NEW
9 9
8 8 7 7
Valve spring compressor clamp Special pliers for valve stem seal
P/N 529 035 724 removal
1
5 Snap-on YA 8230
2
4
3
6 4
V02B064
V00B044 APPLICATION
APPLICATION 4-TEC Engine.
4-TEC Engine.
MAG side PTO side
NEW
F01D885
NEW
1) Puller ass’y Valve stem seal installer
P/N 420 877 635 Valve spring compressor cup P/N 529 035 687
2) Protective cap P/N 529 035 725
P/N 420 876 557
P/N 290 877 414
(947 DI engine)
3) Ring (both ends)

P/N 420 977 490 V04B094
P/N 420 977 480
(947 DI engine) APPLICATION
V04B0H4
4-TEC Engine.
4) Ring halves (PTO) APPLICATION
P/N 420 977 475 (2)
4-TEC Engine.
P/N 420 876 330 NEW
(947 DI engine)
Ring compressor NEW
5) Distance ring (MAG)

P/N 420 876 569 Torque angle gauge
Snap-on RC980
6) Ring halves (MAG) Not sold by Bombardier
P/N 420 276 025 (2) Snap-on TA362
7) Screw M8 x 40
P/N 420 840 681 (2)
V04B084
8) Screw M8 x 70
P/N 420 841 201 (2) APPLICATION
4-TEC Engine.
9) Puller bolt
P/N 420 940 755
APPLICATION V04B0I4
947 DI engine. APPLICATION

4-TEC Engine.
SMR2002-054_01_03A.FM 01-03-3
Leak test kit pump NEW
P/N 529 021 800

Oil VAC
P/N 529 035 880
F18B0B4
V00B084
APPLICATION
APPLICATION
4-TEC Engine.
4-TEC Engine.
COOLING/FUEL/OIL SYSTEMS
Lighted adjustable mirror Hose pincher Flushing adapter
Not sold by Bombardier P/N 295 000 076 P/N 295 500 473
Snap-on
50101
F01B1I4
APPLICATION
All models. F00B104
A01B2I4
APPLICATION
APPLICATION
Hose pincher All models.
All models. Use with coupler hose (P/N 295
P/N 529 032 500
500 258).
Flexible spout (oil)
P/N 414 837 300 NEW
Test radiator cap

P/N 295 021 400
F04B044
F01B234 APPLICATION
APPLICATION All models.
PA
UD
All models.
S
OU A
V RIR A CH
F18E1P4
APPLICATION
4-TEC models.
01-03-4 SMR2002-054_01_03A.FM
PROPULSION SYSTEM
Fitting Slide hammer puller Hacksaw
P/N 295 000 086 Not sold by Bombardier Not sold by Bombardier
Snap-on: Snap-on
Handle: CJ93-1 HS3
Hammer: CJ125-6
Claws: CJ93-4
F01B1M4
APPLICATION
F01J0Z4 All models.
F01B0Z4
APPLICATION
APPLICATION
All 947 DI models.
GTX DI models.
NOTE: This tool is also used to re-
move rotary valve shaft bearing.
WATERCRAFT HANDLING
Dolly (with wheels) Tie-down Tie-down with ratchet
P/N 295 000 126 1.50 m (5 ft) long 3.60 m (12 ft) long
P/N 295 100 103 P/N 295 100 104
APPLICATION
All models.
F01B014
Beach wheels (set of 2 wheels)

F00B014
P/N 295 000 005
APPLICATION
All models.
F01B074
APPLICATION
Dolly.
SMR2002-054_01_03A.FM 01-03-5
Subsection 04 (SERVICE PRODUCTS)
SERVICE PRODUCTS 0
Loctite® is a trademark of Loctite™ Corporation.
Permatex® is a trademark of Loctite™ Corporation.
Dow Corning® is a trademark of Dow Corning Corporation.
Medium strength threadlocker High temperature threadlocker Retaining compound
P/N 293 800 060 P/N 420 899 788 P/N 413 703 100
Loctite 243 (blue) Loctite 648 (green) Loctite RC/609 (green)
(10 mL) (5 g) (10 mL)
A00B3D4 A00B2S4
High temperature retaining General purpose instant adhesive

compound P/N 293 800 021
F00A0O4
P/N 293 800 054 Loctite 495
Loctite 642
High strength threadlocker (50 mL)
P/N 293 800 005
Loctite 271 (red) A00B2V4
(10 mL)
Gasket eliminator
P/N 293 800 038
Loctite 518
(50 mL)
F00B024
F01B124
A00B2U4
SMR2002-054_01_04A.FM 01-04-1
Flange sealant Thread sealant Pipe sealant

P/N 293 800 081 P/N 293 800 050 A) P/N 293 800 013
Loctite 5910 Loctite 577 B) P/N 293 800 018
(300 mL) (250 mL)
A) Loctite 567 (250 mL)
B) Loctite 592 (50 mL)
F00B0W4
A00B2W4
Solvent
P/N 413 711 809 Hylomar sealant
Loctite Safety Solvent
320 g (11 oz)
P/N 293 800 001
PL-32
(100 g)
F00B1A4
A00B3F4
NEW
Sealant
RTV silicone sealant
P/N 293 530 011
P/N 293 800 066
Sikaflex 221 (black)
Loctite 5900 (350 mL)
(300 mL)
F01B1D4
A00B4X4
A02B0B4 NEW
Molykote 111
Chisel gasket remover P/N 413 707 000 High temperature RTV sealant
P/N 413 708 500 P/N 293 800 090
(510 mL)
111
Ultra Copper
(80 mL)
A00B3W4
Primer for gasket eliminator

P/N 293 800 041
Loctite 764
A00B574
A00B5A4
A00B3N4
01-04-2 SMR2002-054_01_04A.FM
Dielectric grease Super Lube grease NEW
P/N 293 550 004 P/N 293 550 030

Dow Corning Loctite 82328 Grease Isoflex
(150 g)
P/N 293 550 021
(50 g)
A00B1X4
Deoxit contact lubricant

P/N 293 550 015
(200 mL)
V00B0I4
Anti-seize lubricant A00B554
P/N 293 800 070

Loctite 76764 BOMBARDIER LUBE
454 g (16 oz)
P/N 293 600 016
(12 x 14 oz)
F00B0X4
Grease
P/N 293 550 005
(400 g)
A00B2L4
A00B624
A00B594
Synthetic grease
P/N 293 550 010
(400 g)
F01B154
SMR2002-054_01_04A.FM 01-04-3
BOMBARDIER storage oil NEW NEW
P/N 413 711 600

(12 x 350 g) Premixed coolant 50/50 BOMBARDIER Formula XP-S II
- 37°C (- 35°F) synthetic injection oil
P/N 293 600 038 P/N 293 600 245
(16 x 1 L) (12 x 1 L)
A00B634
A00B5T4
Sea-Doo fuel stabilizer
P/N 413 408 600 A00B5X4
P/N 293 600 246
236 mL (8 oz) (3 x 4 L)
Sealant adhesive
P/N 293 800 086
Loctite 5150
(29647)
A00B5S4 A00B5U4
P/N 293 600 247

(205 L)
A00B604
732 Multi-purpose sealant

P/N 293 800 086
Dow Corning (90 mL)
(clear)
F01B1C4
01-04-4 SMR2002-054_01_04A.FM
NEW Sea-Doo Cleaner

P/N 293 110 001 (400 g)
Instant gasket P/N 293 110 002 (4 L)
P/N 293 800 088
(7 oz)
F01B2J4
NEW
Pulley flange cleaner

A02B0C4 P/N 413 711 809
Jet pump synthetic oil

P/N 293 600 011
(12 x 6 oz)
A00B5V4
F01B0P4
NEW
Jet pump grease

P/N 293 550 032
(110 g)
SMR2002-054_01_04A.FM 01-04-5
Section 02 MAINTENANCE
TABLE OF CONTENTS 0
PERIODIC INSPECTION CHART ........................................................................................... 02-02-1
FLUSHING AND LUBRICATION ........................................................................................... 02-03-1

GENERAL ........................................................................................................................... 02-03-1
PROCEDURE ...................................................................................................................... 02-03-1
WATER-FLOODED ENGINE .................................................................................................. 02-04-1

GENERAL ........................................................................................................................... 02-04-1
PROCEDURE ...................................................................................................................... 02-04-1
STORAGE............................................................................................................................... 02-05-1
ENGINE DRAINING ........................................................................................................... 02-05-1
FUEL SYSTEM ................................................................................................................... 02-05-1
ENGINE OIL CHANGE AND FILTER ................................................................................. 02-05-2
COOLING SYSTEM FLUSHING AND ENGINE INTERNAL LUBRICATION .................... 02-05-2
ENGINE LUBRICATION ..................................................................................................... 02-05-2
BATTERY............................................................................................................................ 02-05-3
WATERCRAFT CLEANING ................................................................................................ 02-05-3
ADDITIONAL RECOMMENDED PROTECTION ................................................................ 02-05-3
ANTICORROSION TREATMENT....................................................................................... 02-05-5
CHECKLIST ........................................................................................................................ 02-05-6
SMR2002-095_02-01ATOC.FM 02-01-1
Subsection 02 (PERIODIC INSPECTION CHART)
PERIODIC INSPECTION CHART 0

The schedule should be adjusted according to operating conditions and use.
NOTE: The chart gives an equivalence between number of hours and months/year. Perform the maintenance
operation to whatever time comes first.
IMPORTANT: Schedule for watercraft rental operations or higher number of hour use, will require greater
frequency of inspection and maintenance.
DI Models
FREQUENCY
100 HOURS OR
25 HOURS OR
50 HOURS OR
3 MONTHS
6 MONTHS
DESCRIPTION
10 HOURS
1 YEAR
EVERY
EVERY
EVERY
FIRST
GENERAL
Lubrication/corrosion protection ➀ ✔
ENGINE
Support and rubber mount condition/tightness ✔ ✔
Exhaust system fasteners ➄ ✔ ✔
RAVE valve cleaning ➄ ✔ ✔
Top end inspection (leak test, piston and ring clearance) ➄ ➈
Counterbalance shaft oil level ✔ ✔
Spark plug inspection, cleaning and gap adjustment ➄ ✔➃
Spark plug replacement ➄ ✔
TDC setting ➄ ➈
COOLING SYSTEM
Flushing ✔➂
Hose condition and fasteners ✔ ✔
Inspect/clean engine drain tubes ✔➀
Water flow regulator valve inspection ✔
FUEL SYSTEM
Throttle, inspection/lubrication ➀ ✔
Fuel filter and lines inspection ✔ ✔
Fuel filter replacement ➇
Visually check for oil leakage between cylinder head and injector ➄ ✔ ✔
Fuel injection system sensors (except throttle body), visual inspection ➄ ✔ ✔
Throttle body cleaning and their sensors ➄ ➅ ✔ ✔
Fuel vent line pressure relief valve inspection ✔
Fuel lines, connections, check-valve and fuel system leak test ➄ ✔ ✔
Visual inspection: throttle bodies, sensors, fuel lines, fuel rail and fittings ➄ ✔ ✔
Air intake silencer fit/tightness ✔ ✔
Fuel tank straps visual inspection ✔ ✔
SMR2002-055_02_02A.FM 02-02-1
FREQUENCY
100 HOURS OR
25 HOURS OR
50 HOURS OR
3 MONTHS
6 MONTHS
DESCRIPTION
10 HOURS
1 YEAR
EVERY
EVERY
EVERY
FIRST
LUBRICATION SYSTEM
Oil injection pump adjustment ➄ ✔ ✔
Oil filter and lines inspection ✔ ✔
Oil filter replacement ✔
Oil reservoir straps ✔
ELECTRICAL SYSTEM
Check fault codes ✔ ✔
Electrical connections condition and fastening (ignition system, electrical
✔ ✔
box(es), starting system, fuel injectors, etc.)
MPEM mounting brackets/fasteners ✔
Digitally Encoded Security System and safety lanyard/post condition ✔ ✔
Monitoring beeper ✔ ✔
Battery condition and strap(s) ✔ ✔
STEERING SYSTEM
Inspection and cable adjustment ✔ ✔
O.P.A.S. SYSTEM
Check O.P.A.S. system operation and condition including filter ✔ ✔
PROPULSION SYSTEM
Drive shaft boot and spline condition ✔➁
Drive shaft protection hose inspection ✔➁
Shifter system/cable adjustment ✔ ✔
Jet pump reservoir oil level/oil condition Replace ✔ Replace
Jet pump cover pusher inspection ✔
Impeller shaft seal replacement ➆
Impeller condition and impeller/wear ring clearance ✔➁
Water intake grate condition ✔➁
HULL AND BODY
Bailer pick-ups, check for obstructions ✔ ✔
Hull condition ✔ ✔
➀ Every 10 hours in salt water use. ➄ Emission-related component.
➁ These items have to be initially checked after 25 hours. ➅ In salt water use.
Thereafter, servicing to be made as specified in this ➆ Replace at 150 hours.
chart.
➇ Replace at 250 hours.
➂ Daily flushing in salt water or foul water use.
➈ Check at 350 hours or 5 years.
➃ Except DI models.
02-02-2 SMR2002-055_02_02A.FM
4-TEC Models
FREQUENCY
100 HOURS OR
25 HOURS OR
50 HOURS OR
3 MONTHS
6 MONTHS
DESCRIPTION
10 HOURS
1 YEAR
EVERY
EVERY
EVERY
FIRST
GENERAL
Lubrication/corrosion protection ✔
ENGINE
Engine oil and filter replacement ✔ ✔
Support and rubber mount condition/tightness ✔ ✔
Condition of seals and fasteners ✔ ✔
Exhaust system fasteners ➄ ✔ ✔
Spark plug replacement ➄ ✔
COOLING SYSTEM
Flushing (exhaust system) ✔ ➂
Hose condition and fasteners ✔ ✔
Coolant replacement ➆
Coolant expansion tank cap/cooling system pressure test ➃
FUEL SYSTEM
Throttle cable, inspection/lubrication ✔
Fuel injection system sensors, visual inspection ➄ ✔ ✔
Throttle body cleaning and inspection. Fault code reading ➄ ➀ ✔
Fuel vent line pressure relief valve inspection ✔
Fuel lines, connections and fuel system leak test ➄ ✔ ✔
Visual inspection: throttle body, sensors, fuel lines, fuel rail and fittings ➄ ✔ ✔
Air intake silencer fit/tightness ✔ ✔
Fuel tank straps visual inspection ✔ ✔
ELECTRICAL SYSTEM
Check fault codes ✔ ✔
Electrical connections condition and fastening (ignition system, starting system,
✔ ✔
fuel injectors etc.)
MPEM and EMS ECU connectors inspection and lubrication ✔➀
MPEM mounting brackets/fasteners ✔
Digitally Encoded Security System and safety lanyard/post condition ✔ ✔
Monitoring beeper ✔ ✔
Battery condition and fasteners ✔ ✔
SMR2002-055_02_02A.FM 02-02-3
FREQUENCY
100 HOURS OR
25 HOURS OR
50 HOURS OR
3 MONTHS
6 MONTHS
DESCRIPTION
10 HOURS
1 YEAR
EVERY
EVERY
EVERY
FIRST
STEERING SYSTEM
Inspection and cable adjustment ✔ ✔
O.P.A.S. FUEL SYSTEM
Check O.P.A.S. system operation and condition including filter ✔ ✔
PROPULSION SYSTEM
Drive shaft protection boot inspection ✔ ➁
Grease splines in jet pump ✔ ➁
Shifter system/cable adjustment ✔ ✔
Impeller shaft seal replacement ➅
Impeller condition and impeller/wear ring clearance ✔ ➁
Water intake grate condition ✔ ➁
Ride plate inspection including coolant leak ✔ ✔
HULL AND BODY
Bailer pick-ups, check for obstructions ✔ ✔
Hull condition ✔ ✔
➀ In salt water use. ➃ Every 200 hours or 2 years.
➁ These items have to be initially checked after 25 ➄ Emission-related component.
hours. Thereafter, servicing to be made as specified ➅ Replace after the vehicle completed 100 hours of
in this chart. use, not every year.
➂ Daily flushing in salt water or foul water use. ➆ Replace for storage periode.
02-02-4 SMR2002-055_02_02A.FM
Subsection 03 (FLUSHING AND LUBRICATION)
FLUSHING AND LUBRICATION 0

GENERAL
DI Engines
Flushing the cooling system with fresh water is
essential to neutralize corroding effects of salt or
other chemical products present in water. It will
help to clean up sand, salt, shells or other particles
in water jackets (engine, exhaust manifold, tuned
pipe) and/or hoses.
Cooling system flushing and engine internal lubri-
cation should be performed when the watercraft
is not expected to be used further the same day
or when the watercraft is stored for any extended
time. 1
F06E01A
CAUTION: Failure to flush cooling system, when

1. Flushing adaptor
necessary, will severely damage engine and/or
exhaust system. Never flush a hot engine. Make NOTE: A quick connect adapter with a flushing
sure engine operates during entire procedure. adaptor (P/N 295 500 473) can be used to ease
garden hose installation.
PROCEDURE
 WARNING
Perform this operation in a well ventilated area.
Do not touch any electrical parts or jet pump
area when engine is running.
Clean jet pump by spraying water in its inlet and F00E05A 1 2

outlet and then spray BOMBARDIER LUBE lubri- 1. Quick connect adapter
cant. 2. Flushing adaptor (P/N 295 500 473)
 WARNING
Always remove safety lanyard cap from switch
to prevent unexpected engine starting before
cleaning the jet pump area. Engine must not be
running for this operation.
Connect a garden hose to the flushing adaptor.
F07E01B 1 2
1. Garden hose installed
2. Quick connector adaptor
SMR2002-055_02_03A.FM 02-03-1
Start the engine then immediately open the water

tap.  WARNING
Always use spark plug cable grounding de-
 WARNING vice when removing spark plugs.
Do not touch any electrical part or jet pump
CAUTION: Never flush a hot engine. Always start

the engine before opening the water tap. Open
water tap immediately after engine is started to
prevent overheating.
Run the engine about 3 minutes at a fast idle
around 3500 RPM.
Spray BOMBARDIER LUBE lubricant through air
intake silencer keeping engine at fast idle for ap- F01H7DA 1
proximately one minute. 1. Grounding device
Spray, through hole of air intake silencer.
Remove both spark plugs and spray BOMBARDIER
NOTE: An increase of engine RPM may be noticed LUBE lubricant into each cylinder.
while spraying the lubricant in the air intake silencer.
NOTE: Proceeding in this order, no fuel will be inject-
ed and no ignition will occur in the engine.
While engine is stopped, fully depress throttle lever
and HOLD for cranking.
Wait 2 seconds then press the start/stop button
to crank the engine a few turns and distribute the
lubricant onto cylinder walls.
NOTE: A 1 second beep every second indicates the
drowned mode is active.
Apply anti-seize lubricant on spark plug threads
then reinstall them.
Reinstall plug on air intake silencer cover.
NOTE: Engine fogging should be done with
F12F01A 1
BOMBARDIER LUBE lubricant whenever the wa-
1. Partially pull tube out of air box to inject BOMBARDIER LUBE tercraft is to be stored for a few days or a long period.
lubricant or equivalent. Push tube in when finished
CAUTION: Never leave rags or tools in the engine
Close the water tap then stop the engine. compartment or in the bilge.
CAUTION: Always close the water tap before
stopping the engine. 4-TEC Engines
Disconnect the garden hose. Closed Loop Cooling System
CAUTION: Remove quick connect adapter after 4-TEC engines are equipped with a closed loop
flushing operation (if used). cooling system which does not need to be flushed
Wipe up any residual water from the engine. even after salt water use.
Remove spark plug cables and connect them on Open Loop Cooling System
the grounding device.
Flushing the exhaust cooling system with fresh wa-
ter is essential to neutralize corroding effects of salt
or other chemical products present in water. It will
help to remove sand, salt, shells or other particles in
water jackets and/or hoses.
02-03-2 SMR2002-055_02_03A.FM
Flushing should be performed when the watercraft is Flushing

not expected to be used further the same day or
To flush the exhaust cooling system, start the en-
when the watercraft is stored for any extended time.
gine then immediately open the water tap.
 WARNING  WARNING
Perform this operation in a well ventilated area.
Certain components in the engine compartment
Do not touch any electrical part or jet pump
may be very hot. Direct contact may result in skin
burn. Do not touch any electrical part or jet pump
Proceed as follows: area when engine is running.
Clean jet pump by spraying water in its inlet and CAUTION: Never flush a hot engine. Always
outlet and then apply a coating of BOMBARDIER start the engine before opening the water tap.
LUBE lubricant or equivalent. Open water tap immediately after engine is
started to prevent overheating.
 WARNING Run the engine about 20 seconds at a fast idle
Always remove safety lanyard cap from switch between 4000 - 5000 RPM.
to prevent unexpected engine starting before
CAUTION: Never run engine without supplying
cleaning the jet pump area. Engine must not be
water to the exhaust cooling system when wa-
running for this operation.
tercraft is out of water.
Connect a garden hose to connector located at the Ensure water flows out of exhaust outlet while
rear of watercraft on jet pump support. flushing. Otherwise, refer to an authorized Sea-Doo
dealer for servicing.
 WARNING CAUTION: Never run engine longer than 5 min-
When operating the engine while the water- utes. Drive line seal has no cooling when water-
craft is out of the water, the heat exchanger in craft is out of water.
the ride plate may become very hot. Avoid any Close the water tap, then stop the engine.
contact with ride plate as burns may occur.
CAUTION: Always close the water tap before
NOTE: An optional quick connect adapter can be stopping the engine.
used (P/N 295 500 473). No hose pincher is required NOTE: Engine valves fogging should be done
to flush engine. whenever the watercraft is to be stored for a long
period. Refer to STORAGE section.
F07E01C 3 2 1
TYPICAL
1. Hose adapter
2. Quick connect adapter (optional, not mandatory)
3. Garden hose
SMR2002-055_02_03A.FM 02-03-3
Subsection 04 (WATER-FLOODED ENGINE)
WATER-FLOODED ENGINE 0
GENERAL NOTE: Proceeding in this order, no fuel will be in-
jected into the engine and ignition will be cut.
If engine is water-flooded, it must be serviced
Remove the air pressure hose from the compres-
within a few hours after the event. Otherwise en-
sor.
gine will have to be overhauled.
CAUTION: Failure to remove the air pressure
CAUTION: A water-flooded engine must be prop-
hose from the compressor will result in the bend-
erly lubricated, operated then lubricated again,
ing of the compressor connecting rod, when
otherwise parts will be seriously damaged.
cranking the engine.
PROCEDURE 1
DI Models
Check fuel and oil reservoirs for water contamina-
tion. If necessary, siphon and refill with fresh fluids.
Drain bilge if water is present.
Remove spark plug cables and connect them on
the grounding device.
 WARNING
Never crank engine with spark plugs removed
unless spark plug cables are connected to the
grounding device.
F18D1AA
1. Disconnect this hose
Remove the flywheel guard and turn the PTO fly-

wheel several times, by hand.
While engine is stopped, fully depress throttle le-
ver and HOLD for cranking.
Crank engine several times to drain crankcase.
NOTE: A 1 second beep every second indicates
the drowned mode is active.
F01H7DA 1 If water does not completely go out, it may be nec-
GTX DI MODELS essary to remove the air intake silencer then to
1. Grounding device lean the vehicle so that water can flow out from
throttle bodies.
Remove spark plugs and dry them with a clean
cloth. A contact cleaner spray can be used. It may Spray BOMBARDIER LUBE lubricant (P/N 293 600
be preferable to replace spark plugs. Do NOT in- 016) into spark plug holes and into the air compressor.
stall spark plugs on engine yet. Crank engine again.
Reinstall spark plugs and spark plug cables.
 WARNING Reinstall the air pressure hose to the compressor.
Be careful when cranking engine in the fol-
lowing procedure, water will spray out from Reinstall the flywheel guard.
spark plug holes. Start engine according to normal starting proce-
dure.
SMR2002-056_02_04A.FM 02-04-1
CAUTION: To avoid starting motor overheat- Whenever the engine is stopped, all the valves
ing, the cranking period should not exceed 5- close to prevent water from being ingested in the
10 seconds and a rest period of 30 seconds engine.
should be observed between cranking cycles. If water is suspected to be in the intake manifold
NOTE: If engine does not start after several at- and the exhaust system, it must be drained as fol-
tempts, check ignition system for spark occur- lows:
rence. Refer to IGNITION SYSTEM. Remove the intake manifold and suck out the wa-
Check crankshaft if needed, it may be misaligned ter from the intake valve ports. Refer to subsec-
or deflected. Refer to BOTTOM END. tion INTAKE SYSTEM.
After engine has started, spray BOMBARDIER Remove the water from oil/air separator breather
LUBE lubricant through air intake silencer while hose.
engine is running. Remove the exhaust pipe, the muffler and the res-
onator and drain them. Refer to subsection EX-
HAUST SYSTEM.
If water gets in the oil (oil will be milky), change
the engine oil and filter as follows:
Oil Change Procedure

ENGINE WITHOUT THE SCAVENGE OIL PUMP
COVER DRAIN PLUG
CAUTION: Never crank or start engine when si-
phon tube is in dipstick hole. Never start engine
when there is no oil in engine.
1. Using the oil VAC (P/N529 035 880), siphon oil
F12F01A 1 through dipstick hole.
1. Spray BOMBARDIER LUBE here 2. Remove the oil vac tool from the dip stick hole.
3. While in drowned engine mode, crank the en-
Run the engine for at least 30 minutes to ensure
gine for 5 seconds.
that the engine is dried out.
4. Remove the oil filter cap and the oil filter.
CAUTION: Engine must be cooled using the flush
kit. 5. Again, siphon oil from the reservoir.
6. Install a new oil filter and reinstall the oil filter
4-TEC Models cap.
Check fuel reservoir for water contamination. If
7. Fill up the reservoir with fresh oil.
necessary, siphon and refill with fresh fuel.
8. Run the engine for 3 minutes in a test tank or
To limit damages to the engine, perform the fol-
connected to a flush kit
lowing procedure as soon as possible.
9. Repeat the above steps 1 to 7.
Drain bilge if water is present.
10. Boil out the remaining water as follows:
If it was submerged in salt water, spray bilge and
all components with fresh water using a garden a. Recommended procedure BOIL OUT PRO-
hose to stop the salt corroding effect. CEDURE IN A TEST TANK OR TIED TO A
TRAILER WITH WATERCRAFT IN WATER.
CAUTION: Never try to crank or start the
engine. Water trapped in the intake manifold b. Optional procedure: BOIL OUT PROCEDURE
would enter the combustion chamber through CONNECTED TO A FLUSH KIT.
the intake valves and may cause damage to the
engine.
02-04-2 SMR2002-056_02_04A.FM
12. Install a new oil filter and reinstall the oil filter
cap.
13. Fill up the reservoir with fresh oil.
14. Boil out the remaining water as follows:
a. Recommended procedure BOIL OUT PRO-
CEDURE IN A TEST TANK OR TIED TO A
TRAILER WITH WATERCRAFT IN WATER.
b. Optional procedure: BOIL OUT PROCEDURE
CONNECTED TO A FLUSH KIT.
 WARNING
Make sure to safely secure the watercraft.
F18D19A 1
Boil Out Procedure in a Test Tank or Tied to a
1. Scavenge oil pump cover drain plug
Trailer with Watercraft in Water
ENGINE WITH THE SCAVENGE OIL PUMP 1. Run the engine for 5 minutes at 3500 RPM.
COVER DRAIN PLUG
2. With the engine still running at 3500 RPM, in-
CAUTION: Never crank or start engine when si- stall a hose pincher to the coolant line going to
phon tube is in dipstick hole. Never start engine the oil cooler.
when there is no oil in engine.
1. Using the oil VAC (P/N529 035 880), siphon oil  WARNING
through dipstick hole. Certain components in the engine compart-
2. Remove the oil vac tool from the dip stick hole. ment may be very hot. Direct contact may re-
3. While in drowned engine mode, crank the en- sult in skin burn. Do not touch any electrical
gine for 5 seconds. parts or jet pump area when engine is running.
4. Remove the oil filter cap and the oil filter.
1
5. Again, siphon oil from the reservoir.
6. Put a rag under the scavenge oil pump cover.
7. Remove the scavenge oil pump cover drain
plug and install fitting (P/N 293 710 037).
8. Connect the oil vac tool Bombardier (P/N 529
035 880) to the fitting.
9. The front of the engine must be tilt down ap-
proximately 15 degrees to facilitate the remov-
al of the oil. Raise the rear of the boat accord-
ingly. Siphon the oil from the fitting.
10. Level the engine.
F18E1QA
11. Remove the oil vac tool and the fitting. Rein-
stall the drain plug. 1. Oil cooler coolant inlet hose
NOTE: Do not forget to install the sealing washer 3. Continue to run the engine at 3500 RPM for 15
on the drain plug. more minutes (20 minutes total run time).
NOTE: If spillage occurs, clean immediately with 4. Shut the engine off.
the Pulley flange cleaner (P/N 413 711 809) to pre-
vent oil stains.
SMR2002-056_02_04A.FM 02-04-3
3. Run the engine for 5 minutes at 3000 RPM.

 WARNING 4. With the engine still running at 3000 RPM, in-
Certain components in the engine compart- stall a hose pincher to the coolant line going to
ment may be very hot. Direct contact may re- the oil cooler.
sult in skin burn. Do not touch any electrical
parts or jet pump area when engine is run-
ning.
 WARNING
Certain components in the engine compart-
CAUTION: Hose pincher should be remove be- ment may be very hot. Direct contact may re-
fore operating the watercraft engine. Failure to sult in skin burn. Do not touch any electrical
do this will result in damage to the engine. parts or jet pump area when engine is run-
ning.
5. Remove the hose pincher on the coolant line
going to the oil cooler. 5. Continue to run the engine at 3000 RPM for 15
6. Change the oil and filter again. more minutes (20 minutes total run time).
7. Procedure is now completed. 6. Shut off the engine
Boil Out Procedure Connected to a Flush Kit CAUTION: Hose pincher should be remove be-
fore operating the watercraft engine. Failure to
1. On drive shaft, remove the C-Clip then move
do this will result in damage to the engine.
forward the ring seal carrier. Refer to DRIVE
SYSTEM section. 7. Remove the hose pincher on the coolant line
going to the oil cooler
CAUTION: Make sure that the ring seal carrier
is not in contact with the PTO seal assembly, 8. Change the oil and filter again.
neither with the carbon ring. 9. Move rearward the Ring Seal Carrier and rein-
2. Connect a flush kit to the coolant line. stall the C-Clip. Refer to DRIVE SYSTEM sec-
tion.
water to the exhaust cooling system when wa- 10. Procedure is now completed.
02-04-4 SMR2002-056_02_04A.FM
Subsection 05 (STORAGE)
STORAGE 0
DI Models PTO Flywheel
Remove PTO flywheel guard.
ENGINE DRAINING Lubricate PTO flywheel at grease fitting with syn-
Disconnect the quick connect fitting. Press both thetic grease (P/N 293 550 010).
tabs and pull fitting. CAUTION: Do not lubricate excessively. Imme-
diately stop when a slight movement is noticed
on rubber boot.
F01I0BA 1
1. Grease PTO flywheel
CAUTION: Never leave any clothing, tool or oth-

er objects near PTO flywheel and drive shaft.
F18E02A
DISCONNECT THIS HOSE

FUEL SYSTEM
Lower hose as necessary so that draining can take All Engines
place. Verify fuel system. Check fuel lines and injectors
Reconnect fitting when done. for leaks. Replace damaged hoses or clamps if
necessary.
Also ensure air compressor drain line is not ob-
structed. Clean as necessary. Sea-Doo Fuel Stabilizer (P/N 413 408 600) or equiv-
alent should be added in fuel tank to prevent fuel
deterioration. Follow manufacturer’s instructions
PROPULSION SYSTEM for proper use.
Jet Pump Fill up fuel tank completely. Ensure there is no wa-
ter inside fuel tank.
Lubricant in impeller shaft reservoir should be
drained. Reservoir should be cleaned and refilled CAUTION: Should any water be trapped inside
with SEA-DOO synthetic 75W90 GL5 polyolester fuel tank, severe internal damage may occur to
oil. Refer to JET PUMP for proper procedure. the fuel injection system.
CAUTION: Use only SEA-DOO jet pump oil or CAUTION: Fuel stabilizer should be added prior
equivalent synthetic gear oil, otherwise com- to engine lubrication to ensure fuel system com-
ponent service life could be reduced. Do not ponents protection against varnish deposits.
mix oil brands or types.
SMR2002-057_02_05A.FM 02-05-1
CAUTION: Install new O-rings.

 WARNING – Torque the two bolts that hold the fuel rail on.
Fuel is inflammable and explosive under cer-
tain conditions. Always work in a well venti-
lated area. Do not smoke or allow open flames  WARNING
or sparks in the vicinity. Fuel tank may be pres- At preseason preparation, ensure to perform a
surized, slowly turn cap when opening. Never fuel pressure test and ensure there is no leak.
use an open flame to check fuel level. When Also run engine and check for leaks. Refer to
fueling, keep watercraft level. Do not overfill ENGINE MANAGEMENT section.
or top off the fuel tank and leave watercraft in
the sun. As temperature increases, fuel ex- – Pull engine cover upward to remove it.
pands and might overflow. Always wipe off – Disconnect ignition coil connectors.
any fuel spillage from the watercraft. Always
wipe off any fuel spillage from the watercraft.  WARNING
When disconnecting coil from spark plug, al-
ENGINE OIL CHANGE AND FILTER ways disconnect coil from main harness first.
Never check for engine ignition spark from an
4-TEC Engines open coil and/or spark plug in the engine
Change engine oil and filter. Refer to LUBRICA- compartment as spark may cause fuel vapor
TION in ENGINE section. to ignite.
IMPORTANT: Never cut the locking ties of coil

COOLING SYSTEM FLUSHING connectors. This would allow mixing the wires be-
AND ENGINE INTERNAL tween cylinders.
LUBRICATION – Remove ignition coils.
DI Engines CAUTION: Ensure there is no dirt in coil holes
prior to removing the spark plugs. Otherwise,
Cooling system has to be flushed with fresh wa-
dirt would fall into cylinder and will damage the
ter to prevent salt, sand or dirt accumulation which
internal components.
will clog water passages.
– Remove the spark plugs.
Engine must be lubricated to prevent corrosion on
internal parts. – Apply BOMBARDIER LUBE lubricant into the
cylinders
For proper procedure, refer to FLUSHING AND
LUBRICATION. – Reinstall spark plugs and ignition coils.
– Reconnect ignition coil connector.
ENGINE LUBRICATION NOTE: Prior to inserting the ignition coil to its lo-
4-TEC Engines cation, apply some BOMBARDIER LUBE lubricant
around the seal area that touches the spark plug
Fogging of the engine is recommended at the end hole. After installation, ensure the seal seats prop-
of the season and before any extended storage erly with the engine top surface.
period. This will lubricate the intake engine valves,
the cylinders and the exhaust valves. – To reinstall engine cover, push it downward until
it snaps.
To fog the intake engine valves proceed as follows:
– Crank engine several times while keeping throt-
– Remove the two bolts that hold the fuel rail on. tle fully depressed.
– Remove the rail along with the three fuel injec-
tors.
– Apply BOMBARDIER LUBE lubricant into the
intake ports.
– Crank engine at wide open throttle to prevent
fuel injection and ignition.
– Reinstall the injectors.
02-05-2 SMR2002-057_02_05A.FM
In cool regions (where freezing point may be encoun-

1
tered), cooling system should be filled with water and
antifreeze solution (40% water, 60% antifreeze).
CAUTION: Remaining water in cooling system
will freeze. If antifreezing is not performed ade-
quately engine/exhaust system may freeze and
cause severe engine damage. Always use ethyl-
ene glycol antifreeze containing corrosion inhib-
itors specifically recommended for aluminum
engines.
NOTE: When available, it is recommended to use
biodegradable antifreeze compatible with internal
combustion aluminum engines. This will contrib-
ute to protect the environment.
F18M01A
NOTE: The engine will not have to run during this
1. Engine intake ports operation.
BATTERY Hose Pinchers Installation

For battery removal, cleaning and storage, refer to Some hoses have to be plugged to prevent drain-
CHARGING SYSTEM. ing, before filling cooling system jackets with the
antifreeze.
WATERCRAFT CLEANING Install hose pinchers at the following location:
Clean the bilge with hot water and mild detergent
or with bilge cleaner. Rinse thoroughly. Lift front
end of watercraft to completely drain bilge. If any
repairs are needed to body or to the hull, touch up
paint and Gelcote® repair kit are available. Replace
damaged labels/decals.
Wash the body with soap and water solution (only
use mild detergent). Rinse thoroughly with fresh
water. Remove marine organisms from the hull.
Apply a nonabrasive wax.
CAUTION: Never clean fiberglass and plastic
parts with strong detergent, degreasing agent,
paint thinner, acetone, etc.
If the watercraft is to be stored outside, cover it with
an opaque tarpaulin to prevent sun rays and grime
from affecting the plastic components, watercraft
finish as well as preventing dust accumulation. 1
CAUTION: The watercraft must never be Ieft in

water for storage. Never leave the watercraft
stored in direct sunlight.
ADDITIONAL RECOMMENDED
PROTECTION
DI Engines
NOTE: This procedure requires approximately 2.5 L
(2.6 U.S. qt.) of antifreeze. F18E05A
1. Water outlet hose

SMR2002-057_02_05A.FM 02-05-3
Hose Disconnection
Disconnect water INLET hose at engine between
T-fitting and cylinder head fitting.
F18E0FA
1. Crankcase cooling cover outlet hose
F18E0BA
1. Disconnect this side of the T-fitting
Temporarily install a short piece of hose to replace

the one removed.
Antifreeze
Insert a funnel into the temporary hose and pour
antifreeze mix in engine until the colored solution
appears at cooling system bleed outlet.
F18E08A
1. Engine cylinder drain hose
F07E0LA
02-05-4 SMR2002-057_02_05A.FM
At this point, install a hose pincher on bleed outlet Pour approximately 200 mL (7 oz) of antifreeze in
hose. the water regulator valve supply hose to allow an-
tifreeze flowing through the valve and into muffler
to protect it.
Remove temporary hose and reconnect engine
water outlet hose.
Most of the antifreeze will drain out when removing
the hose pinchers. Use a container to recover it. DIS-
POSE ANTIFREEZE AS PER YOUR LOCAL LAWS
AND REGULATIONS.
NOTE: Although antifreeze will mainly drain out,
the antifreeze has mixed with the water that was
possibly trapped in the cylinder water jackets and
thus preventing freezing problems.
At preseason preparation, drain the remaining an-
F18E0EA 1 tifreeze from cooling system prior to using the wa-
1. Bleed outlet hose tercraft.
Continue to pour until antifreeze flows in air com- 4-TEC Engines
pressor water outlet hose. Refer to the COOLING SYSTEM section.
ANTICORROSION TREATMENT
All Engines
Wipe off any residual water in the engine compart-
ment.
Spray BOMBARDIER LUBE lubricant over all me-
tallic components in engine compartment.
Lubricate the throttle cable with BOMBARDIER
LUBE lubricant.
The seat should be partially left opened during
storage. This will avoid engine compartment con-
F18E01A 1 densation and possible corrosion.
1. Air compressor water outlet hose
Remove pinchers in this order to allow proper flow

of antifreeze.
1. Bleed outlet hose.
2. Crankcase cooling cover outlet hose.
3. Engine cylinder drain hose.
4. Water outlet hose.
SMR2002-057_02_05A.FM 02-05-5
CHECKLIST
OPERATION ✔
Check engine drain hose (DI engines)
Drain and clean impeller shaft reservoir
(DI engines)
Lubricate PTO flywheel (DI engines)
Verify fuel system
Add Sea-Doo fuel stabilizer
Flush the cooling system (DI engines)
Change engine oil and filter (4-TEC engines)
Flush the exhaust cooling system by
running the engine (4-TEC engines)
Lubricate the engine
Remove, clean and store the battery
Clean the bilge
Wash the body
Add antifreeze solution to the cooling
system (in cool regions) (DI engines)
Replace antifreeze. Check solution
concentration in the cooling system
(in cool regions) (4-TEC engines)
Spray BOMBARDIER LUBE over all metallic
components in engine compartment and on
throttle cable. For DI engine, spray on
injection pump cables
02-05-6 SMR2002-057_02_05A.FM
Section 03 TROUBLESHOOTING
Subsection 01 (TROUBLESHOOTING CHART)
TROUBLESHOOTING CHART 0
The following is provided to help in diagnosing the probable source of troubles. It is a guideline and should
not be assumed to show all causes for all problems.
NOTE: On DI and 4-TEC models, always check for fault codes recorded in the MPEM (DI models) or
EMS ECU (4-TEC models) first using the VCK (vehicle communication kit (P/N 529 035 844). If a fault
code is detected, service the fault code and recheck operating conditions. Refer to DIAGNOSTIC PRO-
CEDURES in ENGINE MANAGEMENT section.
ENGINE WILL NOT START
OTHER OBSERVATION POSSIBLE CAUSE REMEDY
• Wrong safety lanyard • Use one that has been programmed
for that watercraft
• DESS operation non functional • If 2 short beeps are not heard when
installing safety lanyard, refer to
ELECTRICAL SYSTEM and ENGINE
MANAGEMENT
• Safety lanyard switch faulty or discon- • Replace
nected or harness damaged
• Disconnected or faulty DESS auxil- • Refer to ENGINE MANAGEMENT
liary module (4-TEC models)
• Burnt fuse on MPEM or in rear elec- • Check wiring then replace fuse
trical box: battery, starting system,
fuel pump
• Starting system fuse keeps on burning • Check wiring, starting system solenoid
and MPEM
• Discharged or disconnected battery • Check/recharge
Engine does not turn over • Defective or disconnected start/stop • Check, refer to STARTING SYSTEM or
switch ENGINE MANAGEMENT
• Battery connections • Check/clean/tighten
• Water/fuel hydrolock • Check, refer to section MAINTENANCE
• Starter malfunction • Check, refer to section ELECTRICAL
SYSTEM
• Starter solenoid • Check, refer to section ELECTRICAL
SYSTEM
• Seized or obstructed engine • Check/repair, refer to section ENGINE
• Hydraulically locked air compressor • Check/repair as needed
(DI models)
• Seized jet pump • Check, refer to section PROPULSION
SYSTEM
• Faulty EMS ECU (4-TEC models) or • Check faulty codes in MPEM or EMS
MPEM ECU memory, refer to section ENGINE
MANAGEMENT
SMR2002-058_03-01A.FM 03-01-1
ENGINE WILL NOT START (cont’d)

• Loose battery cable connections • Check/clean/tighten
• Discharged/weak battery • Check/charge/replace
• Restriction in jet pump • Check/clean pump
• Partial seizure in jet pump • Inspect, refer to section PROPULSION
SYSTEM
• Partial engine hydrolock • Check, refer to section MAINTENANCE
Engine turns slowly
• Partial engine seizure • Check compression, refer to section
ENGINE
• Worn starter • Check, refer to section ELECTRICAL
SYSTEM
• Outside temperature too low • Oil is too “thick”. Change oil viscosity
• Battery capacity is not sufficient for
cold temperature
03-01-2 SMR2002-058_03-01A.FM
ENGINE WILL NOT START (cont’d)

• Faulty component in the fuel injection • Check for fault codes with the VCK
system (DI models) (vehicle communication kit). Refer to
DIAGNOSTIC PROCEDURES in
ENGINE MANAGEMENT
• Engine drowned mode is active • Release throttle lever
• Low battery voltage • Recharge or replace battery
• Low or no fuel pressure • Check fuel pump operation
(DI models) • Check fuel pump pressure output
• Check air/fuel rail
• Check fuel pump fuse
• Check wiring harness
• Fuel injectors not working • Check fuel injector operation. Replace
(DI models) as necessary
• Check output signal from MPEM
• Low or no air pressure (DI models) • Check air/fuel rail
• Check air compressor system
• Check RAVE valve system for leaks
• Direct injector not working • Check direct injector operation
(DI models) • Check output signal from MPEM
Engine turns over • No spark at the spark plug • Check spark plugs condition and
replace as necessary
• Check ignition system and repair
• Defective MPEM or EMS ECU • Replace MPEM or EMS ECU
(as applicable)
• Defective crankshaft position sensor • Check operation of CPS and replace if
necessary
• Water-contaminated fuel • Check/siphon and refill
• Dirty fuel filter • Clean/replace
• Fouled or defective spark plug • Replace
• Water in engine • Check, refer to section MAINTENANCE
• Defective ignition circuit • Check, refer to section ELECTRICAL
SYSTEM
• Internal engine damage • Check, refer to section ENGINE
• Defective encoder wheel • Check, refer to section ENGINE MAN-
AGEMENT
• Insufficient engine compression • Replace defective part(s)
• Incorrectly aligned flywheel and en- • Properly position flywheel and encoder
coder wheel (4-TEC models) wheel, refer to section PTO HOUSING/
MAGNETO
• Spark plug faulty, fouled or worn out • Check spark plug condition
• Ignition • Check, refer to section ELECTRICAL
No spark at spark plugs SYSTEM
• Faulty EMS ECU (4-TEC models) or • Replace EMS ECU or MPEM
MPEM (as applicable)
SMR2002-058_03-01A.FM 03-01-3
ENGINE HARD TO START

• Defective idle bypass valve • Refer to ENGINE MANAGEMENT
(4-TEC models)
• Wrong TPS zero setting • Refer to ENGINE MANAGEMENT
(4-TEC models)
• Wrong throttle body mechanical ad- • Refer to ENGINE MANAGEMENT
justment of cable
• Temperature too low for available • Battery capacity is not sufficient for cold
battery capacity temperature
• Air lock in fuel rail (4-TEC models) • Refer to ENGINE MANAGEMENT
• Water in intake system (defective • Check and remove water
sensor) (4-TEC models) • Refer to intake system in ENGINE
MANAGEMENT
• Water in fuel reservoir or • Flush reservoir and refill with fresh gas
contaminated fuel
• Mechanical engine failure • Check cylinder compression
• Check for cylinder head leaks
• Check starting system
• Spark plug faulty, fouled or worn out • Check spark plug condition
• Low fuel pressure • Check fuel pump operation. Refer to
ENGINE MANAGEMENT
• Check fuel pressure regulator. Refer to
ENGINE MANAGEMENT
• Low air pressure (DI models) • Check air/fuel rail. Refer to ENGINE
MANAGEMENT
• Check air compressor system. Refer to
ENGINE MANAGEMENT
• Check RAVE valve for leaks
ENGINE STARTS BUT RUNS ONLY AT IDLE SPEED

• The system is in limp home mode • Refer to section ENGINE and check the
fault codes in the EMS ECU
(4 TEC models) or MPEM or
(DI models)
• Broken or loose throttle cable • Change/readjust
03-01-4 SMR2002-058_03-01A.FM
ENGINE MISFIRES, RUNS IRREGULARLY

• Fouled, defective, worn spark plugs • Check/verify heat range/gap/replace
• Faulty EMS ECU (4-TEC models) • Check, refer to section ENGINE
MPEM (DI models) MANAGEMENT
• Defective encoder wheel • Check, refer to section ENGINE
MANAGEMENT
Weak spark • Too much oil supplied to engine • Adjust oil injection pump
(DI models)
• Bad ignition coil wiring • Check wiring condition and proper
grounding of ignition coil
• Faulty ignition coil, or bad connector • Check coil. Refer to ENGINE
MANAGEMENT
• Low fuel level • Check/refill
• Low fuel pressure • Check pump, regulator, injectors and
hose pinchers or if filter is plugged.
Replace if necessary
• Stale or water fouled fuel • Check/siphon and refill
• Fuel filter dirty or restricted • Check/clean/replace
Lean fuel mixture
Dry spark plug (except • Clogged fuel injectors • Remove and clean fuel injectors
when water fouled) • Clogged direct injectors • Remove and clean direct injectors
(DI models)
• Clogged fuel injectors
(4-TEC models)
• Defective sensor or EMS ECU • Check faulty codes in EMS ECU or
(4-TEC models)/MPEM (DI models) MPEM (as applicable) memory, refer to
section ENGINE MANAGEMENT
• Flame arrester dirty or restricted • Check/replace
• Improper air/fuel rail pressure • Check pressures, refer to ENGINE
(DI models) MANAGEMENT
• Faulty fuel injector(s) • Remove and replace fuel
injector(s), refer to section ENGINE
MANAGEMENT
• Faulty direct injector(s) (DI models) • Remove and replace direct
injector(s), refer to section
ENGINE MANAGEMENT
• Defective sensor or EMS ECU • Check faulty codes in EMS ECU or
(4-TEC models)/MPEM (DI models) MPEM (as applicable) memory, refer to
Rich fuel mixture section ENGINE MANAGEMENT
Fouled spark plug
• Leaking crankshaft seal(s) or intake • Pressure check engine, refer to section
(DI models) ENGINE
• Leak in RAVE valve system • Check, refer to ENGINE MANAGEMENT
(DI models)
• Oil injection pump adjustment • Check/adjust, refer to section
(DI models) LUBRICATION SYSTEM
• Fuel pressure fluctuating • Inspect fuel pressure regulators. Refer
to ENGINE MANAGEMENT
• High fuel pressure • Check pump, regulator, injectors, hose
pinchers or if filter is plugged. Replace
if necessary
SMR2002-058_03-01A.FM 03-01-5
ENGINE MISFIRES, RUNS IRREGULARLY (cont’d)

• Check spark plug condition, check • Check, refer to section ENGINE
fault codes in the EMS ECU or MPEM MANAGEMENT. If some work has
Start but run poorlys memory, check fuel pressure, check been performed on the unit, make sure
RAVE valves operation injector wire connectors were not
mixed. Refer to the wiring diagram for
wire colors and positions
• Bent or missing tooth on encoder • Check, refer to ENGINE
wheel MANAGEMENT under component
Also fuel injection inspection and adjustment
misinjecting • Injector wiring reversed • Check with wiring diagram
• Damaged fuel injector • Check, refer to ENGINE MANAGEMENT
ENGINE CONTINUALLY BACKFIRES

Weak spark • Fouled, defective spark plugs • Clean/replace
Spark plugs • Ignition coil leads or wiring reversed • Check with wiring diagram
• Incorrect setting (DI models) • Check/reset, refer to section
ELECTRICAL SYSTEM
Ignition timing/TDC setting
• Defective encoder wheel • Check, refer to section ENGINE
MANAGEMENT
• Intake or exhaust valve(s) leak • Pressure check engine, refer to section
Engine
(4-TEC models) ENGINE
ENGINE DETONATION OR PINGING

• Timing too far advanced • Check/reset
Ignition
• Spark plug heat range too high • Check/change to correct range
• Engine overheats and exhaust over- • Check, see engine overheats
heats
Engine/exhaust high • Fuel octane too low of poor quality • Use good quality fuel
temperature • KS disconnected or faulty • Check, refer to ENGINE MANAGEMENT
• Bad KS connection • Check, refer to ENGINE MANAGEMENT
• Bad Kostal connection (on engine) • Check, refer to ENGINE MANAGEMENT
03-01-6 SMR2002-058_03-01A.FM
ENGINE LACKS ACCELERATION OR POWER

• Weak spark • Check/replace, refer to section
ELECTRICAL SYSTEM
• Throttle does not open fully • Check/readjust, refer to section
ENGINE MANAGEMENT
• Low compression • Check/repair, refer to section ENGINE
• Water in fuel • Check/siphon/replace
• Impeller leading edge damaged • Check/replace, refer to section
PROPULSION SYSTEM
• Too much engine oil (4-TEC models) • Siphon or adjust level. Refer to LUBRI-
CATION
• Twisted crankshaft (DI models) • Check, refer to section ENGINE
• Poor quality • Siphon then refill with fresh fuel
• Clogged direct injectors • Remove and clean direct injectors
(DI models)
• Clogged fuel injectors • Remove and clean fuel injectors
• Low fuel pressure • Check fuel line and fuel pump pressure
• Incorrect throttle position sensor • Check and adjust TPS, refer to section
(TPS) adjustment ENGINE MANAGEMENT
• Improper timing chain alignment • Refer to section CYLINDER HEAD
(4-TEC models)
• Overheated engine • See ENGINE OVERHEATS in this chart
Engine revs lower than • RAVE valve does not open • Check, refer to section ENGINE
its maximum operational (DI models)
RPM • Limp home mode activated • Refer to ENGINE MANAGEMENT
Peak performance is • RAVE valve is stuck opened • Check, refer to section ENGINE
delayed until higher (DI models)
RPM range is reached
ENGINE STOPS RUNNING

• Spark plug heat range too high • Check/change to correct range
Engine dies during regular • Improper ignition timing (DI only) • Check/reset
operation (piston seizure) • Compression ratio is too high • Install genuine parts
• Poor oil quality • Use proper BOMBARDIER oil
Engine was running below • Electrical noise (DI models) • Refer to section ENGINE
2000 RPM. MANAGEMENT
No maintenance light
• Low air pressure (DI models) • Check air delivery circuit for leaks
Engine stalls at idle • Air in fuel rail (4-TEC models) • Check air compressor
• Refill fuel tank
• Engine running out of fuel • Check fuel delivery system for proper
fuel pressure and delivery
Engine start but stops after • Air in fuel rail • Refill fuel tank
approximately 2 seconds
• Low air pressure (DI models) • Check air system
(compressor, air/fuel rail etc.)
SMR2002-058_03-01A.FM 03-01-7
ENGINE CANNOT REACH MAXIMUM RPM

• RAVE valve does not open • Check, refer to section ENGINE and
(DI models) COOLING SYSTEM
• Faulty water regulator valve • Check, refer to COOLING SYSTEM
(DI models)
• The system is in limp home mode. • Refer to section ENGINE and check the
“MAINT” is displayed on Information fault codes in the EMS ECU
Center
• Low fuel pressure • Check fuel pump pressure output
• Jet pump related problem • Check propulsion components.
Refer to JET PUMP
• Limp home mode activated • Refer to ENGINE MANAGEMENT
• Exhaust system blockage/muffler • Check and repair
damage (DI models)
• Exhaust gases in bilge (leak) • Check exhaust system for leaks
ENGINE RUNS TOO FAST (vehicle cannot reach its top speed)
• Faulty rev limiter in EMS ECU • Check, refer to section ENGINE
(4-TEC models)/MPEM (DI models) MANAGEMENT
• Improper impeller pitch (too low) • Check/replace, refer to section
Engine RPM too high • Incorrect throttle position sensor PROPULSION SYSTEM
(TPS) adjustment • Check and adjust TPS, refer to ENGINE
MANAGEMENT
• Damaged impeller • Replace impeller. Refer to PROPULSION
• Damaged leading or trailing edge of • Check/replace
impeller NOTE: Leading edge damage contributes
to poor performance from start. Trailing
Jet pump cavitation edge damage contributes to poor top per-
formance and stator vanes erosion.
• Sealing of ride plate, jet pump support • Check/reseal, refer to section
or jet pump PROPULSION SYSTEM or HULL/BODY
ENGINE OVERHEATS
• Coolant level low • Refill/check for leaks
• Water leaking out of weep hole
• Replace rotary seal
Coolant level too low (PTO housing)
(4-TEC models) • Hoses or clamps missing/defect • Repair/replace
• Cylinder head gasket leaks • Replace cylinder head gasket
(white exhaust gas)
• Check/replace. Refer to ENGINE
• Temperature sensor defect MANAGEMENT
• Worn water pump impeller • Check/replace
Monitoring beeper sounds • Cooling system restriction • Check/flush, refer to section
continuously MAINTENANCE
• Damaged ride plate or hoses • Check, refer to COOLING SYSTEM
and HULL/BODY
• Thermostat defective
• Check/replace
(4-TEC models)
03-01-8 SMR2002-058_03-01A.FM
ENGINE SMOKE IN THE EXHAUST

• Coolant leak • Check/repair. Refer to LEAK TEST
White smoke • Damaged head gasket • Check/replace the head gasket
(4-TEC models) • Water ingestion • Inspect the intake manifold for the
presence of water
• Valve guide seals • Check/replace valve guide seals, refer
to cylinder head and valves
Blue smoke
(4-TEC models)
• Oil rings worn out • Replace rings
• at engine starting
• Oil rings • Inspect/repair oil rings, refer to engine
• with engine under load block
• Oil level too high • Siphon some oil from the oil tank
LOW OR NO ENGINE OIL PRESSURE (GTX 4-TEC)

• Oil level too low • Refill. See TECHNICAL DATA for
specifications
• Leaking gasket • Replace
• Oil leaking out of weep hole • Replace oil seal on pump shaft
(PTO housing)
• Oil pressure sensor defective • Check/replace
• Oil pump malfunctioning • Clean rotor and check wear limits
• Oil regulator valve sticks open, or • Clean/replace
spring load to small
• Heavy wear on plain bearings • Replace
ENGINE OIL CONTAMINATION (WHITE APPEARANCE) (GTX 4-TEC)

• Oil seal and rotary seal on water pump • Replace both seals. Refer to section
shaft leaking PTO HOUSING. Change oil
• Cylinder head gasket leaking • Replace gasket. Refer to section CYLIN-
Water and oil mixture DER HEAD. Change oil
leaking out of weep hole • Loose screws on cylinder head, PTO • Retorque. Change oil
(PTO housing) housing or oil seperator
(4-TEC models) • Oil contamination due to metal or • Replace possibly damaged parts.
plastic particles Change oil
• Water ingestion (intake manifold, • Refer to MAINTENANCE
TOPS valve, dipstick)
SMR2002-058_03-01A.FM 03-01-9
UNUSUAL ENGINE NOISE AND/OR VIBRATION (GTX 4-TEC)

• Worn chain tensioner • Replace
• Worn chain guide • Replace
• Stretched chain and/or worn out • Replace chain and sprockets
sprockets
• Sprocket screws got loose • Retorque
• Hydraulic element inside rocker • Replace faulty rocker arm(s)
arm(s) is(are) worn out (valve adjust-
ment)
• Rocker arm screws not tightened • Retorque
• Heavy wear on crankshaft and/or bal- • Replace
ancer shaft bearings
• Crankshaft and balancer shaft not • Check marks and readjust shafts
aligned
• Heavy wear on thrust washers, or • Check/replace
thrust washers missing
ABNORMAL NOISE FROM PROPULSION SYSTEM

• Weeds/debris caught in intake grate • Check/clean
or impeller
• Low oil level in jet pump (DI models) • Check/troubleshoot source of leak/
refill supply, refer to section
PROPULSION SYSTEM
• Worn anti-rattle system (DI models) • Check/replace pusher in cover, refer to
section PROPULSION SYSTEM
• Damaged or bent drive shaft • Check/replace, refer to section
PROPULSION SYSTEM
• Idle speed too low • Check fault codes
• Broken engine mounts • Check/replace, refer to section ENGINE
NOTE: Prior to replacing a EMS ECU or MPEM, refer to the appropriate EMS ECU/MPEM section or EMS
ECU/MPEM REPLACEMENT in the ENGINE MANAGEMENT section and read carefully the tests to do
before replacing a EMS ECU/MPEM that could otherwise be good.
03-01-10 SMR2002-058_03-01A.FM
Section 04 ENGINE (DI)
TABLE OF CONTENTS 0
LEAK TEST............................................................................................................................. 04-02-1
GENERAL ........................................................................................................................... 04-02-1
PREPARATION ................................................................................................................... 04-02-1
TESTING PROCEDURE ..................................................................................................... 04-02-1
ENGINE LEAKAGE DIAGNOSTIC FLOW CHART ............................................................ 04-02-4
REMOVAL AND INSTALLATION.......................................................................................... 04-03-1

GENERAL ........................................................................................................................... 04-03-1
ENGINE REMOVAL............................................................................................................ 04-03-1
CLEANING ......................................................................................................................... 04-03-3
INSTALLATION .................................................................................................................. 04-03-4
MAGNETO SYSTEM ............................................................................................................. 04-04-1

DISASSEMBLY .................................................................................................................. 04-04-2
CLEANING ......................................................................................................................... 04-04-3
ASSEMBLY......................................................................................................................... 04-04-3
TOP END ................................................................................................................................ 04-05-1

GENERAL ........................................................................................................................... 04-05-2
DISASSEMBLY................................................................................................................... 04-05-3
CLEANING ......................................................................................................................... 04-05-6
INSPECTION ...................................................................................................................... 04-05-7
USED PISTON MEASUREMENT ...................................................................................... 04-05-8
ASSEMBLY......................................................................................................................... 04-05-10
BOTTOM END........................................................................................................................ 04-06-1

DISASSEMBLY................................................................................................................... 04-06-2
CLEANING ......................................................................................................................... 04-06-5
INSPECTION ...................................................................................................................... 04-06-6
ASSEMBLY......................................................................................................................... 04-06-10
EXHAUST SYSTEM............................................................................................................... 04-07-1

REMOVAL........................................................................................................................... 04-07-2
TUNED PIPE REPAIR ......................................................................................................... 04-07-6
INSTALLATION .................................................................................................................. 04-07-6
SMR2002-095_04-01ATOC.FM 04-01-1
Subsection 02 (LEAK TEST)
LEAK TEST 0
GENERAL PREPARATION
A Sea-Doo Engine Leak Test Kit (P/N 295 500 352) Verify fuel system for leaks.
and Supplementary Engine Leak Test Kit (P/N 295
500 780) are available to help diagnose engine  WARNING
problems such as engine seizure, poor perfor- If any fuel leak is found, do not start the en-
mance, oil leakage, etc. gine. Correct the leak and wipe off any fuel
Before disassembling any components of the en- spillage. Do not use electric powered tools
gine, it is important to perform a leakage test to unless fuel system has passed pressure test.
determine which part is defective.
It is also very important after servicing the engine, Disconnect battery BLACK negative cable.
even for a complete engine rebuilt, to perform an-
other leakage test; at this stage, it may avoid fur-  WARNING
ther engine problems and minimizing the risk of Always disconnect battery cables in the speci-
having to remove and reinstall the engine again. fied order, BLACK negative cable first.
Static bench testing is the most effective way to
Disconnect battery RED positive cable.
conduct a leakage test. Inboard testing does not
allow complete access to, and observation of all
engine surfaces and should be avoided whenever TESTING PROCEDURE
possible.
Engine Cooling System
When installing hoses of the Engine Leak Test Kit
or Supplementary Engine Leak Test Kit, use the Remove the tuned pipe. Refer to EXHAUST SYS-
collars provided in the kit to ensure a proper seal- TEM.
ing. Remove the exhaust manifold gasket and ensure
When pressurizing the engine, first confirm that the surface is clean.
the components of the Engine Leak Test Kit or Disconnect engine cooling hoses.
Supplementary Engine Leak Test Kit are not leak-
Install the appropriate exhaust manifold plate from
ing by spraying a solution of soapy water on all
the Engine Leak Test Kit (P/N 295 500 352) or Sup-
hoses, connections, fittings, plates, etc. If there is
plementary Engine Leak Test Kit (P/N 295 500 780).
a leak, bubbles will indicate leak location.
Tighten plate using fasteners provided in the kit.
Three areas of the engine will be tested in se-
NOTE: Do not torque plate excessively.
quence as per the diagnostic flow chart (see the
end of this subsection). Install a hose pincher on engine drain hose.
1. Engine Cooling System. Use hoses provided in the kit and install them on
the engine.
2. Bottom End and Top End.
Install pump using reducer and appropriate tube(s)
NOTE: If a leak is found, it is important to continue
as necessary.
testing as there is the possibility of having more
than one leak. Continue pumping to compensate
for the air lost to find another leak.
SMR2002-059_04_02A.FM 04-02-1
2 Activate pump and pressurize engine cooling sys-

tem to 34 kPa (5 PSI).
Wait 3 minutes and check if pressure drops; if so,
verify all testing components.
– If kit components are not leaking and pressure
drops, verify all external jointed surfaces, tem-
perature sensor and the O-ring between the
spark plug area and the engine cylinder head
cover. If none of these components are leaking,
there is an internal leak and it can be detected
with Bottom End and Top End testing.
Bottom End and Top End

Remove throttle bodies.
F12E08A 1 Install intake manifold plugs (P/N 529 035 708).
947 DI ENGINE — SIDE VIEW
1. Block engine drain hose with a hose pincher
2. Install pump to water inlet hose
F12D14A 1
1. Intake manifold plugs
Remove the RAVE valves and gaskets.

F12E07A
Install the RAVE valve plates with fasteners from
947 DI ENGINE — FRONT VIEW the kit and tighten adequately.
1. Exhaust manifold plate
The O-ring can be checked for leakage with the
NOTE: Water is not required for testing. valve in place. Simply remove the cover to expose
It is not necessary to pressurize the bottom crank- the parts.
case cover nor the magneto cover. There is no pos- Make sure the spark plugs and the air/fuel rail are
sible water leak path toward the internal compo- installed and tightened.
nents of the engine.
04-02-2 SMR2002-059_04_02A.FM
Install pump to the exhaust plate fitting. Wait 3 minutes and check if pressure drops; if so,
verify all testing components.
1 2
If kit components are not leaking, verify engine
jointed surfaces as per following areas:
– spark plugs
– direct injector sealing
– cylinder head gasket
– cylinder base gasket
– crankcase halves
– engine plugs
– exhaust manifold
– intake flanges.
Check also small oil injection pump lines and fit-
tings; check for air bubbles or oil column going to-
ward pump, which indicate a defective check valve.
Check for leak through cournterbalancing shaft
seal toward air compressor. Air bubbles in lowest
fitting (oil return line) underneath compressor indi-
cates a seal leakage.
At this point, proceed with testing (if so equipped).
F08D05A 3
If there is still some leakage, remove the PTO fly-
947 DI ENGINE
1. Exhaust plate
wheel to verify outer seal.
2. Rave valve plates If no leak is found on the PTO side outer seal, re-
3. Intake plates
move magneto flywheel and verify crankshaft out-
Activate pump and pressurize engine to 34 kPa (5 PSI). er seals.
CAUTION: Do not exceed this pressure.
SMR2002-059_04_02A.FM 04-02-3
ENGINE LEAKAGE DIAGNOSTIC FLOW CHART

947 DI Engine
F00D28T
04-02-4 SMR2002-059_04_02A.FM
Subsection 03 (REMOVAL AND INSTALLATION)
REMOVAL AND INSTALLATION 0

GENERAL Disconnect connectors from fuel injectors and di-
rect injectors.
On some models, it is not necessary to remove
Disconnect connector from knock sensor.
engine from watercraft to service TOP END, PTO
FLYWHEEL or MAGNETO. However, engine remov- Disconnect RAVE valve hose where shown. Inspect
al is necessary to repair BOTTOM END. hose. If it has hardened or is slit, replace hose.
ENGINE REMOVAL
Use the VCK (Vehicle Communication Kit) (P/N 529
035 676) and release the fuel pressure in the fuel
system. Refer to ENGINE MANAGEMENT section.
In order to remove engine from watercraft proceed
as follows.
First, disconnect battery cables from battery.
 WARNING 1
Always disconnect battery cables exactly in
the specified order, BLACK negative cable
first then the RED positive battery cable last. F16D03A
1. Disconnect hose here
Electrical Connections Refer to ENGINE MANAGEMENT for location of sen-

It is recommended to disconnect electrical con- sors and connectors.
nections prior to disconnecting fuel lines. Unplug air compressor lines (inlets and outlets):
Disconnect temperature sensor wire and spark plug cooling, oil (outlet only) and air (inlet only on throt-
cables. tle body side).
Disconnect magneto wiring harness. Disconnect vent hose from balancing shaft gear
housing.
Jet Pump Removal

To withdraw jet pump, refer to JET PUMP.
CAUTION: Whenever removing engine from
watercraft, engine/jet pump alignment must be
performed at reinstallation.
Drive System
To withdraw drive shaft(s), refer to DRIVE SYSTEM.
Cooling System
Disconnect the engine water supply hose.
F07D08A 1 Disconnect the engine water return hose.
1. Unplug connector NOTE: Engine will have to be raised inside bilge
Disconnect both throttle position sensors (TPS), to disconnect drain hose before removing from
manifold air pressure sensor (MAPS) and manifold bilge.
air temperature sensor (MATS). Refer to COOLING SYSTEM for proper water hose
location.
SMR2002-060_04_03A.FM 04-03-1
Tuned Pipe Lifting Engine

To remove tuned pipe, refer to EXHAUST SYSTEM. 947 DI Engine
Air Intake Silencer Engine can be easily lifted using the following sug-
gested tools:
To remove air intake silencer, refer to AIR INTAKE.
– Cut porcelain from two old spark plugs.
Throttle Body – Weld a lock washer approximately 20 mm (3/4 in)
diameter on each spark plug as shown.
Remove air/fuel rail. Refer to ENGINE MANAGE-
MENT.
Engine Support 1
NOTE: Be careful when removing engine sup-
port(s) or rubber mount adapters, shims could
have been installed underneath. Shims control
engine/jet pump alignment. Always note position
of shims for reinstallation, to avoid altering engine
alignment.
Remove engine support mount screws.
F01D0AA 2
1. Weld a lock washer
2. Old spark plug
Remove spark plugs and replace by special tools.

Hook a sling into holes of special tools.
Using a chain block, a hoist or other suitable equip-
ment, slightly lift engine to ease the remaining
component removal.
CAUTION: Take care not to damage cable or oil
injection hoses.
Remove rear engine support.
F06D35A 1
FRONT SUPPORT 1
1. Remove screw
F07F12A
TYPICAL
1. Rear support
F07F12C 1
REAR SUPPORT
1. Remove screws
04-03-2 SMR2002-060_04_03A.FM
Removal of Remaining Components 2

Lift up engine slowly until oil injection hoses can be
reached.
Install a hose pincher to oil supply hoses of oil in-
jection pump then, disconnect hoses.
F06H35A 1
1. Positive starter cable
2. Ground cable
A01B2JB
Carry on engine lifting then tilt engine so that it can
TYPICAL be removed from the body opening.
1. Hose pincher (P/N 295 000 076)
CAUTION: Be careful not to scratch body or to
Disconnect RED positive cable from starter post. hit any component.
F01H1JB 1
TYPICAL F01D7RA
1. Disconnect RED positive cable
TYPICAL
Disconnect BLACK negative cable from engine
crankcase. CLEANING
Wipe off any spillage in bilge. Clean with a bilge
cleaner.
Clean external parts of engine.
SMR2002-060_04_03A.FM 04-03-3
INSTALLATION Positive Starter Cable

Installation of engine in watercraft is essentially Torque nut of positive starter cable to 6 N•m
the reverse of removal procedures. However pay (53 lbf•in). Apply dielectric grease on nut.
particular attention to the following.
Engine/Jet Pump Alignment
Rubber Mount, Shim and Screw Alignment is necessary to eliminate possible vi-
Check tightness and condition of rubber mounts. bration and/or damage to components. Check
If they have been removed, apply Loctite 243 alignment of engine using the following alignment
(blue) on screw threads. Torque screws to 25 N•m tools.
(18 lbf•ft). Support plate kit (P/N 529 035 506).
CAUTION: Strict adherence to this torque is im- NOTE: Use plate (P/N 529 035 508) for the 139.5 mm
portant to avoid damaging threads of alumi- (5-1/2 in) jet pump and plate (P/N 529 035 507) for
num insert in bilge. the 155.6 mm (6-1/8 in) jet pump.
Engine Support
Install and torque the engine support screws to
24 N•m (17 lbf•ft) in the indicated order. Refer to
the following illustration.
4
1 2
3 5
F00B0FA 1 2
1. Plate
F12D13A
2. Support
TORQUE TO 24 N•m (17 lbf•ft) AS PER SEQUENCE
Alignment shaft (P/N 295 000 141).
NOTE: Remember to install sleeves and flat washers.
2 1 2 1 2
F00B0GA 1
1. Alignment shaft
To verify alignment proceed as follows:

– Install the appropriate plate with the support to
hull with four nuts.
F12D13B
1. Sleeves
2. Flat washers
04-03-4 SMR2002-060_04_03A.FM
F00B0HA
– Carefully slide shaft through support.

– Insert shaft end into PTO flywheel. F00D0CA 1
NOTE: Ensure the protective hose and carbon
TYPICAL
ring (or seal carrier) is removed to check engine
1. Shim
alignment. If the alignment is correct, the shaft will
slide easily without any deflection in PTO flywheel. CAUTION: Whenever shims are used to correct
alignment, never install more than 1.3 mm
(0.051 in) shim thickness
Engine Support Screws

Apply Loctite 243 (blue) (P/N 293 800 060) on
screw threads.
Torque engine support screws to 25 N•m (18 lbf•ft)
when procedure is completed.
F07D05A 2 1
TYPICAL
1. Alignment shaft
2. PTO flywheel
If the alignment is incorrect loosen engine support

screws to enable to align PTO flywheel with shaft
end.
NOTE: Use shim(s) (P/N 270 000 024 or P/N 270
000 025) as necessary between engine supports F06D35A 1
and rubber mounts to correct alignment. FRONT ENGINE SUPPORT
1. Torque to 25 N•m (18 lbf•ft)
SMR2002-060_04_03A.FM 04-03-5
F07F12C 1
REAR ENGINE SUPPORT
Final Inspection
Check throttle cable condition and lubricate cable
with BOMBARDIER LUBE lubricant.
After its installation, properly adjust and bleed oil in-
jection pump as specified in OIL INJECTION PUMP
and adjust throttle cable as specified in ENGINE
MANAGEMENT.
Check hose condition and pressure test fuel sys-
tem, refer to FUEL CIRCUIT.
 WARNING
Whenever doing any type of repair on water-
craft or if any components of the fuel system
are disconnected, a pressure test must be done
before starting engine.
Verify all electrical connections.

Run engine and ensure there is no leakage.
CAUTION: If watercraft is out of water, engine
must be cooled using the flush kit.
04-03-6 SMR2002-060_04_03A.FM
Subsection 04 (MAGNETO SYSTEM)
MAGNETO SYSTEM 0
Molykote
111
11
9 Nm 9
(80 lbfin) Molykote
111 Loctite
Loctite 243
243
20
13 Nm
1 (115 lbfin)
29
25 5 Nm 16 Loctite
(44 lbfin) 243
21
9 Nm
(80 lbfin)
Loctite
243
8
14
13
115 Nm
(85 lbfft) Loctite
243
F12D0SS
SMR2002-061_04_04A.FM 04-04-1
DISASSEMBLY
Cover
Loosen screws no. 11. Remove engine magneto
cover no. 1.
F06D0LA 1
1. Screw
To remove the ring gear/rotor assembly, unscrew

nut no. 13 counterclockwise when facing it.
F06D1RA 1 2
TYPICAL
1. Cover
2. Screw
Remove oil pump shaft from magneto rotor nut.
F06D0MA 1
1. Nut
The magneto rotor is easily freed from crankshaft

with puller (P/N 420 976 235).
Install protective cap (P/N 290 877 414) to crank-
shaft.
F06D23A 1
Fully thread puller in magneto rotor.
1. Remove oil pump shaft
Rotor and Ring Gear

To remove the rotor no. 8 or the ring gear no. 3,
the crankshaft must be locked. For procedure, re-
fer to BOTTOM END.
If necessary, the magneto rotor can be removed
without removing the ring gear. Remove the six
screws no. 17.
04-04-2 SMR2002-061_04_04A.FM
CAUTION: Ensure to completely screw the puller CLEANING

until it bottoms. Otherwise, not enough threads
would be engaged and damage may occur. Clean all metal components in a solvent.
CAUTION: Clean coils and magnets using only
a clean cloth.
Clean crankshaft taper and threads using acetone.
Apply the acetone on a rag first then clean the
crankshaft.
ASSEMBLY
Battery Charging Coil
Position new coil, crimp and solder all wires.
Prior to assembly, apply Loctite 243 (blue).
Use magneto coil centering tool (P/N 420 876 922)
and install it so that it fits around armature plate
before tightening screws no. 23.
F06D0PA 1
1
1. Puller
Tighten puller screw and at the same time, tap on

screw head using a hammer to release magneto
rotor from its taper.
CAUTION: Be careful after ring gear removal
not to bend the encoder wheel teeth. Also pay
attention when putting away. If you suspect a
bent tooth, refer to ENGINE MANAGEMENT for
inspection procedure.
F00D0AA
Stator and Trigger Coil/CPS
(Crankshaft Position Sensor) 1. Magneto coil centering tool (P/N 420 876 922)
Loosen screws no. 20 and no. 21 to remove the

stator no. 9 and trigger coil no. 10 from the engine Magneto Flywheel and Ring Gear
magneto cover. Apply Loctite 648 (green) to magneto flywheel
mating surface. Lay ring gear on a steel plate, then
heat with a propane torch in order to install it on
magneto flywheel.
F06D0NA 1
1. Remove screws
SMR2002-061_04_04A.FM 04-04-3
Pay particular attention to position ring gear teeth When reinstalling armature plate on a new crank-
chamfer side as per following illustration. case housing, proceed as follows.
Find manufacturer’s mark on armature plate. In
line with this mark, punch another mark on adja-
cent crankcase lug.
2 1
F01D3BA 1
F01D4FA
1. Teeth chamfer
TYPICAL
NOTE: Ensure that ring gear contacts magneto 1. Manufacturer’s mark on armature plate
flywheel flange. 2. Punch a mark on crankcase lug aligned with plate mark
Whenever replacing either ring gear or magneto The new mark on crankcase will be used for fur-
flywheel, Gun Kote must be applied to prevent ther assembly positioning as a pre-timing position.
possible corrosion.
CAUTION: Always assemble magneto flywheel
and ring gear prior to apply Gun Kote. If not done
correctly, ring gear won’t contact magneto fly-
wheel flange.
To apply Gun Kote proceed as follows:
1. Clean thoroughly and degrease replacement
part using a non oil base solvent.
2. Apply coating in light thin coats using a spray
gun.
NOTE: Do not spray Gun Kote into magneto fly- 1
wheel threaded holes.
3. Bake parts in oven at 175°C (350°F) for 1 hour
to cure Gun Kote.
CAUTION: Do not eliminate Gun Kote heat cur- F01D4GA
ing time because it will lose all its resistance

TYPICAL
and it will not give any protection. 1. For further assembly, use these marks
Magneto Housing Apply a drop of Loctite 243 (blue) on threads of

screws no. 15 and torque to 6 N•m (53 lbf•in).
Install gasket no. 24 between magneto housing
no. 5 and engine crankcase.
Magneto Flywheel
Install magneto housing and torque screws no. 16
to 9 N•m (80 lbf•in). Apply Loctite 243 (blue) on crankshaft taper.
Position Woodruff key and magneto flywheel. Ap-
Armature Plate ply Loctite 243 (blue) on nut no. 13. Install nut with
lock washer and torque to 145 N•m (107 lbf•ft).
Position the armature plate on the crankcase,
aligning the marks on both parts. CAUTION: Never use any type of impact wrench
at magneto installation.
04-04-4 SMR2002-061_04_04A.FM
Ignition Timing Rotor and Ring Gear

For ignition timing procedures, refer to ENGINE Apply Loctite 648 (green) on mating surface of the
MANAGEMENT. rotor no. 8.
When reinstalling rotor to ring gear no. 3, one of
Magneto Housing Cover the protrusion end of rotor must be aligned with
Properly install O-ring no. 25 in magneto housing. Ap- hole in ring gear.
ply Loctite 767 anti-seize on screws no. 11, install
cover and wire support no. 12. Torque screws no. 11 1 2
in a criss-cross sequence to 9 N•m (80 lbf•in).
Stator and Trigger Coil/CPS
(Crankshaft Position Sensor)
Install the stator no. 9 and trigger no. 10 coil in engine
magneto cover. Torque screws to 9 N•m (80 lbf•in).
Reinstall wiring harness bracket no. 29 using tap-
tite screws no. 16.
Torque trigger coil screws no. 21 to 9 N•m (80 lbf•in).
Torque stator screws no. 20 to 13 N•m (115 lbf•in).
NOTE: The trigger coil is not adjustable.
F15D01A
1. Protrusion
2. Hole
Apply Loctite 648 (green) on screws no. 17 retain-

ing rotor to ring gear and torque screws in a criss-
cross sequence to 13 N•m (115 lbf•in).
Apply Loctite 243 (blue) on crankshaft taper.
F06D0NB 1 2 3
1. Torque to 9 N•m (80 lbf•in)
2. Taptite screws
3. Torque to 13 N•m (115 lbf•in)
Cover
Before installing cover, make sure oil pump shaft
is properly positioned.
Before installation, properly install O-ring no. 25 in F06D24A 1
engine magneto cover no. 1. 1. Loctite 243 (blue) on crankshaft taper
Apply Loctite 767 anti-seize compound on screws
Install flywheel and make sure to align keyway
no. 11. Torque screws in a criss-cross sequence
with the crankshaft Woodruff key.
to 9 N•m (80 lbf•in).
Apply Loctite 243 (blue) on nut no. 13. Install nut
with lock washer and torque to 115 N•m (85 lbf•ft).
CAUTION: Never use any type of impact wrench.
Unlock crankshaft. Reinstall pulse fitting with wash-
er and torque to 19 N•m (14 lbf•ft).
SMR2002-061_04_04A.FM 04-04-5
Cover
Before installation, properly install O-ring no. 25 in
engine magneto cover no. 1.
Apply Loctite 767 anti-seize compound on screws
no. 11. Torque screws in a criss-cross sequence
If heat exchanger cover has been removed, en-
sure to align its notch with the emboss in casing.
1
F12R0EA
1. Align notch with the emboss
04-04-6 SMR2002-061_04_04A.FM
Subsection 05 (TOP END)
TOP END 0
7
8 14 40 Nm
Loctite (30 lbfft)
243
Molykote 111
3
Engine oil
4
5
6
Engine oil
2
34
13
40 Nm
15 (30 lbfft) Molykote
111
3 Nm
18 (27 lbfin)
16 17 19 20 Loctite
243
9
Molykote 111 25
24 23 22
26 Loctite 243 10
10 Nm
(89 lbfin)
F12D0TS
SMR2002-062_04_05A.FM 04-05-1
GENERAL 4 5 3 1
The 2-stroke ROTAX engine rotates counterclock-
wise seen from the rear (PTO flywheel).
The 947 engine uses reed valves in the crankcase.
The engine is also equipped with the RAVE system
(Rotax Adjustable Variable Exhaust).
CAUTION: No engine components can be inter-
changed between engines.
RAVE System
(Rotax Adjustable Variable Exhaust)
BASIC OPERATION
The RAVE valves change the height of the exhaust
port. The RAVE valve solenoid, which is controlled by
the MPEM, allows a pressure from the air compres- 6
F12D06A 2
sor to inflate the bellows and open the RAVE valves.
1. Solenoid
To open the RAVE valves, the MPEM activates a so- 2. Pressure from air compressor
lenoid which directs the pressure from air compres- 3. Pressure to RAVE valves
4. Vent to air intake silencer
sor to the valves. 5. Check valve
6. Vent from counterbalancing shaft oil cavity
1
To close the RAVE valves, the MPEM deactivates the
solenoid which blocks the air compressor pressure.
The RAVE valves are opened to the atmosphere.
The vent on couterbalancing shaft oil cavity is neces-
sary to prevent pressure buildup in the cavity by the
air compressor piston movement. The check valve al-
lows pressure to escape from the cavity but does not
allow liquid to enter into the cavity.
F12D02A
1. Pressure from solenoid
04-05-2 SMR2002-062_04_05A.FM
MAINTENANCE
3 There are no wear parts anywhere in the system
2
and there are no adjustments to be periodically
checked. The only possible maintenance required
4 would be cleaning of carbon deposits from the
guillotine slide. Cleaning intervals would depend
upon the user’s riding style and the quality of the
oil used. We suggest annual cleaning of the valve.
If a customer uses a lower quality oil, than recom-
mended, more frequent cleaning may be required.
No special solvents or cleaners are required when
cleaning the valve.
BORING PRECAUTION
In its stock configuration the RAVE valve guillotine
has a minimum of 0.5 mm (.020 in) clearance to the
cylinder bore measured at the center line of the cyl-
1 inder. This is the minimum production clearance.
F12D04A
There is only a first oversize piston available. That pis-
RAVE VALVE OPENED
ton is 0.25 mm (.010 in) larger in diameter than the
1. Pressure from air compressor
2. Solenoid activated stock piston. When the oversize is installed, the guil-
3. Pressure to solenoid lotine will have a minimum clearance of 0.375 mm
4. Pressure to RAVE valves
(.015 in) with the cylinder bore. This is the minimum
operating clearance the guillotine should be used
3 with. Clearance less than 0.375 mm (.015 in) will re-
2 quire reworking of the guillotine to achieve the proper
clearance and radius.
4
DISASSEMBLY
6
RAVE Valve
Loosen Allen screws no. 26 each side of RAVE valve.
7
1
F12D05A
RAVE VALVE CLOSED

1. Pressure from air compressor
2. Solenoid deactivated
3. Pressure to solenoid
4. Pressure to RAVE valves blocked by the solenoid
5. Vent to air intake silencer
6. Check valve
7. Counterbalancing shaft oil cavity vent
F12D0UA 1 1
1. Remove screws
SMR2002-062_04_05A.FM 04-05-3
Remove RAVE valve no. 15. Unscrew valve piston no. 20 from sliding valve
Remove the cover no. 18 of the valve by releasing no. 22.
the spring no. 16. NOTE: Hold the sliding valve to prevent it from
turning.
 WARNING 2
Firmly hold cover to valve base. The com-
pression spring inside the valve is applying
pressure against the cover.
F12D0XA 1
1. Unscrew piston
F12D0VA 1 2. Hold sliding valve
1. Spring Remove sliding valve from valve housing.

Remove the compression spring no. 19.
F12D0YA 1 2 3
1. Valve piston
2. Valve housing
3. Sliding valve
Cylinder Head Cover and Cylinder Head

Disconnect temperature sensor wire and spark
plug cables.
F12D0WA 1
Connect spark plug cables on grounding device.
1. Remove spring
Disconnect hose of RAVE valves.
Remove air/fuel rail. Refer to ENGINE MANAGE-
MENT.
Use Snap-On Torx socket E12 and unscrew cylin-
der head screws no. 14 following the sequence
shown in the next illustration.
04-05-4 SMR2002-062_04_05A.FM
To extract piston pin no. 4, use piston pin puller

1 (P/N 529 035 503) with the appropriate set of
5
2 11 sleeves.
10 8 ENGINE SLEEVE SET

6 9
12 947 DI P/N 529 035 543
4
7 1 2 3
3
F12D08B
Remove cylinder head no. 2 and gasket no. 34.
Cylinder
NOTE: When removing cylinder, be careful that
connecting rods do not hit crankcase edge.
Remove cylinders screws then cylinders no. 9.
F00B0IA
Piston
1. Puller
NOTE: All engines feature cageless piston pin 2. Shoulder sleeve
3. Sleeve
bearings.
To remove circlip no. 5, insert a pointed tool in pis- – Fully thread on puller handle.
ton notch then pry it out and discard. – Insert extractor spindle into the piston pin.
– Slide the sleeve and shoulder sleeve onto the
 WARNING spindle.
Always wear safety glasses when removing – Screw in extracting nut with the movable ex-
piston circlips. tracting ring towards spindle.
1 2 3 4
F00B0JA
1. Puller
2. Sleeve
F01D0PA 3. Shoulder sleeve
4. Extracting nut
TYPICAL
1. Piston notch
SMR2002-062_04_05A.FM 04-05-5
NOTE: The tool cutout must be positioned toward

1
the bottom of the piston.
F00B0MA
1. Remove shoulder sleeve

F00B0KA 1
1. Tool cutout toward bottom of piston
– Carefully remove the piston no. 3.
– The needles, thrust washers and the sleeve re-
– Firmly hold puller and rotate handle to pull pis- main in the connecting rod bore and may be
ton pin no. 4. used again.
– Rotate spindle until the shoulder sleeve is
flushed with the piston recess. 1 2
F00B0NA
1. Needles and thrust washer

2. Sleeve
F00B0LA
CLEANING
1. Shoulder sleeve flush with piston recess
Discard all gaskets and O-rings.
– Loosen the extracting nut and remove puller. Clean all metal components in a solvent.
– Remove the shoulder sleeve from piston. Clean water passages and make sure they are not
clogged.
Remove carbon deposits from cylinder exhaust
port, RAVE valve, cylinder head and piston dome.
Clean piston ring grooves with a groove cleaner
tool, or a piece of broken ring.
04-05-6 SMR2002-062_04_05A.FM
INSPECTION
Visually inspect all parts for corrosion damage.
Inspect piston for damage. Light scratches can be
sanded with a fine sand paper.
NOTE: When repairing a seized engine, connecting
rods should be checked for straightness and crank-
shaft for deflection/misalignment. Refer to BOTTOM
END for procedures.
Inspect plane surfaces for warpage. Small deforma- 1
tion can be corrected by grinding surface with a fine
sand paper. Install sand paper on a surface plate and A
rub part against oiled sand paper.
The inspection of engine top end should include
the following measurements.
TOLERANCES
ENGINE 2
NEW PARTS WEAR F01D8AA
MEASUREMENT
(min.) (max.) LIMIT 1. Measuring perpendicularly (90°) to piston pin axis
2. Auxiliary transfer port
0.05 mm 0.1 mm A. 16 mm (5/8 in)
Cylinder taper N.A.
(.002 in) (.004 in)
0.08 mm 0.08 mm Cylinder Out of Round
Cylinder out of round N.A.
(.003 in) (.003 in) Using a cylinder bore gauge, measure cylinder di-
Piston/cylinder wall 0.12 mm 0.20 mm ameter at 16 mm (5/8 in) from top of cylinder. Mea-
N.A.
clearance for the (.0047 in) (.008 in) sure diameter in piston pin axis direction then per-
Ring/piston groove 0.044 mm 0.089 mm 0.20 mm pendicularly (90°) to it. If the difference between
clearance for the (.002 in) (.003 in) (.008 in) readings exceed specification, cylinder should be
rebored and honed or replaced.
0.55 mm 0.70 mm 1.1 mm
Ring end gap for the
(.022 in) (.028 in) (.043 in)
N.A.: Not Applicable
NOTE: Replacement cylinder sleeves are available if

necessary. Also, oversize pistons of 0.25 mm (.010 in)
are available for all engines and oversize pistons of
0.5 mm (.020 in) are available for the 717 engine.
Cylinder Taper
Using a cylinder bore gauge, measure cylinder diam-
eter at 16 mm (5/8 in) from top of cylinder just below A A
auxiliary transfer port, facing exhaust port and just be- 2
low the auxiliary transfer port facing the exhaust port.
Compare readings. If the difference between read-
ings exceed specification, cylinder should be rebored
and honed or replaced.
F01D8BA
1. Measuring in piston pin axis

2. Measuring perpendicularly (90°) to piston pin axis
A. 16 mm (5/8 in)
SMR2002-062_04_05A.FM 04-05-7
USED PISTON MEASUREMENT The measured dimension must not be less than
0.12 mm (.005 in) of the one scribed on piston
Note the measurement on the piston dome. dome. Otherwise, install a new piston.
Piston/Cylinder Wall Clearance

Used and New Pistons
IMPORTANT: Make sure used piston is not worn
more than specified. See USED PISTON MEA-
SUREMENT above.
To determine the piston dimension, take the mea-
surement on the piston dome.
F00D0EA 2 1
1. Piston dome
2. Piston measurement
Using a micrometer, measure piston skirt perpen-

dicularly (90°) to piston pin according to the follow-
ing table.
MAXIMUM A
ENGINE TYPE
mm (in)
F00D0EA 2 1
947 DI 24 (.945)
1. Piston dome
2. Piston measurement
Adjust and lock a micrometer to the specified val-

ue on the piston dome.
A 1
1
F01D0NA
F00B08A

A. See previous table 1. Micrometer set to the piston dimension
With the micrometer set to the piston dimension,

MAXIMUM PISTON adjust a cylinder bore gauge to the micrometer di-
ENGINE TYPE SKIRT WEAR
mm (in)
mension and set the indicator to zero.
All 0.12 (.005)
04-05-8 SMR2002-062_04_05A.FM
Read the measurement on the cylinder bore gauge.

The result is the exact piston/cylinder wall clearance.
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.
2 1
Ring/Piston Groove Clearance
F00B09A
1. Use the micrometer to set the cylinder bore gauge

2. Dial bore gauge
1 2
F01D0XA
1. Feeler gauge
2. Rectangular ring (bottom)
Due to the semi-trapez rings, it is not possible to

accurately measure ring/piston groove clearance.
Ring End Gap

Position ring halfway between exhaust port and
top of cylinder.
1
NOTE: In order to correctly position ring in cylin-
der, use piston as a pusher.
F00B0AA
Using a feeler gauge, check ring end gap. If gap

1. Indicator set to zero
exceeds specified tolerance, rings should be re-
Position the dial bore gauge at 16 mm (5/8 in) be- placed.
low cylinder top edge.
2
A
F01D0OA 1
F01D0KA
1. Top of cylinder
2. Ring end gap
A. 16 mm (5/8 in)
SMR2002-062_04_05A.FM 04-05-9
Cylinder Base Gasket

NOTE: The general procedure is to install a new
gasket of the same thickness. However, if you do
not know the gasket thickness that was installed
or if a crank repair has involved replacement of
connecting rods, refer to the COMBUSTION CHAM-
BER VOLUME MEASUREMENT to properly deter-
mine the required gasket thickness.
Different thicknesses of cylinder base gaskets are
used for a precise adjustment of the combustion
chamber volume. F12D0ZA 1
To identify gasket thickness, refer to the identifi- 1. Piston valve O-ring
cation holes on the gasket. Check the sliding valve O-ring. Replace if neces-
sary.
1
F01D67A
TYPICAL
1. Identification holes
F12D10A 1
GASKET IDENTIFICATION
1. Sliding valve O-ring
THICKNESS HOLES
Check the O-ring under valve housing. Replace if
0.3 MM (.012 IN) 3 necessary.
0.4 MM (.016 IN) 4
0.5 MM (.020 IN) 5
0.6 MM (.024 IN) 6

0.8 MM (.031 IN) 8
ASSEMBLY
Assembly is essentially the reverse of disassem-
bly procedures. However pay particular attention
to the following.
Check the piston valve O-ring. Replace if neces-
sary.
F12D11A 1
1. Valve housing O-ring
04-05-10 SMR2002-062_04_05A.FM
There is only one way to insert the sliding valve – Replace the inner halves by the appropriate
no. 22 in valve housing no. 25. sleeve tool in the connecting rod bore.
– Insert piston pin into piston until it comes flush
with inward edge of piston hub.
– Warm piston to approximately 50 - 60°C (122 -
140°F) and install it over connecting rod.
NOTE: Make sure thrust washers are present each
side of needles.
– Install the shoulder sleeve tool on the opposite
1 side of the piston pin.
1 2
F06D12A
1. Sliding valve ridge toward housing groove
Piston
At assembly, place the pistons no. 3 with the let-
ters “AUS” (over an arrow on the piston dome)
facing in direction of the exhaust port.
F00B0OA
1. Piston pin
2. Shoulder sleeve
1
AUS – Insert extractor spindle into the piston pin,
screw on extracting nut.
2 1
A01C01A
1. Exhaust side
NOTE: The exhaust ports are located on the same

side as the intake.
Carefully cover crankcase opening as for disas-
sembly.
Piston Pin and Roller Bearing F00B0PA
To install roller bearing no. 6 and piston pin no. 4

1. Puller installed on the opposite side of the piston pin
use, piston pin puller (P/N 529 035 503) with the 2. Tighten extracting nut
appropriate set of sleeves as for disassembly.
– Rotate handle to pull piston pin carefully into the
– Replacement bearings are held in place by a lo- piston.
cating sleeve outside and 2 plastic cage halves
inside.
– Push needle bearing together with inner halves
out of the locating sleeve into the connecting
rod bore.
SMR2002-062_04_05A.FM 04-05-11
Plastic Mounting Device Method – Insert piston pin into piston until it comes flush
This is an alternate method when no service tool with inward edge of piston hub.
is available.
Replacement roller bearings are delivered in a con-
venient plastic mounting device. For installation,
proceed as follows: 1
– Align replacement roller bearing with connect-
ing rod bore.
– Carefully push inner plastic sleeve into connect-
ing rod bore; outer plastic ring will release rollers.
2
1
F01D0RA
1. Piston pin flush here

2. Thrust washers
– Place piston over connecting rod and align

bores, then gently tap piston pin with a fiber
hammer to push out inner plastic ring on oppo-
site side. Support piston from opposite side.
F01D0QA
1. Outer ring removal after inner sleeve insertion into bore
– Make sure thrust washers are present each

side of rollers.
F01D0SA
1
– As necessary, pull halves of inner sleeve with
long nose pliers.
F01D0VA
1. Thrust washer each side
04-05-12 SMR2002-062_04_05A.FM
F06B01A 1
1 1. Circlip installer
– Remove sleeve from pusher then insert circlip

into its bore.
– Reinstall sleeve onto pusher and push until cir-
clip comes in end of tool.
F01D0TA 1
1. Pulling inner sleeve half
Circlip
Always use new circlips.
 WARNING
Always wear safety glasses when installing
F00B0QA
piston circlips.
TYPICAL
CAUTION: Always use new circlips. At installa- 1. Circlip near end of tool
tion, take care not to deform them. Circlips – Position end of tool against piston pin opening.
must not move freely after installation.
– Firmly hold piston against tool and tap tool with
Secure circlip in piston groove with its bent end in a hammer to insert circlip into its groove.
piston notch as shown.
1
F00B0RA
F07D0AB
1. Circlip end in piston notch CAUTION: The hand retaining the piston should
To easily insert circlip into piston, use circlip installer. absorb the energy to protect the connecting rod.
ENGINE TOOL P/N

947 DI 529 035 563
SMR2002-062_04_05A.FM 04-05-13
Cylinder Base Gasket NOTE: For each ring, make sure to align ring end
gap with piston locating pin.
Install new base gasket.
Install cylinder block.
NOTE: The general procedure is to install a new
gasket of the same thickness. However, if you do
not know the gasket thickness that was installed
Cylinder Screw
or if a crankshaft and/or crankcase repair or re- Apply Molykote 111 below the screw head.
placement was involved, refer to the COMBUS- The blue coating underneath the cylinder screw
TION CHAMBER VOLUME MEASUREMENT to head can be only used once. Either replace with
properly determine the required gasket thickness. new bolts or remove blue coating and apply Loc-
Five thicknesses of cylinder base gaskets are tite 243 (blue) below the screw heads.
available for a precise adjustment of the squish Install and torque screws to 40 N•m (30 lbf•ft) in the
gap. indicated order. Refer to the following illustration.
To identify gasket thickness, refer to the identifi-
cation holes on the gasket.
Cylinder Block 7 3
2 5
Install cylinder base gasket no. 10. There is only
one way to install gasket.
The cylinder block is positioned with locating dowels.
Line up dowels with corresponding holes in cylin-
der block.
6 4 1 8
1
F12D07A
Cylinder Head
Install cylinder head gasket.
Apply Loctite 243 (blue) (P/N 293 800 060) below
head of cylinder head bolts no. 14.
Apply Molykote 111 on threads of cylinder head
bolts no. 14.
Torque bolts to 20 N•m (15 lbf•ft) as per following
sequence in the next picture. Repeat the torquing
sequence by retightening to 40 N•m (30 lbf•ft).
F02D0UA 1
1. Dowels 12
2 8
To easily slide cylinder block over pistons, use ring 11 3
compressor (P/N 290 876 965).
7 4
1 5
6 9
10
A01B1TA 1 F12D08A
1. Slide this edge
04-05-14 SMR2002-062_04_05A.FM
Combustion Chamber Volume 3. Open burette valve to fill its tip. Add liquid in
Measurement burette until level reaches 0 cc.
NOTE: This procedure is required to determine 4. Inject the burette content through direct injec-
the thickness of the cylinder base gasket to be in- tor hole until liquid touches the top hole.
stalled if a crank repair has involved replacement
of connecting rods or if you are experiencing re-
petitive engine seizure.
The combustion chamber volume is the region in
the cylinder head above the piston at Top Dead
Center. It is measured with the cylinder head in-
stalled on the engine.
F00D0HA 1
1. Top of spark plug hole
F01D5VA
NOTE: The liquid level in cylinder must not drop
1. Combustion chamber
for a few seconds after filling. If so, there is a leak
NOTE: When checking the combustion chamber between piston and cylinder. The recorded vol-
volume, engine must be cold, piston must be free ume would be false.
of carbon deposit and cylinder head must be lev- 5. Let burette stand upward for about 10 minutes,
eled. until liquid level is stabilized.
1. Remove both direct injectors and bring one pis- 6. Read the burette scale to obtain the quantity of
ton to Top Dead Center using a TDC gauge. liquid injected in the combustion chamber.
Keep spark plugs in their holes.
Compare the obtained value with the table below.
2. Obtain a graduated burette (capacity 0 - 50 cc) The volume should be within the allowable range.
and fill with an equal part (50/50) of gasoline and
If the volume of the combustion chamber is not
injection oil.
within specifications, change cylinder base gasket
thickness as follow.
A higher volume dictates a thinner gasket.
A lower volume dictates a thicker gasket.
COMBUSTION CHAMBER
ENGINE
VOLUME
1
947 DI 45.7 - 48.4 cc
7. Repeat the procedure for the other cylinder(s).
F00B0BA
1. Graduated burette (0 - 50 cc)
SMR2002-062_04_05A.FM 04-05-15
Subsection 06 (BOTTOM END)
BOTTOM END 0
1.5 Nm
(13 lbfin)
28 Loctite
243
29
Loctite 243
30 9 Nm
(80 lbfin) 2
Molykote
111
6 Molykote
Loctite 111
243 14
6
5 16
4 15 17 13
Anti-seize Molykote
4 lubricant 31 111
32
7 Nm Loctite 243 15 Engine
(62 lbfin) Anti-seize oil
6
lubricant Molykote
Loctite
243 3 111
6 13
9 2 1 Loctite
Molykote 648
24 111 4
Loctite Synthetic 6.5 Nm
5910 grease (58 lbfin)
25 4 22 20 Loctite
27 648
5
23
Loctite 21
Loctite 243
518 115 Nm 23 Nm
7 (17 lbfft)
7 (85 lbfft)
Molykote 7
111 27 Nm 27 Nm
8 (20 lbfft)
(20 lbfft) 20 Nm
(15 lbfft)
8 40 Nm
Anti-seize (30 lbfft)
lubricant
6.5 Nm
F12D12S
(58 lbfin)
SMR2002-063_04_06A.FM 04-06-1
DISASSEMBLY Loosen bolt no. 22 retaining the PTO flywheel to the

crankshaft using a suitable socket and breaker bar.
Engine has to be removed from watercraft and top
end has to be disassembled to open bottom end. 3
Refer to REMOVAL AND INSTALLATION and TOP
END.
PTO Flywheel
Use PTO flywheel remover (P/N 295 000 001) to
hold flywheel and remove Allen screws no. 21 re-
taining coupler no. 20 to PTO flywheel.
F06D38A 2 1
F01J0TA 1. Puller plate
2. Extension handle
PTO FLYWHEEL REMOVER TOOL 3. Loosen bolt with socket and breaker bar
Remove the PTO flywheel using puller plate (P/N

529 035 533) and puller (P/N 529 035 547) and bolt
(P/N 529 035 549).
F06D37A 2 1
1. Loosen Allen screws
2. Breaker bar locking crankshaft F06D39A 4 3 1 2
Remove the coupler no. 20. 1. Puller plate
2. Puller
Install puller plate (P/N 529 035 533) and extension 3. Bolt
4. Extension handle
handle (P/N 295 000 125) to PTO flywheel.
NOTE: Puller plate can be used without the exten-
sion handle.
04-06-2 SMR2002-063_04_06A.FM
Starter Drive Assembly

Loosen 2 Allen screws no. 24 retaining starter
drive cover no. 25.
F06D0JA 1
1. Carburetor flange
Remove reed valves no. 28 from crankcase.
F06D1CA 2 1 Crankcase
1. Cover Before opening the bottom end, remove the fol-
2. Allen screw lowing parts:
Remove starter drive cover no. 25 and spring no. 9. – magneto flywheel
Remove starter drive assembly no. 27. (refer to MAGNETO SYSTEM subsection)
– starter
– starter drive assembly
– reed valves
– air compressor cover
Place engine upright on crankcase magneto side.
Loosen crankcase screws.
F06D1DA 1
1
1. Starter drive assembly
Reed Valve 1
Remove both carburetor flanges.
2
F07D09D
1. M8 x 45 flanged screws
2. M10 x 73.5 flanged screws
SMR2002-063_04_06A.FM 04-06-3
Put engine back on a support. Insert a pry bar be-

tween crankcase lugs to separate halves.
CAUTION: Be careful to precision machined sur-
faces.
1
F01D1KA
F06D1GA 1
TYPICAL
TYPICAL
1. Separate halves by prying at provided lugs
1. End seal
To remove end bearings from crankshaft, use the

following tools.
6 1 3 4 5
2
F06B03A 6
1 1. Puller (P/N 420 877 635)
2. Protective cap (P/N 290 877 414)
3. Distance ring (P/N 420 876 569)
F01D1LA 4. Ring (P/N 420 977 480)
5. Ring halves (P/N 420 876 330)
TYPICAL 6. Screw (P/N 420 940 755)
1. Separate halves by prying at provided lugs
Remove crankshaft and counterbalance shaft.

Open air compressor and disconnect the piston as
described in ENGINE MANAGEMENT. 1
Crankshaft Bearing and Seal

If a crankshaft end seal no. 5 has to be replaced,
bottom end must be opened.
NOTE: Do not needlessly remove crankshaft bear-
ings.
Remove end seal(s).
F01D1OA
TYPICAL
1. Removing crankshaft bearing
04-06-4 SMR2002-063_04_06A.FM
Or, use a bearing extractor such as Proto no. 4332 CLEANING

and a press to remove two bearings at a time.
Discard all oil seals, gaskets, O-rings and sealing
rings.
Clean oil passages and make sure they are not
1 clogged.
Clean all metal components in a solvent.
Crankcase mating surfaces are best cleaned using
a combination of the chisel gasket remover (P/N
413 708 500) and a brass brush. Brush a first pass
in one direction then make the final brushing per-
pendicularly (90°) to the first pass cross (hatch).
CAUTION: Do not wipe with rags. Use a new clean
hand towel only.
F01D1PA
2
1. Press bearings out

2. Bearing extractor
Counterbalance Shaft
Use a press to remove counterweights no. 16 and
bearings no. 15.
CAUTION: There is no woodruff key to position
the counterweights. An index mark must be traced
to retain the proper position of the counterweight.
F00D2BA
F06D1HA 1
1. Trace an index mark
Remove seals no. 17.

Remove bearing no. 31 and washer no. 32.
F00D2CA
Use a press to remove gear no. 14.
FIRST PASS
SMR2002-063_04_06A.FM 04-06-5
F01D1NA 1
1. Main journal alignment here
To accurately check if crankshaft is twisted on cen-

ter main journal, proceed as follows:
F00D2DA
– Remove magneto housing cover.
SECOND PASS
– Remove flywheel nut and magneto rotor. Refer
Finish the cleaning with acetone. to MAGNETO SYSTEM for procedures.
CAUTION: Ensure to clean compressor lubrica- – Install Bombardier degree wheel (P/N 529 035
tion nipple. 607) on crankshaft end. Hand-tighten nut only.
CAUTION: Be careful not to spray cleaner on – Remove both spark plugs.
the painted surface of the engine.
– Install a TDC gauge in spark plug hole on MAG
CAUTION: Never use a sharp object to scrape side.
away old sealant as score marks incurred are
– Bring MAG piston at Top Dead Center.
detrimental to crankcase sealing.
– As a needle pointer, secure a wire with a cover
INSPECTION screw and a washer.
– Rotate degree wheel (NOT crankshaft) so that
Assembled Engine needle pointer reads 360°.
The following checks can be performed with en-
gine in watercraft without overhauling engine.
Crankshaft Alignment at Center Main

Journal
Since it is an assembled crankshaft it can become
misaligned or deflected. Crankshaft can be twist-
ed on center main journal, changing timing of one
cylinder in relation with the other.
04-06-6 SMR2002-063_04_06A.FM
Such misalignment may cause a crankshaft hard

to be manually turned. Verification can be done by
1 measuring deflection each end of crankshaft.
If deflection is found greater than specified toler-
ance, this indicates worn bearing(s), bent and/or
2 disaligned crankshaft. Proceed with the disassem-
bly of the engine.
Disassembled Engine
The following verifications can be performed with
3 the engine disassembled.
4 Crankcase
Inspect plane surfaces for warpage. Small defor-
mation can be corrected by grinding surface with
a fine sandpaper. Install sandpaper on a surface
plate and rub part against oiled sand paper.
Bearing
F01D4IA
Inspect crankshaft bearings no. 4. Check for cor-
TYPICAL rosion, scoring, pitting, chipping or other evidence
1. TDC gauge of wear. Make sure plastic cage is not melted. Ro-
2. Degree wheel
3. Hand tighten nut tate and make sure they turn smoothly.
4. Needle pointer
– Remove TDC gauge and install on PTO side. Crankshaft

– Bring PTO piston at Top Dead Center. NOTE: If crankshaft and/or components are found
defective, it must be repaired by a specialized
Interval between cylinders must be exactly 180°
shop or replaced.
therefore, needle pointer must indicate 180° on
degree wheel (360° - 180° = 180°). Connecting Rod Straightness
Any other reading indicates a misaligned crank- Align a steel ruler on edge of small end connecting
shaft. rod bore. Check if ruler is perfectly aligned with
edge of big end.
Crankshaft Alignment at Connecting
Rod Journal 1
Counterweights can also be twisted on connect-
ing rod journal on any or both cylinder(s).
F01D1Q A 2
1. Ruler must be aligned with edge of connecting rod here
2. Align ruler here
F01D1NB 1
1. Connecting rod journal alignment here
SMR2002-063_04_06A.FM 04-06-7
Crankshaft Deflection
MEASUREMENT MAG SIDE PTO SIDE

Crankshaft 0.050 mm 0.030 mm 1
deflection (max.) (.002 in) (.001 in)
Crankshaft deflection is measured each end with

a dial indicator.
First, check deflection with crankshaft in crank-
case. If deflection exceeds the specified toler-
ance, it can be either ball bearings wear, bent or
twisted crankshaft at connecting rod journal.
F01D97A
1. Measuring MAG side deflection on V-shaped blocks
F01D1SA
1. Measuring PTO side deflection in crankcase
F01D98A
1. Measuring PTO side deflection on V-shaped blocks
NOTE: Crankshaft deflection cannot be correctly

measured between centers of a lathe.
Connecting Rod Big End Axial Play
CONNECTING ROD BIG END AXIAL PLAY

F01D1TA
NEW PARTS WEAR
1. Measuring MAG side deflection in crankcase MODEL
(min.) (max.) LIMIT
Remove crankshaft bearings and check deflection
0.390 mm 0.737 mm 1.2 mm
again on V-shaped blocks as illustrated. 947 DI engine
(.015 in) (.029 in) (.047 in)
04-06-8 SMR2002-063_04_06A.FM
Using a feeler gauge, measure distance between

thrust washer and crankshaft counterweight.
F01J0ZA
1
Close puller claws so that they can be inserted in
end bearing. Holding claws, turn puller shaft clock-
wise so that claws open and become firmly tight
against bearing.
Slide puller hammer outwards and tap puller end.
Retighten claws as necessary to always maintain
them tight against bearing. Continue this way until
bearing completely comes out.
For installation, see below in this section.
2
F01D1WA Reed Valve
1. Measuring big end axial play Check reed valve petals no. 29 for cracks or other
2. Feeler gauge
defects. The reed petals must lie completely flat
Starter Drive Bearing against the reed valve body no. 30. To check, hold
against light.
Check bearing no. 23 of starter drive assembly
no. 27 in crankcase.
F06D1IA 1 F06D1JA 1
1. Bearing of starter drive assembly 1. No play
Removal In case of a play, turn reed petals upside down and
Starter drive bearing can be easily removed from recheck. If there is still a play, replace petals.
lower crankcase half using the following suggest- Check perfect condition of rubber coating on reed
ed tool or equivalent: valve body.
– Snap-on hammer puller including:
– handle CJ93-1
– hammer CJ125-6
– claws CJ93-4.
SMR2002-063_04_06A.FM 04-06-9
Check stopper distance from center of reed valve To properly position the outer bearing(s), a dis-
block. tance gauge must be temporarily installed against
the inner bearing. Slide the outer bearing until
stopped by the distance gauge, then remove it.
ENGINE DISTANCE GAUGE

P/N 529 035 100 (MAG)
947 DI
P/N 529 035 000 (PTO)
F01B0HA
F06D1EA
1. Distance gauge
A. 13 ± 0.25 mm (.512 ± .010 in)
NOTE: Distance should be the same on both sides. 1

Bent stopper as required to obtain the proper dis-
tance.
Air Compressor
Refer to ENGINE MANAGEMENT for compo-
nents inspection. However, if you find aluminum
dust or debris in this area, they may have flowed
toward the injection oil reservoir. In this case, the
oil reservoir and lines must be flushed and the fil- 2
ter replaced.
CAUTION: Failure to properly clean the oil sys-
tem will result in serious engine damage. F01D1YA
TYPICAL
ASSEMBLY 1. Distance gauge
2. Outer bearing
bly procedures. However pay particular attention Distance Ring
to the following.
When installing the distance ring no. 12, make
NOTE: It is recommended to spray BOMBARDIER- sure to position it with its chamfer toward the
ROTAX injection oil on all moving parts when re- counterweight of the crankshaft.
assembling the engine.
Crankshaft Seal
Crankshaft and Bearing
When installing seal assembly no. 5, apply a light
Apply Loctite 767 anti-seize on part of crankshaft coat of lithium grease on seal lips.
where bearing fits.
Seals are positioned with the outer lip in the crank-
Prior to installation, place bearings no. 4 into a case recess.
container filled with oil, previously heated to 75°C
(167°F). This will expand bearing and ease instal-
lation.
04-06-10 SMR2002-063_04_06A.FM
1
Crankshaft and Counterbalance Shaft
Install crankshaft no. 3 first in crankcase.
After crankshaft installation, install counterbal-
ance shaft no. 13. Make sure to properly index
crankshaft and counterbalance shaft by aligning
marks of gears.
CAUTION: Marks on the crankshaft and coun-
terbalance shaft must be aligned, otherwise en-
gine will vibrate and premature wear will occur.
F06D1LA
1. Seal lip in crankcase recess
Drive Pin
Make sure drive pins no. 6 of bearings are proper-
ly installed in crankcase recesses at assembly.
1
F06D1MA 1
1. Marks must be aligned
Turn by hand the crankshaft and counterbalance

shaft. Make sure they do not interfere with the
crankcase.
Properly position bearing no. 31 and washer
no. 32. Ensure to position lubrication hole on top
(if so equipped).
F00D0OA
1. Drive pins
Counterbalance Shaft
Install bearing no. 31 and washer no. 32.
When installing seals no. 17, apply a light coat of
Molykote 111 on seal lips.
Prior to installation, place bearings no. 15 into a
container filled with oil, previously heated to 75°C
(167°F). This will expand bearings and ease their F12R16A 3 2 1
installation.
1. Bearing
Reinstall counterweights no. 16 using a press and 2. Washer in crankcase groove
3. Lubrication hole on top (if so equipped)
take care to align index marks previously traced.
SMR2002-063_04_06A.FM 04-06-11
Place seals no. 17 in their respective positions. CAUTION: Do not use Loctite 515 or 518 to seal
crankcase. Do not use Loctite Primer N with the
Loctite 5910. Using these products or non silicone-
based sealant over a previously sealed crankcase
with Loctite 5910 will lead to poor adhesion and
possibly a leaking crankcase. These products are
chemically incompatibles. Even after cleaning, the
Loctite 5910 would leave incompatible microscos-
pic particules.
Use a plexyglass plate and apply some sealant on
it. Use a soft rubber roller (50 - 75 mm (2 - 3 in))
(available in arts products suppliers for printmak-
ing) and roll the sealant to get a thin uniform coat
on the plate (spread as necessary). When ready,
apply the sealant on crankcase mating surfaces.
F06D1OA 1
1. Seal in place
Air Compressor
Refer to ENGINE MANAGEMENT for procedures.
Crankcase
Crankcase halves are factory matched and there-
fore, are not interchangeable or available as single
halves.
Add 40 mL (1.35 oz) of Sea-Doo synthetic jet
pump oil (P/N 293 600 011) or standard gear oil in
the counterbalance shaft gear cavity.
CAUTION: Using different type of oil may re- F12R17A
duce engine component life.
IMPORTANT: When beginning the application of
the crankcase sealant, the assembly and the first
torquing should be done within 10 minutes. It is
suggested to have all you need on hand to save
time.
NOTE: It is recommended to apply this specific
sealant as described here to get an uniform appli-
cation without lumps. If you do not use the roller
method, you may use your finger to uniformly dis-
tribute the sealant (unlike the Drei Bond sealing
compound, using a finger will not affect the adhe-
sion).
Use the silicone-based Loctite 5910 (P/N 293 800 F12R18A
081) on mating surfaces.
NOTE: The sealant curing time is similar to the Do not apply in excess as it will spread out inside
Loctite 518 without using the Primer N. crankcase.
CAUTION: If sealant spread out inside air com-
pressor area, it could plug the compressor lu-
brication nipple and serious compressor dam-
age may occur.
04-06-12 SMR2002-063_04_06A.FM
NOTE: Do not use Loctite Primer N with this seal-

ant. The sealant curing time is similar to the Loc- 10
9
tite 518 without using the Primer N, which is 4 to
24 hours. 8
7
Make sure all locating dowels are in place.
3 4
1 2
5 6
11
12
F07D09C
F06D1PA 1
1. Dowel
Starter Drive Bearing
To install bearing no. 23 of starter drive assembly,
Crankcase Screws use pusher (P/N 290 876 502) and handle (P/N 420
Apply Molykote 111 below head of screws and 877 650).
Loctite 518 on threads.
Torque crankcase screws to 12 N•m (106 lbf•in)
as per following sequence. Repeat procedure, re-
1
tightening all screws to 27 N•m (20 lbf•ft).
10
9 24
8
7
21 2
20 F06D32A
14
4 1. Handle
3 15 2. Pusher
1 13 PTO Flywheel
2
Apply Loctite 243 (blue) on bolt no. 22.
16 17
18 Using the same tools as for disassembly proce-
5 6 dure, torque bolt no. 22 to 115 N•m (85 lbf•ft).
19 Apply Loctite 648 on mating surface of PTO fly-
11 23 wheel and coupler.
22 12 Apply Loctite 243 (blue) to Allen screws no. 21 of
F07D09E coupler and torque to 23 N•m (17 lbf•ft).
As a final step, torque only the M10 x 73.5 bolts Final Assembly
to 40 N•m (30 lbf•ft) as per following sequence.
Add approximately 10 mL (.3 oz) of injection oil in
bottom of crankcase for each cylinder. This will give
an additional lubrication for the first engine startup.
SMR2002-063_04_06A.FM 04-06-13
Subsection 07 (EXHAUST SYSTEM)
EXHAUST SYSTEM 0
48 Nm 9 15 5 25 Nm
(35 lbfft) 14 Nm (18 lbfft)
(124 lbfin)
19
7 4
10 RTV sealant
16 22 12-13 18
14
6
40 Nm
(30 lbfft)
48 Nm 25 Nm
(35 lbfft) (18 lbfft) 21
19
8 9
18
Loctite 243
1 4 Nm 20
(35 lbfin)
40 Nm
(30 lbfft)
3
2 1 1
Ultra Cooper
sealant
11
Silicone
sealant
Body
RTV
RTV sealant
F18D2JS
sealant
SMR2002-065_04_07A.FM 04-07-1
REMOVAL Tuned Pipe Removal with Separation from

Tuned Pipe Head and Tuned Pipe Cone
Remove seat(s).
1. Disconnect water return hose at tuned pipe
Remove rear vent hose support from body opening. head no. 10.
F06L0WA 1
F06E08A 1
TYPICAL
1. Rear vent hose support 1. Water return hose
Remove seat support. 2. Disconnect small hose from water outlet fitting
at the tuned pipe head no. 10.
2
F06E09A 1
F07L1KA 2 1
1. Disconnect hose from outlet fitting
TYPICAL
1. Seat support
2. Remove screws
To remove this tuned pipe, there are 2 possible

ways to proceed.
The first procedure separates the tuned pipe head
from the tuned pipe cone, using the following pro-
cedure. The second procedure removes the tuned
pipe without tuned pipe head and tuned pipe cone
separation. This procedure is explained further.
04-07-2 SMR2002-065_04_07A.FM
3. Disconnect the water injection hose at tuned 5. Loosen clamp no. 1 retaining exhaust hose no. 3
pipe head no. 10. to tuned pipe cone no. 5.
1
F06E0AA 1 F06D14A
1. Water injection hose TYPICAL

1. Loosen clamp
4. Disconnect the water bleed hose.
6. Loosen and remove clamp no. 4 retaining tuned
pipe head no. 10 to tuned pipe cone no. 5.
F06E0BA 1
1. Water bleed hose 1
F06D1SA
1. Loosen and remove clamp
SMR2002-065_04_07A.FM 04-07-3
7. Loosen Allen screw retaining carburetor brack-

et to tuned pipe head.
F06D1UA 1
1. Remove bolt
F06D3JA 1
11. Remove tuned pipe head no. 10.
1. Loosen Allen screw
12. Loosen bolt no. 6 of tuned pipe cone beside
8. Remove external seal. the engine water return hose.
9. Loosen Allen screws no. 7 and nut no. 8 at tuned
pipe flange.
NOTE: To loosen nut, use polygonal wrench (P/N
529 035 505).
F06D1VA 1
1. Loosen bolt
13. Remove tuned pipe cone no. 5.

F06D1TA 1 14. Block exhaust opening in the manifold to keep
debris from entering cylinder during threads
1. Tuned pipe flange
cleaning procedure.
10. Loosen bolt no. 20 of tuned pipe head above 15. Remove the stud no. 21 from “Y” manifold.
the engine magneto then remove bolts retain-
ing bracket to engine. 16. Use a M10 x 1.5 screw/tap to clean the 4
threaded holes on the “Y” manifold and the 2
threaded holes on tuned pipe. Clean out the
debris with a spray cleaner and air pressure.
CAUTION: It is very important that the threads
are free of debris before installing new self-
locking fasteners.
04-07-4 SMR2002-065_04_07A.FM
Tuned Pipe Removal without Separation from Loosen bolt no. 20 of tuned pipe head above the
Tuned Pipe Head and Tuned Pipe Cone engine magneto then remove bolts retaining
Execute the above procedures 1 through 5. bracket to engine.
Later, use the following procedure:
Remove the strap no. 2 retaining the muffler then
remove the exhaust hose no. 3 from tuned pipe
cone no. 5.
Loosen Allen screw retaining carburetor bracket
to tuned pipe head.
F06D1UA 1
1. Remove bolt
Remove tuned pipe assembly.

Block exhaust opening in the manifold to keep de-
bris from entering cylinder during threads cleaning
procedure.
F06D2DA 1 Remove the stud no. 21 from “Y” manifold.
1. Loosen Allen screw Use a M10 x 1.5 screw/tap to clean the 4 threaded
Loosen Allen screws no. 7 and nut no. 8 at tuned holes on the “Y” manifold and the 2 threaded
pipe flange. holes on tuned pipe. Clean out the debris with a
spray cleaner and air pressure.
NOTE: To loosen nut, use polygonal wrench (P/N
529 035 505). CAUTION: It is very important that the threads
are free of debris before installing new self-
locking fasteners.
Exhaust Manifold
Remove 8 Allen screws no. 12 and lock washers
no. 13 then withdraw exhaust manifold.
Muffler
Disconnect the EGT (exhaust gas temperature)
sensor.
Disconnect hoses from muffler no. 11.
F06D1TA 1
1. Tuned pipe flange
SMR2002-065_04_07A.FM 04-07-5
Disconnect hoses of the water flow regulator INSTALLATION

valve.
Installation is essentially the reverse of removal
procedures. However, pay particular attention to
the following.
Exhaust Manifold
Make sure gasket(s) no. 17 are properly posi-
tioned prior to finalizing manifold installation.
Apply Molykote 111 on threads of Allen screws
no. 12.
Install and hand tighten Allen screws no. 12 as per
following picture.
F01E1FD 1 2
TYPICAL
1. Water supply hose
2. To injection fitting on tuned pipe
Disconnect retaining strap no. 2 of muffler.

Pull muffler no. 11 out of bilge.
TUNED PIPE REPAIR

This procedure is given to repair tuned pipe cracks
using T.I.G. welding process.
F06D1YA 1 2 1
Procedure
1. M10 x 60 Allen screws
– Sand the cracked area to obtain bare metal. 2. M10 x 110 Allen screws
– Perform a 1.50 mm (1/16 in) depth chamfer over Torque Allen screws to 24 N•m (17 lbf•ft) as per fol-
crack. lowing illustrated sequence. Repeat the procedure,
– Use pure argon gas with 5.55 mm (3/32 in) tung- retightening Allen screws to 40 N•m (30 lbf•ft).
sten electrode (puretung “green”, zirtung
“brown”) and AC current. 8 2 3 6
– Use a 5.55 mm (3/32 in) aluminum welding rod
(no. 4043), to fill crack.
– Sand welding slightly to remove material sur-
plus.
Test
– Use compressed air at 124 kPa (18 PSI) to pres-
surize tuned pipe.
CAUTION: Always ensure water passages are not
blocked partially or completely while welding
tuned pipe.
NOTE: Prior to verify leaks, plug all holes and pres- 7 4 1 5
F06D1YB
surize tuned pipe while immerging it in water.
04-07-6 SMR2002-065_04_07A.FM
Tuned Pipe Apply a thin layer of Ultra Copper heat resistant

sealant (P/N 413 710 300) all around sealing ring
CAUTION: Torque wrench tightening specifica-
no. 15.
tions must be strictly adhered to. Locking de-
vices (ex.: locking tabs, elastic stop nuts, self- CAUTION: Damage to bushings and/or sleeve
locking fasteners, etc.) must be installed or re- will eventually cause stress to tuned pipe and
placed with new ones where specified. If the may cause cracking.
effiency of a locking device is impaired, it must CAUTION: It is very important that the threads
be renewed. are free of debris before installing new self-
NOTE: Loosen all pipe supports from engine be- locking fasteners. Refer to removal procedure
fore install tuned pipe. for the proper thread cleaning procedure.
Make sure to install the sealing ring no. 15 on Clean the “Y” manifold and tuned pipe surfaces.
tuned pipe cone if it was removed. Screw stud no. 21 into the “Y” manifold. Torque
to 47 N•m (35 lbf•ft).
Install the new bushing no. 18.
Torquing Sequence:
CAUTION: Torque the tuned pipe in accor-
dance with the following sequence, otherwise
serious engine damage may occur.
NOTE: Apply Loctite 243 (P/N 293 800 060) on
stud nut before tightening to 2.5 N•m (22 lbf•in).
Use special tool (P/N 529 035 505).
Install external seal no. 22 and secure with a lock-
ing tie.
F07D0RA
1
TYPICAL
1. Sealing ring
SMR2002-065_04_07A.FM 04-07-7
40 Nm 40 Nm
6 (30 lbfft) 7 (30 lbfft)
6 Nm
(53 lbfin) 5
14 Nm 6 Nm
(124 lbfin) 16 9 (53 lbfin)
25 Nm
15 (18 lbfft)
6 Nm
(53 lbfin) 8
25 Nm
(18 lbfft) 14
6 Nm
6 Nm 3 (53 lbfin)
(53 lbfin) 2
48 Nm
48 Nm 12 (35 lbfft)
(35 lbfft) 11
2.5 Nm
(22 lbfin) 4 6 Nm
1 (53 lbfin)
48 Nm
(35 lbfft) 13 48 Nm
10 (35 lbfft)
F07D0SS
04-07-8 SMR2002-065_04_07A.FM
Install exhaust hose.

1
F06D14A
1. Torque clamp to 4 N•m (35 lbf•in)
SMR2002-065_04_07A.FM 04-07-9
Section 05 ENGINE (4-TEC)
TABLE OF CONTENTS 0
LEAK TEST............................................................................................................................. 05-02-1
LEAK TEST PROCEDURE .................................................................................................. 05-02-1
PREPARATION................................................................................................................... 05-02-1
PROCEDURE ...................................................................................................................... 05-02-2
INSTALLATION.................................................................................................................. 05-02-3
INTAKE SYSTEM ................................................................................................................... 05-03-1

REMOVAL........................................................................................................................... 05-03-2
ASSEMBLY......................................................................................................................... 05-03-6
EXHAUST SYSTEM............................................................................................................... 05-04-1

EXHAUST PIPE .................................................................................................................. 05-04-2
EXHAUST MANIFOLD ...................................................................................................... 05-04-5
MUFFLER (LH) ................................................................................................................... 05-04-6
MUFFLER (RH) ................................................................................................................... 05-04-7
EXHAUST OUTLET ........................................................................................................... 05-04-7
REMOVAL AND INSTALLATION.......................................................................................... 05-05-1

GENERAL ........................................................................................................................... 05-05-1
ENGINE REMOVAL............................................................................................................ 05-05-1
CLEANING ......................................................................................................................... 05-05-2
INSTALLATION .................................................................................................................. 05-05-2
PTO HOUSING/MAGNETO .................................................................................................. 05-06-1

GENERAL ........................................................................................................................... 05-06-2
PTO HOUSING................................................................................................................... 05-06-2
PTO SEAL........................................................................................................................... 05-06-5
COUPLING ......................................................................................................................... 05-06-5
STATOR ............................................................................................................................. 05-06-6
ROTOR AND ENCODER WHEEL....................................................................................... 05-06-7
RING GEAR ........................................................................................................................ 05-06-7
STARTER DRIVE ASS’Y .................................................................................................... 05-06-8
LUBRICATION SYSTEM ........................................................................................................ 05-07-1

GENERAL ........................................................................................................................... 05-07-3
OIL LEVEL VERIFICATION................................................................................................. 05-07-3
ENGINE PRESSURE TEST ................................................................................................ 05-07-4
OIL STRAINERS ................................................................................................................. 05-07-7
ENGINE OIL PRESSURE REGULATOR ............................................................................ 05-07-9
OIL PRESSURE PUMP....................................................................................................... 05-07-10
OIL SUCTION PUMP ......................................................................................................... 05-07-13
OIL FILTER BYPASS .......................................................................................................... 05-07-16
OIL COOLER....................................................................................................................... 05-07-16
OIL SEPARATOR ............................................................................................................... 05-07-17
SMR2002-095_05-01ATOC.FM 05-01-1
CYLINDER HEAD AND VALVES ........................................................................................... 05-08-1

GENERAL............................................................................................................................ 05-08-2
SPARK PLUG ...................................................................................................................... 05-08-2
VALVE COVER .................................................................................................................... 05-08-2
ROCKER ARM..................................................................................................................... 05-08-3
CAMSHAFT TIMING GEAR................................................................................................ 05-08-6
TIMING CHAIN ................................................................................................................... 05-08-8
CYLINDER HEAD ................................................................................................................ 05-08-8
CAMSHAFT......................................................................................................................... 05-08-10
VALVE SPRING................................................................................................................... 05-08-11
VALVE ................................................................................................................................. 05-08-12
ENGINE BLOCK ...................................................................................................................... 05-09-1

GENERAL............................................................................................................................ 05-09-3
CRANKSHAFT LOCKING ................................................................................................... 05-09-3
CRANKSHAFT .................................................................................................................... 05-09-3
TIMING CHAIN ................................................................................................................... 05-09-8
CHAIN TENSIONER............................................................................................................ 05-09-8
BALANCER SHAFT............................................................................................................. 05-09-9
ENGINE BLOCK .................................................................................................................. 05-09-11
PISTON/CONNECTING ROD ............................................................................................. 05-09-17
PISTON RINGS ................................................................................................................... 05-09-22
05-01-2 SMR2002-095_05-01ATOC.FM
LEAK TEST 0
LEAK TEST PROCEDURE – oil dipstick
The procedure has to be done when engine operat- 1

ing temperature of approx. 70°C (158°F) is reached.
 WARNING
Prevent burning yourself due to handling on
the hot engine.
PREPARATION
Remove:
– seat and vent tube support
– safety lanyard.
 WARNING
R1503motr153A
Safety lanyard must be removed to prevent
engine to be cranked while fuel rail is re- 1. Oil dipstick
moved to prevent fuel to be sprayed out.
– unplug ignition coil and pull it out
Fuel is flammable.
– spark plug from cylinder head.
– fuel rail cover then remove fuel rail retaining NOTE: Ignition coil may be used as an extractor.
screws and move away just enough to see the
injection holes 2 1
– exhaust pipe (refer to EXHAUST SYSTEM)
– drive shaft
(refer to JET PUMP in PROPULSION SYSTEM)
– coolant tank cap
 WARNING
To prevent burning yourself only remove the
coolant tank cap by wearing the appropriate
safety equipment.
R1503motr154A
1. Ignition coil
2. Spark plug
SMR2002_066_05_02A.FM 05-02-1
– Remove valve cover cowl. Hold the crankshaft in this position by using the im-
– Unscrew and remove valve cover. peller remover/installer tool (P/N 529 035 820) and
a wrench.
2 1 Install gauge adapter into previously cleaned spark
plug hole.
Connect to adequate air supply.
NOTE: Each tester will have specific instruction
on the gauge operation and required pressure.
Set needle of measuring gauge to zero.
Supply combustion chamber with air.
R1503motr155A
1. Valve cover 3
2. Valve cover screw
2
PROCEDURE
The following procedure has to be performed for
each cylinder separately, because of the 120° off-
set between the TDCs.
Rotate crankshaft until all valves are closed by using
PTO flywheel remover/installer (P/N 529 035 820). R1503motr157A
Therefore you have to monitor the rocker arms. 1. Measuring gauge

2. Adequate adapter for spark plug hole
1 3. Air supply
Note the amount of leaking or percentage (de-

pending on tester).
LEAKAGE ENGINE
PERCENTAGE CONDITION
0% to 7% Excellent condition
Fair condition; proceed
8% to 15% with tuned up or adjust-
ment
Poor condition; engine will
r un a nd p er for ma nc e
16% to 30%
might be down in some
cases.
R1503motr156A Very poor condition, diag-
30% and higher
nose and repair engine.
1. Intake rocker arms
Rotate the crankshaft counterclockwise until the

intake rocker arm has performed a full stroke.
Then rotate crankshaft for another half turn to be
sure that the valves are closed.
05-02-2 SMR2002_066_05_02A.FM
Diagnose General Engine Leakage

Pressurize area to be tested, spray soap/water so- Spray soap/water solution at the indicated location
lution at the indicated location and look and/or lis- and look and/or listen for air bubbles.
ten for air bubbles. Paying attention to the following checkpoints:
– air escaping on intake port means leaking intake – clamp(s) tightened
valve(s)
– coolant hoses
– air escaping on exhaust port means leaking ex-
haust valve(s) – air/oil escaping from crankcase means damaged
gasket(s) and/or loosened screws
– air bubbles out of coolant tank means leaking (refer to ENGINE BLOCK)
cylinder head gasket
– air/water escaping from cylinder/head means
– air escaping into crankcase area means exces- damaged gasket(s) and/or loosened screws
sively worn and/or broken piston rings. (refer to CYLINDER HEAD AND VALVES)
– oily contamination on weep hole (speed sensor
INSTALLATION area) means a damaged oil seal on coolant
NOTE: For installation use the torque values and pump shaft
Loctite products from the exploded views (refer to – coolant out of weep hole means a damaged ro-
proper engine subsection). tary seal on coolant pump shaft
For installation, reverse the preparation proce- (refer to COOLING SYSTEM)
dure.
NOTE: Prior to inserting the ignition coil to its lo-
cation, apply some BOMBARDIER LUBE lubricant
hole. After installation, ensure the seal seats prop-
erly with the engine top surface.
R1503motr158A 1
1. Weep hole
– coolant escaping from coolant pump housing

means damaged gasket(s) and/or loosened
screws (refer to COOLING SYSTEM).
NOTE: For all the checkpoints mentioned above
see the appropriate engine section to diagnose
and repair the engine.
SMR2002_066_05_02A.FM 05-02-3
Subsection 03 (INTAKE SYSTEM)
INTAKE SYSTEM 0
4-TEC Engines
Loctite 243
10 Nm
(88 lbfin)
Oil
Loctite 243
6 Nm 10 Nm
(53 lbfin) (88 lbfin)
Loctite 243
Loctite 243
10 Nm
(88 lbfin)
Loctite 243
6 Nm 18 Nm 10 Nm
(53 lbfin) (159 lbfin) (88 lbfin)
R1503motr63S
SMR2002-067_05_03A.FM 05-03-1
REMOVAL 2
Air Intake Manifold
Remove seat and storage basket. 1
Disconnect vent tube as follows.
Lift lock tab and holding the tab, pull the tube to
release it.
1
F18E1MA
Step 1 : Push tab (each side) to release

Step 2 : Pull tank out
Remove vent tube support.

NOTE: Pay attention not to drop the nuts under
support when removing screws.
F18E0PA
1 2
1. Lift lock tab
Then proceed with the tab under the tube. Refer

to the following illustration to see it.
F18L1GA 2 3
1. Vent tube support
2. Remove retaining screws
3. Pay attention to nuts underneath
F18E0QA 1 Remove oil dipstick.

1. Other lock tab under tube Pull fuel rail cover out.
Unlock coolant expansion tank, pull out then move Disconnect battery cables from battery.
away.
05-03-2 SMR2002-067_05_03A.FM
 WARNING 1 2 3 10
the specified order, BLACK negative cable
first then the RED positive battery cable last.
Release the fuel pressure in the system, refer to 9

ENGINE MANAGEMENT section. 8
Disconnect fuel hose connector at fuel rail. 7
6
1
2
1
2 R1503motr60A 5 4
1. Ignition coils
2. TOPS
3. TPS (hidden behind throttle body)
4. Idle bypass valve
5. Engine connector
6. KS
7. CPS
8. Magneto
9. “B” Kostal connector
10. OSPS
1 1 For the TOPS valve connector, refer to the follow-
ing illustration.
1
R1503motr78A
Step 1 : Squeese
Step 2 : Pull out
1. Supporting tabs
2. Squeeze in middle of supporting tabs, hold and pull out
Cut locking ties where shown.
1
R1503motr69A
1. Push here and hold while pulling connector out
F18D0CA
1. Cut locking ties
Unplug connectors from ignition coils, TOPS valve,

OSPS, TPS, idle bypass valve, engine connector,
CTS, CAPS, KS, CPS, magneto, OPS and EGT.
SMR2002-067_05_03A.FM 05-03-3
NOTE: The TPS connector is hidden behind the

TOPS hose. Disconnect hose from TOPS valve
then move away to access the TPS connector.
Slightly pry locking tab of connector to unlock.
R1503motr65A 1
1. CAPS connector
R1503motr75A
1. TOPS hose disconnected and moved away

2. TPS connector
3. Slightly pry tab to unlock
R1503motr66A 1
1. EGT connector
R1503motr64A 1
1. CTS connector
F18D0BA 1 2
1. Oil filter housing
2. OPS
05-03-4 SMR2002-067_05_03A.FM
Unplug the “B” Kostal connector from the Engine

ECU.
2
R1503motr72A
1. Air intake silencer collar

2. Unlock throttle cable housing
R1503motr70A 1
Remove 7 retaining screws and push the oil dip-
1. Push this end to unlock
stick tube out of the manifold slot.
R1503motr71A
1. Pull here to release R1503motr59A
Pull the connectors for KS, CPS and magneto out

of the ECU support. Lift intake manifold up to pull it out of the mount-
ing brackets just enough to reach throttle cable
Pull wiring harness away from intake manifold. end.
Slacken air intake silencer collar.
Unlock throttle cable housing from throttle body.
Cable is to be detached further.
SMR2002-067_05_03A.FM 05-03-5
NOTE: The flame arrester in intake manifold is

maintenance free.
ASSEMBLY
Assembly is essentially the reverse of removal
procedures. However pay particular attention to
the following.
CAUTION: Do not modify air intake system,
otherwise calibration will be affected.
Air Intake manifold

Ensure that all gaskets are properly installed and
in a good condition.
R1503motr61A 1
1. Mounting brackets
Detach throttle cable end from throttle body.
R1503motr62A 1
INTAKE MANIFOLD
1. Gaskets
First, position intake manifold on front mounting

bracket then push manifold toward engine to thus
R1503motr76A 1 allow proceeding with rear mounting bracket.
1. Detach cable end from throttle body When installing the intake manifold, lift up the oil
dipstick tube a little bit to fit in the slot of the man-
Pull intake manifold out.
ifold.
R1503motr77A
05-03-6 SMR2002-067_05_03A.FM
R1503motr59B
1. Oil dipstick tube
Apply Loctite 243 (blue) on the intake manifold

screws. Torque them to 10 N•m (88 lbf•in) follow-
ing the tightening sequence shown.
5 3 1
6
2 7
4
R1503motr210A
Ensure to properly route and resecure wiring har-

ness with locking ties.
 WARNING
Always check O-ring for damage such as defor-
mation at reinstallation. Replace the O-ring if it is
damaged.
SMR2002-067_05_03A.FM 05-03-7
EXHAUST SYSTEM 0
9
11 Nm
(97 lbfin)
3 4
2
8 12
5
11 8 Nm
(71 lbfin) 15
4 Nm
16 (35 lbfin)
15
7 15
16 Nm
(142 lbfin) 17
4 Nm 10
(35 lbfin) 13
Silicone
sealant
6
14
Loctite 296
F18D0HS
SMR2002-068_05_04A.FM 05-04-1
EXHAUST PIPE Loosen the exhaust hose clamp no. 5 to the top
portion of the hose between muffler (LH) no. 6
Removal and the exhaust pipe no. 1.
1 2
 WARNING
Certain components in the engine compartment
may be very hot. Direct contact may result in skin
burn. Let exhaust system cool down prior to re-
moving parts.
Remove seat and seat extension.

Remove seat support.
2
F18D0RA
1. Exhaust hose clamp

2. Exhaust pipe
Loosen both exhaust hose clamps no. 15 and re-

move the exhaust hose no. 16 between the muf-
F18L2GA 2 1
fler (LH) and the muffler (RH).
1. Seat support
2. Remove screws
Disconnect the 3 cooling hoses from exhaust pipe

no. 1.
1 3
F18D0QA 2 1
1. Hose clamp
2. Exhaust hose
Detach the strap no. 11 from the muffler (LH) using

the spring installer/remover (P/N 529 035 559).
F18D0IA 2
1. Exhaust pipe
2. Gear clamp
3. Exhaust clamp
05-04-2 SMR2002-068_05_04A.FM
Move muffler (LH) no. 6 backward enough to allow

the exhaust pipe to be pulled out.
Squeeze the exhaust hose no. 7 going to the exhaust
outlet with one hand, and withdraw the exhaust pipe
no. 1 from the exhaust manifold.
A00C3SA
2 1
F18D0KA
F18D0JA 3 1 2
1. Exhaust pipe
1. Muffler (LH) 2. Squeeze this hose to ease removal of pipe
2. Strap
3. Spring installer/remover
Apply sealant (P/N 413 710 200) on the welds of the
Slowly unscrew exhaust clamp nut no. 4 and re- exhaust tube, while the exhaust pipe is removed from
move it. the muffler (LH).
NOTE: Unscrewing the nut too fast generates heat
that will make it harder to unscrew.
2 1
F18D0TA 2 1
1. Sealant (P/N 413 710 200)
2. Exhaust pipe
F18D0SA
1. Exhaust clamp
2. Exhaust pipe
SMR2002-068_05_04A.FM 05-04-3
Inspection 2 1
Inspect exhaust pipe condition paying attention for
cracks or other damage. Check joints, coupling areas,
heat shield and hoses. Replace any defective part.
Installation
Installation is essentially the reverse of the remov-
al procedures. However, pay particular attention to
the following:
Insert the exhaust pipe end in the exhaust hose.
Align the exhaust pipe flange to the engine manifold.
To achieve a good fit, it could be necessary to push
the exhaust pipe further down into the hose over the
step of the exhaust pipe. Take note of the dimension
it is over the step, then cut the hose by this dimension.
Add a second clamp no. 5 to the top portion of the
hose. The two clamps must be separated by 3 - 5 mm F18D0UA
(1/8 - 3/16 in) and the screws must be at least 25 mm 1. Engine manifold
(1 in) apart. 2. Exhaust pipe flange
CAUTION: Exhaust pipe alignment with the man-

ifold is critical to the bellows life. Any constraint
on the flexible joint will result in the bellows fail-
ure. Gap between the exhaust pipe flange and
the engine manifold should not exceed 1 mm
(3/64 in).
Reinstall the exhaust clamp no. 4 to the exhaust
pipe flange and tighten enough to maintain the ex-
haust pipe in the proper position.
F18D0VA 3 2 1
1. Exhaust pipe step
2. Exhaust hose
3. Exhaust hose clamp
Pre-align the exhaust pipe no. 1 by rotating (axially)

and moving (longitudinally) the muffler (LH) so that
the exhaust pipe flange makes perfect contact with
the engine manifold.
F18D0XA 3 2 1
1. Exhaust pipe flange
2. Exhaust clamp
3. Engine manifold
05-04-4 SMR2002-068_05_04A.FM
Rotate (axially) and move (longitudinally) the muf-

fler (LH) so that the exhaust pipe flange makes
perfect contact with the engine manifold. A maxi-
mum gap of 1 mm (3/64 in) is allowed.
Torque the exhaust clamp no. 4 to 11 N•m (97
lbf•in) while maintaining the exhaust pipe in the
proper position.
Reinstall the muffler (LH) strap no. 11 using the
spring installer/remover (P/N 529 035 559). Care
must be taken not to induce strain in the flexible
joint of the exhaust tube.
Torque the two clamps located in the upper part
of the muffler (LH) hose to 8 N•m (71 lbf•in). Care
must be taken not to induce strain in the flexible
joint of the exhaust tube. R1503motr151A 2 1
1. Exhaust manifold
Reconnect the water lines to the exhaust pipe and 2. Cooling system supply hose location
torque to 8 N•m (71 lbf•in).
Unscrew the exhaust manifold no. 9 beginning
with the bottom screws. This will help holding the
water to the exhaust cooling system when water-
manifold while you remove the screws.
craft is out of water.
Remove the manifold and move it out toward the
After installation, ensure there is no water or exhaust
front of the watercraft to withdraw.
gas leak when engine is running. Test run the engine
while supplying water to the flushing connector.
EXHAUST MANIFOLD
Removal
Disconnect the cooling hoses no. 2 and no. 3
from the exhaust pipe no. 1.
Remove the exhaust clamp no. 4 and detach the
muffler (LH) from its support. Move the muffler
(LH) no. 6 rearwards to separate the exhaust pipe
from the manifold. See above in EXHAUST PIPE.
Disconnect the cooling system supply hose no. 8
F18D0LA
underneath the front part of the exhaust manifold.
Inspection
Inspect exhaust manifold condition paying attention
for cracks or other damage. Check contact surfaces
and hose. Replace any defective part.
Inspect plane surfaces for warpage. Small deforma-
tion can be corrected by grinding surface with a fine
sand paper. Install sand paper on a surface plate and
rub part against oiled sand paper.
SMR2002-068_05_04A.FM 05-04-5
Installation
procedures. However, pay particular attention to
the following:
NOTE: There is no gasket between engine block
and exhaust manifold.
Apply Loctite 518 on threads of screws.
To help holding the manifold while installing
screws, first insert the exhaust manifold into the
exhaust pipe no. 1 then, install the upper front
screw. Continue with the remaining screws.
Torque screws to 10 N•m (88 lbf•in) as per follow-
ing illustrated sequence. Repeat the procedure, F18D0MA 1 2
torquing screws again to 10 N•m (88 lbf•in). 1. Temperature sensor connector
2. Outlet hose
7 5 1 3 9 11
Detach the strap no. 11 from the muffler (LH) using
the spring installer/remover (P/N 529 035 559).
A00C3SA
R1503motr152A 8 6 4 2 10 12

water to the exhaust cooling system when water-
After installation, ensure there is no coolant or ex-
haust gas leak when the engine is running. Test run
the engine while supplying water to the flushing con-
nector.
F18D0JA 3 1 2
MUFFLER (LH) 1. Muffler (LH)
2. Strap
Removal
Remove the exhaust pipe no. 1. See above. Carefully pull out the muffler (LH) no. 6.
Disconnect the temperature sensor connector.
Inspection
Disconnect the outlet hose.
Inspect parts condition paying attention for cracks or
other damage. Check hoses. Replace any defective
part.
05-04-6 SMR2002-068_05_04A.FM
Installation 1 2
Installation is the reverse of the removal procedures.
the engine while supplying water to the flushing con-
nector.
MUFFLER (RH)
Removal
Loosen both exhaust hose clamps no. 15 and discon-
nect the exhaust hoses no. 7 and no. 16 from the
muffler (RH) no. 10.
F18D0OA 3
1. Muffler (RH)
2. Strap
Carefully pull out the muffler (RH) no. 10.
Inspection
other damage. Check hoses. Replace any defective
part.
Installation
Installation is the reverse of the removal procedures.
F18D0NA 1
1. Disconnect inlet and outlet hoses from muffler (RH)
Detach the strap no. 12 from the muffler (RH) using the engine while supplying water to the flushing con-
the spring installer/remover (P/N 529 035 559). nector.
EXHAUST OUTLET
Removal
Remove the muffler (LH) no. 6. See above.
A00C3SA Remove the jet pump as an assembly. Refer to
PROPULSION SYSTEM.
SMR2002-068_05_04A.FM 05-04-7
From outside of hull, unscrew nut no. 13 with the

exhaust outlet tool (P/N 295 000 132).
F01B2AA
TYPICAL
F18D0PA 2
1. Exhaust outlet nut
2. Tool
From inside the bilge, pull out the exhaust hose

no. 7 and the adapter no. 14 together.
Detach the adapter no. 14 from the exhaust hose
no. 7.
Inspection
other damage. Check hose. Replace any defective
part.
Installation
Installation is essentially the reverse of the removal
procedures. However, pay particular attention to the
following:
Apply Loctite silicone sealant (P/N 293 800 086)
on the adapter flange to seal the bilge.
Test the bilge for water leaks.
05-04-8 SMR2002-068_05_04A.FM
REMOVAL AND INSTALLATION 0

GENERAL Drive System
Engine removal is necessary to repair BOTTOM To withdraw drive shaft, refer to PROPULSION
END. section.
ENGINE REMOVAL Cooling System

To remove cooling system hoses, refer to COOL-
Use the VCK (Vehicle Communication Kit) (P/N 529 ING SYSTEM section
035 844) and release the fuel pressure in the fuel sys-
tem. Refer to ENGINE MANAGEMENT section. Exhaust Pipe
In order to remove engine from watercraft proceed To remove exhaust pipe, refer to EXHAUST SYS-
as follows. TEM in ENGINE section.
First, disconnect battery cables from battery. Air Intake Silencer
 WARNING To remove air intake silencer, refer to INTAKE.
the specified order, BLACK negative cable Air Intake Module
first then the RED positive battery cable last. To remove air intake manifold, refer to INTAKE
section.
Electrical Connections Engine Support
It is recommended to disconnect electrical con- NOTE: Be careful when removing engine sup-
nections prior to disconnecting fuel lines. port(s) or rubber mount adapters, shims could
Disconnect magneto wiring harness. have been installed underneath. Shims control
engine/jet pump alignment. Always note position
Disconnect the throttle position sensor (TPS), of shims for reinstallation, to avoid altering engine
manifold air pressure sensor (MAPS) and manifold alignment.
air temperature sensor (MATS) (refer to INTAKE
section). Remove engine support mount screws.
Refer to ENGINE MANAGEMENT for location of sen-
sors and connectors.
OPAS
To disconnect OPAS, refer to STEERING section.
Jet Pump Removal

To withdraw jet pump, refer to PROPULSION
section.
CAUTION: Whenever removing engine from
watercraft, engine/jet pump alignment must be
performed at reinstallation.
F18D13A 1
FRONT SUPPORT
1. Remove screw
SMR2002-069_05_05A.FM 05-05-1
Removal of Remaining Components

Disconnect RED positive cable from starter post.
F18D14A 1
REAR SUPPORT
1. Remove screws
F18D12A 1
Lifting Engine TYPICAL
1. Disconnect RED positive cable
Using a chain block, a hoist or other suitable equip-
ment, slightly lift engine to ease the remaining com- Carry on engine lifting to remove from the body
ponent removal. opening.
CAUTION: Take care not to damage cables. CAUTION: Be careful not to scratch body or to
hit any component.
1 1
CLEANING
Wipe off any spillage in bilge. Clean with a bilge
cleaner.
Clean external parts of engine.
INSTALLATION
Installation of engine in watercraft is essentially
the reverse of removal procedures. However pay
particular attention to the following.
F18D11A
TYPICAL
1. Transport brackets
05-05-2 SMR2002-069_05_05A.FM
Rubber Mount, Shim and Screw

Check tightness and condition of rubber mounts.
If they have been removed, apply Loctite 243
(blue) on screw threads. Torque screws to
25 N•m (18 lbf•ft).
CAUTION: Strict adherence to this torque is im-
portant to avoid damaging threads of alumi-
num insert in bilge.
Engine Support
Loctite 243 Loctite

243 1
1
F00B0FA 1 2
1. Plate
2. Support
Alignment shaft (P/N 295 000 141).
1 F00B0GA 1
1. Alignment shaft
Loctite 243
Engine alignment adapter (P/N 529 035 719).
F18D10A
1. Torque screws to 25 N•m (18 lbf•ft)
Positive Starter Cable F18D16A 1

Torque nut of positive starter cable to 7 N•m 1. Engine alignment adapter
(62 lbf•in). Apply dielectric grease on nut.
To verify alignment proceed as follows:
Engine/Jet Pump Alignment – Install the appropriate plate with the support to
Alignment is necessary to eliminate possible vi- hull with four nuts.
bration and/or damage to components. Check
alignment of engine using the following alignment
tools.
Support plate kit (P/N 529 035 506).
NOTE: Use plate (P/N 529 035 508) for the 139.5 mm
(5-1/2 in) jet pump and plate (P/N 529 035 507) for
the 155.6 mm (6-1/8 in) jet pump.
F00B0HA
TYPICAL
SMR2002-069_05_05A.FM 05-05-3
– Install adaptor (P/N 529 035 719) on drive shaft.
F18D15A 1
F18D18A 1 TYPICAL
1. Shim
1. Engine alignment adaptor
– Carefully slide shaft through support. CAUTION: Whenever shims are used to correct
alignment, never install more than 5 mm
– Insert shaft end into engine alignment adaptor. (0.196 in) shim thickness.
NOTE: Ensure the protective hose and carbon
ring (or seal carrier) is removed to check engine Engine Support Screws
alignment. If the alignment is correct, the shaft will Apply Loctite 243 (blue) (P/N 293 800 060) on
slide easily without any deflection in engine align- screw threads.
ment adaptor.
Torque engine support screws to 25 N•m (18 lbf•ft)
when procedure is completed.
Loctite 243 Loctite

243 1
1
F18D17A 1 2
TYPICAL
1. Engine alignment adapter 1
2. Alignment shaft
If the alignment is incorrect loosen engine support Loctite 243

screws to enable to align engine alignment adap-
tor with shaft end.
NOTE: Use shim(s) (P/N 270 000 024 or P/N 270
000 025) as necessary between engine supports F18D10A
and rubber mounts to correct alignment. 1. Torque to 25 N•m (18 lbf•ft)
05-05-4 SMR2002-069_05_05A.FM
Properly align exhaust pipe. Refer to EXHAUST

SYSTEM in ENGINE section.
Final Inspection
Check throttle cable condition and lubricate cable
with BOMBARDIER LUBE lubricant.
After its installation, properly adjust throttle cable as
specified in ENGINE MANAGEMENT.
Check hose condition and pressure test fuel sys-
tem, refer to FUEL SYSTEM section.
 WARNING
F18D13A 1 Whenever doing any type of repair on water-
craft or if any components of the fuel system
1. Torque to 25 N•m (18 lbf•ft) are disconnected, a pressure test must be done
before starting engine.
Verify all electrical connections.

Run engine and ensure there is no leakage.
must be cooled using the flush kit.
F18D14A 1
SMR2002-069_05_05A.FM 05-05-5
Subsection 06 (PTO HOUSING/MAGNETO)
PTO HOUSING/MAGNETO 0
10 Nm
10 Nm (88 lbfin)
(88 lbfin)
1 Engine oil
24 Nm(17 lbfft)
Loctite 10 Nm Multi-purpose grease

243 (88 lbfin)
3 30 Nm Loctite
10 (22 lbfft) 243
11
Engine oil
9 24 Nm
(17 lbfft) 76
8
15
14
3 Nm (26 lbfin) 22
Left handed threads 10 Nm
4 (88 lbfin)
Engine oil
18 250 Nm
10 Nm (88 lbfin) (184 lbfft)
Loctite 243 5 17 16 13
Loctite
243 12
Loctite 5910
Engine oil 19
18 Nm 20
(159 lbfin) Engine
Loctite 243 Engine 21 oil
oil 10 Nm
(88 lbfin) Loctite anti-seize
12 Nm
(106 lbfin) Loctite
243
R1503motr57S
SMR2002_070_05-06A.FM 05-06-1
GENERAL A tube is to be inserted to siphon oil out of PTO

housing. To ensure tube will be inserted far in
Always perform the electric tests before removing enough, measure 381 mm (15-3/8 in) from tube
or installing any components. end (the end that will be inserted in engine) and
Clean threads before using Loctite when installing trace a mark or put tape on the tube at this loca-
the screws. tion.
Insert the tube along timing chain as shown until
PTO HOUSING you reach the mark (or tape). Then, siphon the oil
out using the oil VAC (P/N 529 035 880).
Removal
1
NOTE: When drive shaft will be removed, some
oil will flow out. To prevent it, start engine, run at
4000 RPM for 10 seconds and stop engine at this
RPM. This will move oil out of PTO housing into
oil tank.
If engine cannot be started, up to 1L (34 oz) could
flow out at PTO housing removal. To prevent this,
follow instructions REMOVING OIL IN PTO HOUS-
ING WHEN ENGINE CANNOT BE STARTED be-
low. Otherwise, skip to instructions PTO HOUSING
REMOVAL below.
Removing Oil in PTO Housing when Engine
cannot be Started
F18D2KA A
Remove chain tensioner plug screw and tensioner.
Refer to ENGINE BLOCK subsection. PTO HOUSING AND MAGNETO REMOVED FOR EXPLANATION
A. 381 mm (15-3/8 in) from tube end
1. Siphon tube
3 2
PTO Housing Removal
Drain engine oil. Refer to LUBRICATION in ENGINE
section.
Place rags under PTO housing to prevent spillage.
Up to 250 mL (8 oz) of oil could flow out when
removing PTO housing. If spillage occurs, clean
immediately with the Pulley flange cleaner (P/N
413 711 809) to prevent oil stains.
Disconnect CPS and magneto generator from wir-
ing harness.
 WARNING
R1503motr39A 1 Always disconnect battery or starter cables
1. Plug screw
exactly in the specified order, BLACK nega-
2. Gasket ring tive cable first. Disconnect electrical connec-
3. Chain tensioner tions prior to disconnecting fuel lines.
Remove valve cover. Refer to CYLINDER HEAD
AND VALVES subsection.
05-06-2 SMR2002_070_05-06A.FM
Remove: NOTE: Carefully separate the PTO housing from

– jet pump (refer to JET PUMP in PROPULSION the engine using two flat screwdrivers prying
SYSTEM) equally at the same time. Proceed slowly so that
starter gear disc springs no. 6 and washer no. 7
– drive shaft (refer to DRIVE SYSTEM in PRO- do not fall down.
PULSION SYSTEM)
– PTO housing no. 5
– slightly lift rear part of engine and safely block
in this position. Remove rear LH side engine CAUTION: Ensure to use prying lugs to sepa-
support no. 1. rate PTO housing to prevent damaging contact
surface.
1 2
R1503motr50A
1. Engine support R1503motr58A
Remove: 1. Disc springs

2. Washer
– thru-hull fitting boot 3. Starter drive gear
– gasket no. 9.
2
Inspection
Check PTO housing for cracks or other damages.
Replace if necessary.
Installation
NOTE: Clean all metal component in a non-ferrous
metal cleaner.
 WARNING
Wear safety glasses and work in a well venti-
lated area when working with strong chemical
products. Also wear suitable non-absorbent
F18J0BA 1 gloves to protect your hands.
1. Thru-hull fitting boot
2. Remove this collar For installation, reverse the removal procedure.
However, pay attention to the following.
– coolant pump housing no. 2 (refer to COOLING
SYSTEM) NOTE: Turn the oil/coolant pump shaft in the right
position to fit into the balance shaft.
– screws nos. 3 and 4
SMR2002_070_05-06A.FM 05-06-3
Position the disc springs no. 6 and washer no. 7

2 1 2 2
as per the following illustration.
1 2 3 4
R1503motr46A
1. Washer
2. Disc spring
3. Flange washer
4. Starter drive ass’y 1 2
CAUTION: Ensure the starter drive gear shaft is 1
well engaged in its bore. R1503motr15A 2
Gently install PTO housing. 1. Screws M6 x 35
2. Screws M6 x 85
CAUTION: While installing housing, pay partic- Tightening sequence for screws on PTO housing
ular attention that gasket does not get pinched is as per following illustration.
or slide out of its contact surface in the area
shown in the following illustration. Never force 15 14 1 13 12 11 10
to install cover. If there is a strong resistance,
remove housing and check oil/coolant pump
alignment and starter gear alignment.
1
16
9
17
18
8
19 7
20 6
R1503motr15B
21 2 3 4 5
Reinstall LH engine support. Apply Loctite 243 (blue)

on screw threads then torque to 24 N•m (17 lbf•ft).
Remove block under engine.
F18D2LA Properly reinstall chain tensioner. Refer to ENGINE
1. Pay attention that gasket remains properly positioned on this BLOCK subsection.
surface.
Properly reinstall valve cover. Refer to CYLINDER-
Refer to the following illustration for proper instal- HEAD AND VALVES subsection.
lation of screws. Refill engine with oil and cooling system with coolant.
Refer to ENGINE and COOLING SYSTEM sections.
Check engine alignment. Refer to REMOVAL AND
INSTALLATION in ENGINE section.
05-06-4 SMR2002_070_05-06A.FM
PTO SEAL COUPLING

Inspection Removal
Check the PTO seal no. 10 on the PTO housing. If Lock crankshaft with locking tool (P/N 529 035 821).
brittle, hard or damaged, or if you see a sign of oil Refer to CRANKSHAFT LOCKING in ENGINE BLOCK
leakage, replace it. subsection.
Remove:
Removal
– jet pump
oil will flow out. To prevent it, start engine, run at – drive shaft
4000 RPM for 10 seconds and stop engine at this – PTO seal as described above
RPM. This will move oil out of PTO housing into – coupling no. 12 using impeller remover/installer
oil tank. (P/N 529 035 820).
CAUTION: Never run engine without supplying CAUTION: Apply some oil on the tool to protect
water to the exhaust cooling system when wa- the seal located in the PTO coupling.
If spillage occurs, clean immediately with the Pul-
ley flange cleaner (P/N 413 711 809) to prevent oil
stains.
Remove:
– Oetiker clamp no. 11 located close to the PTO
housing
– jet pump (refer to JET PUMP in PROPULSION
SYSTEM)
– drive shaft (refer to DRIVE SYSTEM in PRO-
PULSION SYSTEM)
R1503motr48A
– PTO seal no. 22.
2
Inspection
Check if seal no. 13 is brittle, cracked or hard.
Check coupling for worn splines.
If damaged, replace faulty part.
R1503motr47A 1
1. Oetiker clamps
2. PTO seal
Installation R1503motr49A
Reinstall removed parts in the reverse order.
SMR2002_070_05-06A.FM 05-06-5
Installation 1 2
For installation, reverse the removal procedure.
Torque PTO coupling to 250 N•m (184 lbf•ft). Ap-
ply Loctite anti-seize on threads.
STATOR
Removal
Remove:
– PTO housing (refer to PTO HOUSING REMOVAL
elsewhere in this section)
– holding plate no. 14 with CPS no. 15
R1503motr26A
1. Stator screws
2. Stator
Inspection
Check stator and CPS condition. If damaged re-
place the faulty part.
For electrical inspection, refer to CHARGING SYS-
TEM for the stator and to ENGINE MANAGE-
MENT for the CPS.
3
Installation
R1503motr21A 1 2 NOTE: There is only one position for the stator
1. CPS screws
(notch in the magneto housing cover).
2. Holding plate
3. CPS
– screws no. 16
– stator no. 17.
R1503motr51A 1
1. Notch for stator
05-06-6 SMR2002_070_05-06A.FM
Place the rubber grommets on both cables in the Inspection

proper notches at the PTO housing.
Check rotor, bent teeth and encoder wheel condi-
2 1 tion. If damaged, replace faulty part.
Installation
Encoder wheel position has to be located with the
location pin on the crankshaft gear.
IMPORTANT: If rotor has balancing holes, never
install it so that they are inside the large gap be-
tween encoder wheel teeth. This would create a
non-starting condition of the engine.
R1503motr52A
1. Grommet on CPS cable

2. Grommet on stator cable
Apply Loctite 243 on threads.Torque stator and 4

CPS screws to 10N•m (88 lbf•in).
ROTOR AND ENCODER WHEEL

Removal
Lock crankshaft with locking tool (P/N 529 035
821). Refer to CRANKSHAFT LOCKING in ENGINE
BLOCK subsection.
F18D0AA 2 1 3
Remove:
WRONG INSTALLATION
– PTO housing 1. Rotor
2. Balancing holes
– hexagonal screws no. 18 retaining rotor. 3. Encoder wheel
4. Large gap
Withdraw rotor no. 19 with encoder wheel no. 20.
Apply Loctite 243 on threads.Torque rotor screws
3
RING GEAR
2 Removal
1
Lock crankshaft with locking tool (P/N 529 035 821).
Refer to CRANKSHAFT LOCKING in ENGINE BLOCK
subsection.
Remove:
– PTO housing cover
1
– hexagonal screws no. 18.
R1503motr53A
1. Hexagonal screws
2. Rotor
3. Encoder wheel
SMR2002_070_05-06A.FM 05-06-7
Withdraw rotor no. 19, encoder wheel no. 20 and STARTER DRIVE ASS’Y
starter ring no. 21.
Removal
4
Remove:
3
– PTO housing and ring gear as described above
2 – starter drive ass’y no. 8.
R1503motr54A
1. Hexagonal screws
2. Rotor
3. Encoder wheel
4. Ring gear 1
Inspection
Check ring gear condition, especially teeth condi- R1503motr55A
tion. If damaged, replace faulty part. 1. Starter drive ass’y
Installation CAUTION: Be careful not to lose the distance

washer, disc springs no. 6 and washer no. 7 lo-
For installation, reverse the removal procedure. cated on the starter drive shaft.
Ring gear and encoder wheel position has to be lo-
cated with the location pin on the crankshaft gear.
3
1
2
R1503motr58A
R1503motr54B 1. Disc springs

2. Washer
1. Location pin 3. Starter drive gear
2. Location pin holes
Apply Loctite 243 on threads.Torque rotor screws

05-06-8 SMR2002_070_05-06A.FM
Inspection
Check condition of the teeth, shaft, etc. and if the
sprag clutch operates well. If damaged, replace
faulty part.
Installation
Apply some Isoflex Topas NB52 grease (P/N 293
550 021) on the starter drive bearing located in the
engine block and on the starter drive support in the
PTO housing cover.
R1503motr56A
1. Starter drive bearing
R1503motr45A
1. Starter drive support
CAUTION: Be sure not to forget the distance

washer, disc springs and washer on the starter
drive shaft when assembling.
SMR2002_070_05-06A.FM 05-06-9
Subsection 07 (LUBRICATION SYSTEM)
LUBRICATION SYSTEM 0
10 Nm
10 Nm (88 lbfin)
(88 lbfin) 1
2 Engine oil
4
Loctite 3 10 Nm Multi purpose
243 (88 lbfin) grease
28 Nm
(21 lbfft)
24 Nm
(17 lbfft)
Loctite
19 243
3 Nm (26 lbfin) 32
20 10 Nm
Left handed threads 25 (88 lbfin)
26
Engine oil
33
31
10 Nm (88 lbfin) 6
Loctite
Loctite 243 5 243
18
17 39 Loctite 5910
Engine oil 16
23
15 24
21
Loctite 243 22 10 Nm
12 Nm (88 lbfin)
18 Nm
(106 lbfin) (159 lbfin) Engine Loctite
oil 243
R1503motr112S
SMR2002_071_05_07A.FM 05-07-1
Oil
18 Nm
(159 lbfin)
10 Nm
Loctite 243 Loctite 243 (88 lbfin)
41 18 Nm
(159 lbfin) 8
10 Nm
(88 lbfin)
10 Nm
Oil 7 (88 lbfin)
34 10 Nm Loctite 243
Loctite
(88 lbfin) 243
Loctite 243
Oil
35 Loctite 243
Oil
Loctite 243 Horizontal
to exhaust side
14
13 9
Oil 27
38 28 29 5-25 Nm
37
Oil (44-221 lbfin)
36 40 30 Oil
10 Nm Loctite 243 18 Nm 10
(88 lbfin) (159 lbfin) Loctite 243 10 Nm
(88 lbfin)
42 12
10 Nm 10 Nm Loctite 243
(88 lbfin) (88 lbfin) 11
R1503motr113S
05-07-2 SMR2002_071_05_07A.FM
GENERAL Check the oil level as follows:

1. Watercraft must be level. Check oil level either
Prior to change the oil, ensure vehicle is on a level
with watercraft in water or out of water. Engine
surface.
should be warm.
Oil and oil filter must be replaced at the same time.
Oil change and oil filter replacement should be done
with a warm engine.
 WARNING 2. If out of water, raise trailer tongue and block in
position when bumper rail is level. Install a gar-
The engine oil can be very hot. Wait until en-
den hose to the flushing connector. Refer to
gine oil is warm.
Flushing in MAINTENANCE and follow the pro-
Dispose oil and filter as per your local environmen- cedures.
tal regulations. CAUTION: Failure to flush exhaust cooling sys-
tem, when engine is out of water, may severely
OIL LEVEL VERIFICATION damage engine and/or exhaust system.
3. Warm-up engine then let idle for 30 seconds
CAUTION: Check level frequently and refill if before stopping.
necessary. Do not overfill - it would make the
engine smoke and reduce its power. Operating 4. Stop engine.
the engine with an improper level may severely 5. Wait at least 30 seconds then pull dipstick out
damage engine. Wipe off any spillage. and wipe clean.
 WARNING
Engine oil may be hot. Certain components in
the engine compartment may be very hot. Di-
rect contact may result in skin burn.
CAUTION: Never run engine longer than 5 min-

utes. Drive line seal has no cooling when water-
6. Reinstall dipstick, push in completely.
F18D04A
1. Dipstick
SMR2002_071_05_07A.FM 05-07-3
7. Remove dipstick and read oil level. It should be

between marks.
F18G03A 1 2
2
1. Oil filter housing
2. Pressure test plug
F18D05A
NOTE: Oil pressure switch works between 180 kPa
(26 PSI) and 220 kPa (32 PSI).
1. Full
2. Add The engine oil pressure should be within the follow-
3. Operating range
ing values.
8. Otherwise, add oil up to have the level between
marks as required. OIL PRESSURE TEST
9. To add oil, unscrew oil cap. Place a funnel into ENGINE RPM PRESSURE kPA (PSI)
the opening and add the recommended oil to
Idle (cold) 300 - 400 (44 - 58)
the proper level. Do not overfill.
Idle (at 80°C (176°F) min. 160 (23)
ENGINE PRESSURE TEST 4000 - 7500 300 - 400 (44 - 58)
NOTE: The engine pressure test should be done
with a warm engine and the recommended oil. If the engine oil pressure is out of specifications,
check the points described in TROUBLESHOOT-
Remove plug below oil filter housing.
ING section.
Use oil pressure gauge (P/N 529 035 709) and hose
Reinstall plug.
adaptor (P/N 529 035 652) and install where shown.
Start engine and read pressure at different RPM Oil change
as per following table.
Engine in vehicle
NOTE: If water is found in oil (oil will be milky),
refer to submerged engine in MAINTAINANCE
section and follow the procedure to flush it.
Bring engine to its normal operating temperature.
05-07-4 SMR2002_071_05_07A.FM
CAUTION: Failure to flush exhaust cooling sys- Pull siphon tube out of dipstick hole then crank
tem, when engine is out of water, may severely engine (do not start) while in engine drown mode
damage engine and/or exhaust system. (fully depress throttle lever and HOLD, then crank
engine).
 WARNING Crank engine for 10 seconds. Siphon oil again. Re-
Engine oil may be hot. Certain components in peat the crank-siphon cycle 2-3 times.
the engine compartment may be very hot. Di-
Engine removed
rect contact may result in skin burn.
There are two separate drain plugs on the engine.
CAUTION: Never run engine longer than 5 min- One is located in the lower crankcase half and the
utes. Drive line seal has no cooling when wa- other one in the PTO housing.
Run engine for 10 seconds at 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.
Using the oil VAC (P/N529 035 880), siphon oil
through dipstick hole.
CAUTION: Never crank or start engine when si-
phon tube is in dipstick hole. Never start engine
when there is no oil in engine. R1503motr211A 1
NOTE: So that siphon tube is located at the proper 1. Drain plugs
height to siphon oil, it is suggested to put some Place a drain pan under the engine drain plug area.
electrical tape on siphon tube at 475 mm (18.7 in)
from its end. Then, insert siphon tube until you Clean the drain plug area.
reach the tape. Unscrew drain plugs no. 39 and no. 40 then remove
dipstick.
2
CAUTION: Pay attention not to lose gasket rings
on drain plug.
– Wait a while to allow oil to flow out of oil filter.
Change gasket ring on drain plug if damaged.
Inspection
Oil condition gives information about the engine
condition. See TROUBLESHOOTING section.
Installation
Reinstall removed parts and fill in the new engine oil.
Oil Type and System Capacity

Refer to TECHNICAL DATA. For refilling procedure,
refer to OIL LEVEL VERIFICATION above.
R1503motr150A 1
1. Oil vac
2. Siphon tube in dipstick hole
SMR2002_071_05_07A.FM 05-07-5
OIL FILTER Inspection

Removal Check oil filter cover O-ring no. 4 and oil filter screw
O-ring, change if necessary.
Remove:
Check and clean the oil filter inlet and outlet area
– engine oil (refer to OIL CHANGE) for dirt and other contaminations.
– oil filter screw no. 1
– oil filter cover no. 2
– oil filter no. 3.
3 2 1
R1503motr115A 2 1
1. Inlet bore from the oil pump to the oil filter
2. Outlet bore to the engine oil providing system
R1503motr114A
Installation
The installation is the opposite of the removal pro-
1. Oil filter screw
2. Oil filter cover cedure. Pay attention to the following details.
3. Oil filter
Install a new oil filter.
Place rags in fillet area to prevent spillage. If spillage Install O-ring on oil filter cover.
occurs, clean immediately with the pulley flange
cleaner (P/N 413 711 809) to prevent stains.
 WARNING
gloves to protect your hands.
R1503motr116A
Torque oil filter screw to 9 N•m (80 lbf•in).
05-07-6 SMR2002_071_05_07A.FM
OIL STRAINERS
The oil strainers do not need to be cleaned at every
oil change. Clean them during other inspections,
especially when the engine is disassembled.
PTO - Oil strainer

Removal
Remove:
– engine oil (refer to OIL CHANGE)
– PTO cover no. 5
(refer to PTO COVER/MAGNETO section)
– oil strainer no. 6.
1 R1503motr118A 1
1. Oil inlet to the oil pump
Installation
Refill engine at the proper level with the recom-
mended oil. Refer to TECHNICAL DATA for capacity
and OIL LEVEL VERIFICATION above for procedure.
Suction Pump - Oil strainer

Removal
– Remove blow-by ventilation hose no. 7.
R1503motr117A
1
1. Oil strainer
Cleaning and Inspection

Clean oil strainer with a part cleaner then use an air
gun to dry it.
 WARNING
Always wear eye protector. Chemicals can
cause a rash break out in and an injury to your
eyes.
Check and clean the oil outlet area for dirt and oth-
er contaminants.
R1503motr133A
1. Blow-by ventilation hose
– Disconnect wiring harness from blow-by valve

no. 8 and blow-by pressure switch no. 9.
– Detach air silencer box from throttle body.
SMR2002_071_05_07A.FM 05-07-7
– Disconnect battery cables and vent tube then re- Inspect rubber rings no. 13 and no. 14.
move battery. Refer to BATTERY in CHARGING
SYSTEM section for proper procedures.
– Remove retaining screws no. 10 and no. 11. 1
– Place rags under cover to prevent spillage. If
spillage occurs, clean immediately with the pul-
ley flange cleaner (P/N 413 711 809) to prevent
stains.
 WARNING 2
R1503motr121A
– Remove suction pump cover with oil separator.
1. O-ring
– Remove oil strainer no. 12. 2. Rubber ring gasket
If rubber rings are brittle, cracked or hard, replace

them.
Clean both contact surfaces of oil strainer cover.
Check and clean the oil inlet and outlet area for dirt
and other contaminations.
R1503motr120A 1
1. Oil strainer
Cleaning and Inspection

Clean oil strainer with a part cleaner then use an
air gun to dry it.
R1503motr122A 1
 WARNING 1. Oil inlet to the oil pump
Always wear eye protector. Chemicals can

cause a rash break out in and an injury to your
eyes.
05-07-8 SMR2002_071_05_07A.FM
Installation
Position screw length as shown.
R1503motr123A
1. Oil pressure regulator
NOTE: The oil pressure regulator system opens

when the oil pressure exceeds 400 kPa (58 PSI).
R1503motr119A 1 2 Removal
1. Screws M6 x 25
2. Screws M6 x 85 Remove:
Torque suction pump cover screws to 10 N•m (88 – engine oil (refer to OIL CHANGE)
lbf•in) as per sequence illustrated below. Apply – oil pressure regulator plug no. 15, compression
Loctite 243 on threads. spring no. 16, valve piston no. 17 and valve pis-
ton guide no. 18.
6
 WARNING
Oil pressure regulator plug on oil pump housing
1 is spring loaded.
2
3
R1503motr144A 4
ENGINE OIL PRESSURE

REGULATOR
The oil pressure regulator is located on the bottom
of the PTO housing.
R1503motr124A 4 3 2 1
1. Valve piston guide
2. Valve piston
3. Compression spring
4. Oil pressure regulator plug
SMR2002_071_05_07A.FM 05-07-9
Inspection – oil pump cover no. 22

Inspect valve piston and valve piston guide for scor- 2
ing or other damages.
Check compression spring for free length.
COMPRESSION SPRING FREE LENGTH
NEW NOMINAL 60 mm 2.362 in)
SERVICE LIMIT 50.3 mm (1.980 in)
Replace parts if important wear or damage are

present.
Clean bore and threads in the PTO housing from
metal shavings and other contaminations.
Installation R1503motr125A 1
1. Screws
Pay attention to the following details. 2. Oil pump cover
Be careful that the O-Ring on plug screw is in place. – outer oil pump rotor no. 23
Torque plug screw to 12 N•m (106 lbf•in) maxi-
1
mum. Apply Loctite 243 on threads.
OIL PRESSURE PUMP

The oil pressure pump is located in the PTO hous-
ing and is driven by the balance shaft.
Removal
Remove:
– engine oil (refer to OIL CHANGE)
– PTO housing
(refer to PTO HOUSING/MAGNETO section)
– Coolant pump housing no. 19 and impeller no. 20.
(refer to COOLING SYSTEM section) R1503motr126A
– screws no. 21 1. Outer oil pump rotor
– Extract the coolant/oil pump shaft no. 24 from

outside PTO housing with a pusher.
05-07-10 SMR2002_071_05_07A.FM
– Remove rotary seal no. 25 with a screwdriver.
R1503motr129A 1
1. Pittings on the teeth
Using a feeler gauge, measure the clearance be-

tween inner and outer rotors.
R1503motr127A
CAUTION: Be careful not to damage the surface

of the rotary seal bore in PTO housing cover. B
– oil seal no. 26.
A
1
R1503motr130A 2 1
1. Outer rotor
2. Inner rotor
R1503motr128A
1. Oil seal OUTER AND INNER ROTOR CLEARANCE

mm (in)
Inspection SERVICE LIMIT
Inspect oil pump shaft assembly, housing and cov- A
er for marks or other damages. B 0.25 mm (.009 in)
Check inner rotor for corrosion pin-holes or other C
damages. If so, replace oil pump shaft assembly.
Ensure to also check oil pump housing and cover If clearance between inner and outer rotors ex-
and replace if damaged. ceeds the tolerance, replace coolant/oil pump shaft
assembly. 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 complete
oil pump and the PTO housing.
SMR2002_071_05_07A.FM 05-07-11
Using a vernier depth gage, measure side wear as Installation

shown.
For installation, reverse the removal procedure. Pay
attention to the following details.
NOTE: Never use oil in the press fit area of the ro-
tary seal.
Push coolant/oil pump shaft seal in place by using
thumb.
1
R1503motr131A 2 1
1. PTO housing surface
2. Vernier depth gauge
R1503motr128A
1. Oil seal
Install the new rotary seal by using the rotary seal

pusher (P/N 529 035 823).
CAUTION: Never use a hammer for the rotary
seal or coolant/oil pump shaft installation. Only
use a press to avoid damaging the ceramic com-
ponent.
R1503motr132A 2 1
1. Oil pump outer rotor surface
2. Vernier depth gage
Difference between pump housing and outer rotor

should not exceed 0.1 mm (.004 in). If so, replace
replace the complete oil pump assembly.
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.
R1503motr141A 2 1
1. Rotary seal
2. Rotary seal pusher
05-07-12 SMR2002_071_05_07A.FM
Install the coolant/oil pump shaft using the rotary OIL SUCTION PUMP
seal pusher (P/N 529 035 823) on the opposite
side to support the rotary seal. Use the oil seal The oil suction pump is located on the front side
guide (P/N 529 035 822) with a press. of the engine at the bottom of the oil separator.
Removal
– Remove blow-by ventilation hose no. 7.
1
R1503motr142A 2 1
1. Oil seal guide
2. Coolant/oil pump shaft
R1503motr133A
1. Blow-by ventilation hose
– Disconnect wiring harness from blow-by pres-

sure switch no. 9 and blow-by valve no. 8.
– Detach air silencer from throttle body.
– Disconnect battery cables and vent tube then
remove battery. Refer to BATTERY in CHARG-
ING SYSTEM section for proper procedures.
– Remove retaining screws no. 42.
R1503motr143A 2
1. Coolant/oil pump shaft with oil seal guide
2. Rotary seal pusher spillage occurs, clean immediately with the pul-
ley flange cleaner (P/N 413 711 809) to prevent
Tighten oil pump cover screws and torque to 10 N•m stains.
(88 lbf•in). Apply Loctite 243 on threads.
Final Test  WARNING

After engine is completely reassembled, start en- lated area when working with strong chemi-
gine and make sure oil pressure is within specifi- cal products. Also wear suitable non-absor-
cations. bent gloves to protect your hands.
– Remove oil suction pump housing with oil sep-

arator.
SMR2002_071_05_07A.FM 05-07-13
– Remove oil pump screws no. 27 and cover no. 28.

1
R1503motr137A
1. Pittings on the teeth
Using a feeler gauge, measure the clearance be-

R1503motr135A 1 tween inner and outer rotors.
1. Oil pump cover
– Remove oil pump shaft ass’y no. 29.

– Remove outer rotor no. 30. A
B
C
R1503motr138A 2 1
1. Outer rotor
2. Inner rotor
OUTER AND INNER ROTOR CLEARANCE

R1503motr136A 1 2 mm (in)
1. Oil pump shaft ass’y SERVICE LIMIT
2. Outer rotor
A
Inspection B 0.25 mm (.009 in)
Inspect oil pump shaft assembly, housing and cov- C
er for marks or other damages.
If clearance between inner and outer rotors ex-
Check inner rotor for corrosion, pin-holes or other
ceeds the tolerance, replace oil pump shaft as-
damages. If so, replace oil pump shaft assembly.
sembly. Ensure to also check oil pump housing
Ensure to also check oil pump housing and cover
and cover and replace if damaged.
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.
05-07-14 SMR2002_071_05_07A.FM
Using a vernier depth gage, measure side wear as Installation

shown.
For installation, reverse the removal procedure. Pay
1
R1503motr139A 1 2
1. Oil pump housing surface
2. Vernier depth gage
R1503motr134A 2 2
1. Screws M6 x 85
2. Screws M6 x 25
Torque oil pump cover screws to 10 N•m (88 lbf•in).

Tighten suction pump screws as per following se-
quence and torque to 10 N•m (88 lbf•in). Apply
Loctite 243 (blue) on threads.
1
R1503motr140A 1 2
1. Oil pump outer rotor surface
2. Vernier depth gage 7
Difference between pump housing and outer rotor 3

should not exceed 0.1 mm (.004 in). If so, replace 6
the complete oil pump assembly. 4
NOTE: When the axial clearance of the oil pump
shaft assembly increases, the oil pressure de- R1503motr145A 2 5
creases.
Check the inside of oil pump housing and its cover
for scoring or other damages and replace if dam-
aged.
SMR2002_071_05_07A.FM 05-07-15
OIL FILTER BYPASS OIL COOLER

The oil filter bypass valve is located in the PTO The oil cooler is located below the air intake man-
housing below the oil filter. ifold.
Removal
Remove the PTO housing. Refer to PTO HOUSING/
MAGNETO section.
Remove plug screw no. 31 and pull out the oil fil-
ter bypass valve ball no. 32 and spring no. 33.
3 2 1
R1503motr110A
1
1. Oil cooler
Removal
Remove:
– cooling hoses no. 34 and no. 35
– retaining screws no. 36
R1503motr146A
– oil cooler no. 37
1. Plug screw
2. Compression spring 2 1
3. Ball
Inspection
Inspect ball for scoring or other damages.
Check compression spring for free length.
COMPRESSION SPRING FREE LENGTH
NEW NOMINAL 21.5 mm (0.846 in)
SERVICE LIMIT 21 mm (0.826 in)
Replace parts if important wear or damage are

R1503motr147A 1
present.
1. Screws
Clean bore and threads in the PTO housing from 2. Oil cooler
metal shavings and other contaminations.
Installation
Pay attention to the following details.
Torque plug screw to 28 N•m (21 lbf•ft). Apply Loc-
tite 243 (blue) on threads.
05-07-16 SMR2002_071_05_07A.FM
– O-rings no. 38.

1
R1503motr148A 1
1. O-Rings
R1503motr133A
Inspection 1. Blow-by ventilation hose

If O-rings are brittle, cracked or hard, replace them.
– Disconnect wiring harness from blow-by valve
Clean both contact surfaces of oil cooler. no. 8 and blow-by pressure switch no. 9.
Check and clean the oil inlet and outlet area for dirt – Detach air silencer box from throttle body.
and other contaminations.
– Disconnect battery cables and vent tube then
remove battery. Refer to BATTERY in CHARG-
Installation ING SYSTEM section for proper procedures.
For installation, reverse the removal procedure. – Remove retaining screws no. 42.
Apply grease on O-rings. spillage occurs, clean immediately with the pul-
Torque oil pump cover screws to 10 N•m (88 lbf•in). ley flange cleaner (P/N 413 711 809) to prevent
Apply Loctite 243 (blue) on threads. stains.
OIL SEPARATOR  WARNING

Pressure Test Wear safety glasses and work in a well venti-
Refer to ENGINE MANAGEMENT section. products. Also wear suitable non-absorbent
Removal
– Remove blow-by ventilation hose no. 7. – Remove suction pump cover with oil separator
ass’y.
– Remove blow-by valve no. 8 from oil separator.
Refer to BLOW-BY VALVE in ENGINE MANAGE-
MENT section.
– Completely disassemble oil separator ass’y.
SMR2002_071_05_07A.FM 05-07-17
Inspection
If O-rings and rubber rings are brittle, cracked or
hard, replace them.
Clean all contact surfaces of oil separator.
Check and clean the oil and blow-by channels for
dirt and other contaminations.
Installation
R1503motr119A 1 2
1. Screws M6 x 25
2. Screws M6 x 85
Apply grease on O-rings and rubber rings.

Torque screws to 10 N•m (88 lbf•in). Apply Loctite
243 (blue) on threads.
05-07-18 SMR2002_071_05_07A.FM
Subsection 08 (CYLINDER HEAD AND VALVES)
CYLINDER HEAD AND VALVES 0

NOTE: For cylinder head removal, it is not necessary to remove engine from vehicle.
10 Nm
1 (88 lbfin)
Engine oil
10 5
Grease Klueber 6
Isoflex Topas NB52 11
9
10
Engine 7 20 Nm (14.5 lbfft) + 90°
Loctite oil 8
243 18 Nm
6 Nm 24 (159 lbfin)
(53 lbfin) 10 Nm
12 25 10 Nm (88 lbfin)
14 22 (88 lbfin)
23 2
Loctite
243
13 21 28
29 16 Loctite
10 Nm 15 30 10 Nm
243
20 Engine
oil
Loctite 243
40 Nm (29.5 lbfft)
+ 120° + 90°
17
6 Nm
(53 lbfin)
18 Nm
(159 lbfin) 18
Engine oil
Engine oil
19
26
Loctite 243
27
10 Nm (88 lbfin)
R1503motr43S
SMR2002_072_05_08A.FM 05-08-1
GENERAL Unscrew spark plug no. 2 then use the single-

spark ignition coil to take spark plug out of spark
NOTE: When diagnosing an engine problem, al- plug hole.
ways perform a cylinder leak test. This will help
pin-point a problem. Refer to the instructions in- 1
cluded with your leak tester and LEAK TEST sec-
tion for procedures. 2
Always place the vehicle on level surface.
NOTE: For a better understanding, the following
illustrations are taken with engine out of vehicle.
To perform the following instructions, it is not nec-
essary to remove engine from vehicle.
Always disconnect the negative wire from the bat-
tery before working on the engine.
Even if the removal of many parts is not necessary
to reach another part, it is recommended to re- R1503motr44A
move these parts in order to check them.
1. Single-spark ignition coil
For installation, use the torque values and Loctite 2. Spark plug
products as mentioned. Clean threads before us-
ing Loctite product when installing screws. Inspection
When disassembling parts that are duplicated in Check spark plug and single-spark ignition coil con-
the engine, (e.g.: valves, bushings), it is strongly dition (refer to ENGINE MANAGEMENT SYSTEM).
recommended to note their position (cylinder 1, 2
or 3) and to keep them as a “group”. If you find a Installation
defective component, it would be much easier to For installation, reverse the removal procedure.
find the cause of the failure among its group of Pay attention to the following details.
parts (e.g.: you found a worn valve guide. A bent
spring could be the cause and it will be easy to Check spark plug gap.
know which one among the springs is the cause Place spark plug into single-spark ignition coil,
to replace it if you grouped them at disassembly). screw spark plug then remove the single-spark ig-
Besides, since used parts have matched together nition coil. Torque spark plug. Reinstall the single-
during the engine operation, they will keep their spark ignition coil.
matched fit when you reassemble them together NOTE: Prior to inserting the ignition coil to its lo-
within their “group”. cation, apply some BOMBARDIER LUBE lubricant
SPARK PLUG hole. After installation, ensure the seal seats prop-
erly with the engine top surface.
Removal
Remove fuel rail cover from engine. VALVE COVER
Unplug the single-spark ignition coil connector on
the spark plug you need to remove.
Removal
Remove the single-spark ignition coil no. 1. Remove:
Clean spark plug and single-spark ignition coil area – valve cover shield no. 3
before disassembly. – valve cover screws no. 4
05-08-2 SMR2002_072_05_08A.FM
3 1 5
R1503motr81A
1. Valve cover screws

R1503motr159A 8 2 4 6
– valve cover no. 5 and profile sealing ring no. 6.
Torque screws first to 40 N•m (29 lbf•ft) and in a
second sequence to 55 N•m (40 lbf•ft).
2
ROCKER ARM
Removal
Lock crankshaft with crankshaft locking tool
(P/N 529 035 821), refer to CRANKSHAFT LOCK-
ING in ENGINE BLOCK section.
1 Remove:
R1503motr82A – spark plug
1. Valve cover – valve cover
2. Profile sealing ring
– spark plug tube no. 7
Inspection
1
Check the profile sealing ring on the valve cover
and the rubber bushing on the valve cover screws
if they are brittle, cracked or hard. If so, replace the
profile sealing ring or the valve cover screw accord-
ingly.
Installation
NOTE: Install the valve cover screws according to
following sequence.
R1503motr83A
1. Spark plug tube
SMR2002_072_05_08A.FM 05-08-3
– rocker arm shaft screws no. 8. Discard screws. Inspection

Spark Plug Tube
1
Check seals on spark plug tube. If seals are brittle,
cracked or hard, replace spark plug tube.
R1503motr93B 2 1 3
R1503motr86A
1. Rocker arm shaft screws

1. Spark plug tube
2. Seal to the valve cover
– rocker arm shaft no. 9 with rocker arm assem- 3. Seal to the cylinder head
bly (exhaust side no. 10 and intake side no. 11).
Rocker Arm
1 Inspect each rocker arm for cracks and scored fric-
tion surfaces. If so, replace rocker arm assembly.
3 Check the rocker arm rollers for free movement,
wear and excessive radial play. Replace rocker
arm assembly as necessary.
R1503motr84A 2
1. Rocker arm shaft
2. Rocker arms (exhaust side)
3. Rocker arm (intake side)
1
A
1 2
R1503motr87A
1. Rocker arm (intake side)

2. Roller
A. Bore for rocker arm shaft
R1503motr85A
1. Oil supply from the camshaft to the rocker arm shaft, then to the
rocker arms and finally to the valve adjustment
05-08-4 SMR2002_072_05_08A.FM
Measure rocker arm shaft diameter.
ROCKER ARM SHAFT DIAMETER
NEW MINIMUM 19.980 mm (.7866 in)
NEW MAXIMUM 20.007 mm (.7877 in)
SERVICE LIMIT 19.965 mm (.7860 in)
A
1
R1503motr88A 2
1. Rocker arm (exhaust side)
2. Roller
A. Bore for rocker arm shaft
Measure rocker arm bore diameter. If diameter is R1503motr90A A

out of specification, change the rocker arm assem- A. Measure rocker arm shaft diameter here
bly.
Any area worn excessively will require parts replace-
ROCKER ARM BORE DIAMETER
ment.
NEW MINIMUM 20.007 mm (.7877 in) Installation

NEW MAXIMUM 20.020 mm (.7881 in) For installation, reverse the removal procedure. Pay
SERVICE LIMIT 20.035 mm (.7887 in) Apply engine oil on rocker arm shaft.
Press the hydraulic lifter with your thumb. If the IMPORTANT: The rocker arm shaft can only be
hydraulic lifter groove disappears inside rocker installed in one specific position. Therefore crank-
arm casting, replace rocker arm assembly. Lifter shaft as well as camshaft has to be positioned
must turn freely in rocker arm bore. Otherwise, with their locking pins when the piston of cylinder
replace. no. 3 is on ignition TDC. Refer to CRANKSHAFT
LOCKING in ENGINE BLOCK section for crank-
shaft and the following for the camshaft locking.
Use camshaft locking tool (P/N 529 035 839). Ro-
tate camshaft so that tool can be pushed in cam-
shaft hole and lock camshaft in place.
R1503motr89A
1. Hydraulic lifter groove
Rocker Arm Shaft

Check for scored friction surfaces, if so, replace parts. R1503motr111A
1. Camshaft locking tool
SMR2002_072_05_08A.FM 05-08-5
Then, the camshaft sprocket lines should be lined – Torque screws at first to 10 N•m (88 lbf•in) ac-
up as shown in the following illustration. cording to following sequence.
1 1 1 3 4
5 2
6
R1503motr93A
R1503motr95A
– Torque screws to 20 N•m (177 lbf•in).

1. Position lines
– Finish tightening screws turning an additional
Position the rocker arm shaft with the notches on 90° rotation with a torque angle gauge.
top.
2
1
2
1
R1503motr92A
R1503motr91A 1. Rocker arm shaft screw

2. Torque angle gauge
1. Rocker arm shaft
2. Rocker arm shaft notches
CAMSHAFT TIMING GEAR
Install NEW rocker arm shaft screws no. 8. Torque
as per following procedure: NOTE: Although it is not necessary to position
crankshaft to TDC for disassembly, it is a good
CAUTION: This assembly use stretch screws. practice to do it, as a troubleshooting step, to
As the screws have been stretched from the know before disassembly if valve timing was ap-
previous installation, it is very important to use propriate.
new screws at assembly. Failure to replace
screws and to strictly follow the torque proce-
dure may cause screws to loosen and lead to
engine damage.
05-08-6 SMR2002_072_05_08A.FM
Removal Install the camshaft timing gear with the writing

visible, i.e. to be able to see the position lines when
looking from outside of engine.
ING in ENGINE BLOCK section. 1
Remove:
– valve cover
– chain tensioner. Refer to CHAIN TENSIONER
REMOVAL in ENGINE BLOCK section
– chain guide no. 12
– Allen screws no. 13
– camshaft timing gear no. 14.
NOTE: Secure timing chain no. 15 with a retaining
wire.
Inspection
2
Check camshaft timing gear for wear or deteriora-
tion.
If gear is worn or damaged, replace it as a set
(camshaft timing gear and timing chain).
For crankshaft timing gear, refer to ENGINE BLOCK
section.
Installation
R1503motr97A
A
Using the camshaft locking tool (P/N 529 035 839),
lock camshaft on TDC position. 1. Good (with 1503 aligned)
2. Never
Install timing chain. Refer to ENGINE BLOCK sec-

tion.
1
Ensure chain guides are in place.
Loosely install screws.
Install chain tensioner.
Tighten screws and torque to 10 N•m (88 lbf•in)
Remove locking tools.
2 CAUTION: Crankshaft and camshaft must be
locked on TDC position to place camshaft tim-
ing gear and timing chain in the proper posi-
tion. To double check, take a look at the timing
R1503motr94A
gear lines. They must be parallel to the cylinder
1. Camshaft locking tool head surface.
2. Camshaft on TDC position
SMR2002_072_05_08A.FM 05-08-7
1 1
R1503motr95A R1503motr110A
1
1. position lines 1. Blow-by ventilation hose
CAUTION: Ensure to remove locking tools when – coolant hose

finished.
TIMING CHAIN
Refer to ENGINE BLOCK section.
CYLINDER HEAD
Removal
ING in ENGINE BLOCK section.
Drain coolant (refer to COOLING SYSTEM).
Disconnect coolant temperature and cam position
sensors (CTS and CAPS). R1503motr120A 1
Remove: 1. Blow-by ventilation hose
– exhaust manifold (refer to EXHAUST MANI- – chain tensioner (refer to CHAIN TENSIONER
FOLD REMOVAL elsewhere in this section) REMOVAL in ENGINE BLOCK section)
– engine coolant outlet hose – valve cover shield
– valve cover and profile sealing ring
(see VALVE COVER REMOVAL above)
– camshaft timing gear
– cylinder head screws M6 no. 16
05-08-8 SMR2002_072_05_08A.FM
Installation
Ensure dowel pins are in place.
1
Install new cylinder head gasket.
CAUTION: Each installation of the cylinder head
requires a new cylinder head gasket. Using a
gasket twice will cause engine damage, even if
the engine had not run.
Install cylinder screws M11 no. 17. Torque screws
as per following procedure.
R1503motr98A
CAUTION: This assembly use stretch screws.
As the screws have been stretched from the
1. Cylinder head screws M6
previous installation, it is very important to
– cylinder head screws M11 no. 17 retaining cyl- measure each screw at assembly. If screw is
inder head to engine block. out of specification, replace by a new. Failure
to replace screws and to strictly follow the
torque procedure may cause screws to loosen
1 and lead to engine damage.
CYLINDER SCREW M11

Torque screws according to following sequence.

First torque to 40 N•m (30 lbf•ft).
Then tighten screws turning an additional 120° ro-
tation with a torque angle gauge and finish tight-
ening with a 90° rotation. Torque screws no. 16 to
R1503motr99A
10 N•m (88 lbf•in).
1. Cylinder head screws M11
Pull up cylinder head no. 18. 1

2
Remove gasket no. 19.
Cleaning
Remove carbon deposits from combustion cham-
ber, exhaust port and piston top.
Inspection
Check for cracks between valve seats, if so, replace
cylinder head.
Check mating surface between cylinder and cylin-
der head for contamination. If so, clean both sur-
faces. R1503motr100A
1. Cylinder screws M11

2. Angle torque wrench
Remove crankshaft locking tool then install plug

with sealing ring.
SMR2002_072_05_08A.FM 05-08-9
CAMSHAFT CAMSHAFT LOBE - EXHAUST VALVE
Removal NEW MINIMUM 31.699 mm (1.248 in)

Remove: NEW MAXIMUM 31.809 mm (1.252 in)
– valve cover SERVICE LIMIT 31.670 mm (1.247 in)
– rocker arms
CAMSHAFT LOBE - INTAKE VALVE
– chain tensioner (refer to CHAIN TENSIONER
REMOVAL in ENGINE BLOCK section) NEW MINIMUM 31.480 mm (1.239 in)
– camshaft timing gear NEW MAXIMUM 31.590 mm (1.244 in)
– camshaft lock no. 20
– camshaft no. 21.
CAMSHAFT BEARING JOURNAL
1
NEW MINIMUM 39.892 mm (1.5705 in)
2
NEW MAXIMUM 39.905 mm (1.5711 in)
CAMSHAFT BEARING JOURNAL - ENGINE FRONT

R1503motr101A CAMSHAFT BORE

MEASURED IN DIAMETER
1. Camshaft lock
2. Camshaft
Inspection NEW MAXIMUM 40.016 mm (1.5754 in)
Check each lobe and bearing journal of camshaft
for scoring, scuffing, cracks or other signs of wear. SERVICE LIMIT 40.050 mm (1.5767 in)
Measure camshaft bearing journal diameter and CAMSHAFT BORE - ENGINE FRONT
lobe height using a micrometer. MEASURED IN DIAMETER
Measure clearance between both ends of cam- NEW MINIMUM 25.000 mm (.9842 in)
shaft and cylinder head.
D A B A C C A B A C C A B A C SERVICE LIMIT 25.050 mm (.9862 in)
Replace parts that are not within specifications.
Installation
R1503motr102A
A. Camshaft lobe (exhaust valves) Pay attention to the following details.
B. Camshaft lobe (intake valves)
C. Camshaft bearing journal Grease the camshaft bearing journals well by us-
D. Camshaft bearing journal — engine front
ing the grease Klueber Isoflex (P/N 293 550 021)
or a similar product.
Install camshaft then place the camshaft lock no. 20
in the slot.
05-08-10 SMR2002_072_05_08A.FM
1
2
R1503motr101B
1. Camshaft lock position
For other parts, refer to proper installation proce-

dure.
R1503motr103A
VALVE SPRING 1. Valve spring compressor clamp

2. Valve spring compressor cup
Removal
Remove:
– rocker arms
– cylinder head.
Compress valve springs no. 22 and no. 23. Use
valve spring compressor clamp (P/N 529 035 724)
and valve spring compressor cup (P/N 529 035
725).
 WARNING
Always wear safety glasses when disassem-
bling valve springs. Be careful when unlock-
ing valves. Components could fly away be-
cause of the strong spring preload. R1503motr104A
LOCATE VALVE SPRING COMPRESSOR CLAMP IN CENTER OF

THE VALVE
Remove valve cotters no. 24.
SMR2002_072_05_08A.FM 05-08-11
Withdraw valve spring compressor, valve spring Installation

retainer no. 25 and valve springs.
1 Pay attention to the following details.
2 Colored area of the valve spring must be placed on
3 top.
NOTE: Valve cotters must be properly engaged in
valve stem grooves.
R1503motr105A
1. Valve spring retainer

2. Inner valve spring
3. Outer valve spring
Inspection
Check valve springs for rust, corrosion or other vis- R1503motr105B
ible damages. If so, replace faulty valve springs.
1. Position of the valve spring
Check valve springs for free length and straight-
ness. VALVE
Replace valve springs if not within specifications.
Removal
Remove valve spring.
Push valve stem then pull valves no. 26 and
no. 27 out of valve guides.
A
R610motr122A
2
A. Valve spring length
OUTER VALVE SPRING FREE LENGTH
NEW NOMINAL 45.45 mm (1.789 in)

R1503motr106A
SERVICE LIMIT 43 mm (1.693 in)
1. Intake valve 38 mm
INNER VALVE SPRING FREE LENGTH 2. Exhaust valve 31 mm
NEW NOMINAL 41.02 mm (1.615 in) Remove valve stem seal no. 28 with special pliers
such as Snap-on YA 8230.
05-08-12 SMR2002_072_05_08A.FM
R610motr126A
A. Valve stem diameter

R610motr125A
VALVE STEM DIAMETER mm (in)

Inspection NEW MINIMUM
Valve Stem Seal
Exhaust 5.946 mm (.2341 in)
Inspection of valve stem seals is not needed be-
cause new seals should always be installed when- Intake 5.961 mm (.2347 in)
ever cylinder head is removed.
NEW MAXIMUM
Valve
Exhaust 5.960 mm (.2346 in)
Inspect valve surface, check for abnormal stem
wear and bending. If so, replace by a new one. Intake 5.975 mm (.2352 in)
Valve Stem and Valve Guide Clearance SERVICE LIMIT
Measure valve stem and valve guide in three places,
Exhaust
using a micrometer and a small bore gauge. 5.93 mm (.233 in)
NOTE: Clean valve guide to remove carbon depos- Intake
its before measuring.
Change valve if valve stem is out of specification
or has other damages such as wear or friction sur-
face.
SMR2002_072_05_08A.FM 05-08-13
Replace valve guide if it is out of specification or Measure valve seat width, using a caliper.
has other damages such as wear or friction sur-
face. VALVE SEAT CONTACT WIDTH mm (in)
VALVE GUIDE DIAMETER mm (in) NEW
NEW MINIMUM 1.25 to 1.55 mm

Exhaust
(.049 to .061 in)
Exhaust
5.994 mm (.2359 in) 1.10 to 1.30 mm
Intake
Intake (.043 to .051 in)
NEW MAXIMUM SERVICE LIMIT
Exhaust Exhaust 2 mm (.078 in)

6.018 mm (.2369 in)
Intake Intake 1.8 mm (.07 in)
SERVICE LIMIT If valve seat contact width is too wide or has dark
Exhaust
spots, replace the cylinder head.
6.060 mm (.2386 in)
Intake
A B
Valve Face and Seat
2 3
V01C1HA
A. Valve face contact width

B. Valve seat contact width
Installation
R1503motr107A 1 For installation, reverse the removal procedure.
1. Valve seat
2. Exhaust valve contaminated area Install thrust washer no. 30, valve spring guide
3. Valve face (contact surface to valve seat)
no. 29 then valve stem seal no. 28.
– Check valve face and seat for burning or pittings
and replace valve or cylinder head if there are
signs of damage.
Ensure to seat valves properly. Apply some lap-
ping compound to valve face and work valve on its
seat with a lapping tool.
Measure valve face contact width.
NOTE: The location of contact area should be in
center of valve seat.
05-08-14 SMR2002_072_05_08A.FM
R1503motr108A 2 1
1. Thrust washer
2. Valve spring guide
3. Valve stem seal
Apply engine oil on valve stem and install it.

CAUTION: Be careful when valve stem is passed
through sealing lips of valve stem seal.
R1503motr108B
1. Sealing lips of valve stem seal
To ease installation of cotters, apply oil or grease

to them so that they remain in place while releas-
ing the spring.
After spring is installed, ensure it is properly locked
by tapping on valve stem end with a soft hammer
so that valve opens and closes a few times.
CAUTION: An improperly locked valve spring will
cause engine damage.
SMR2002_072_05_08A.FM 05-08-15
Subsection 09 (ENGINE BLOCK)
ENGINE BLOCK 0
Grease Klueber Isoflex Topas NB52 Grease

Loctite 243 Engine
oil
10 Nm
24 Nm 21 (88 lbfin)
(17 lbfft)
22 Loctite 243
Engine
oil 20
Loctite 243 19
18 Nm
(159 lbfin)
18
Engine
10 Nm oil
24 Nm (88 lbfin)
(17 lbfft)
Engine
oil Loctite 243
16
Loctite 243
18 Nm 24 Nm
17 (159 lbfin)
(17 lbfft)
Loctite 243
24 Nm
(17 lbfft)
Engine
oil Loctite 243
3 18 Nm
(159 lbfin)
2
7 24 Nm
(17 lbfft)
10 Nm 1 40 Nm 55 Nm
(88 lbfin) +
(30 lbfft) (41 lbfft)
Loctite 243 24 Nm
(17 lbfft)
R1503motr01S
SMR2002_073_05_09A.FM 05-09-1
9 Engine
8
oil 10
Engine Engine
oil oil
Engine
oil
Engine
260 Nm oil
(191 lbfft) Engine
4 oil
Loctite
Engine anti-seize 4 12
oil
Engine
oil
Engine
oil 45 Nm
11 (33 lbfft) + 90°
6
13
Engine
oil
6
Engine 5
oil
Engine
15 oil
14
Engine Engine
Engine oil
oil oil
15
R1503motr02S
05-09-2 SMR2002_073_05_09A.FM
GENERAL 1
When disassembling parts that are duplicated in
the engine, (e.g.: pistons, connecting rods etc.), it
is strongly recommended to note their position
(Cylinder 1, 2 or 3) and to keep them as a “group”.
If you find a defective component, it would be
much easier to find the cause of the failure among
its group of parts (e.g.: you found a worn valve
guide. A bent spring could be the cause and it will
be easy to know which one among the springs is
the cause to replace it if you grouped them at dis-
assembly). Besides, since used parts have
matched together during the engine operation,
they will keep their matched fit when you reas-
semble them together within their “group”. R1503motr03A
1. Screwdriver
CRANKSHAFT LOCKING In this position, the crankshaft can be locked by
Remove: using crankshaft locking tool P/N 529 035 821.
– seat and vent tube support When finished, reinstall all removed parts.
– air intake manifold (refer to AIR INTAKE MANI-
FOLD REMOVAL in ENGINE section) CRANKSHAFT
– fuel rail cover
Removal
– spark plugs
Remove:
– plug screw.
– engine oil
2 1 (refer to OIL CHANGE in LUBRICATION section)
– engine from vehicle
(refer to REMOVAL AND INSTALLATION)
– cylinder head (refer to CYLINDER HEAD RE-
MOVAL in CYLINDER HEAD section)
in PTO HOUSING/MAGNETO section)
– starter gear (refer to STARTER GEAR REMOV-
AL in PTO HOUSING/MAGNETO section)
– starter drive ass’y
– oil suction pump with oil separator ass’y (refer
to SUCTION PUMP REMOVAL in LUBRICA-
TION section)
R1503motr04A
– engine mounting brackets
1. Plug screw
2. Gasket ring
Put a screwdriver or similar into the spark plug

hole of cylinder no. 3 and feel when the piston
reaches TDC.
SMR2002_073_05_09A.FM 05-09-3
– oil tank plug screws no. 1 with O-ring no. 2 NOTE: Before removing the connecting rod bear-
ing caps, mark them to remember the right posi-
1 tion when reassembling.
R1503motr05A
ENGINE UPSIDE DOWN

1. Oil tank plug screw with O-ring
– engine block screws no. 3 and no. 7

R1503motr07A 1
1. Mark on connecting rod
– thrust washers no. 4
1
R1503motr06A
BOTTOM VIEW OF ENGINE

1. Screws
– bottom engine block half

– connecting rod screws R1503motr09A
1 1. Thrust washer
R1503motr08A
1. Connecting rod screws
05-09-4 SMR2002_073_05_09A.FM
– crankshaft no. 5.
1 2
1
R1503motr12A
R1503motr10A
1. Crankshaft
1. Crankshaft 2. Feeler gauge
Inspection CONNECTING ROD BIG END

Replace crankshaft if the gears are worn or other- mm (in)
wise damaged. NEW MINIMUM 0.150 mm (.06 in)
2 NEW MAXIMUM 0.302 mm (.01 in)
Crankshaft Radial Play

Measure all crankshaft journals. Compare to inside
diameter of crankshaft bushings (elsewhere in this
section).
1
1
R1503motr11A
1. Balancer gear
2. Crankshaft timing gear
Connecting Rod Big End Axial Play

Using a feeler gauge, measure distance between 2
butting face of connecting rod and crankshaft
counterweight. If the distance exceeds specified
tolerance, replace the worn part.
R1503motr13A
1. Micrometer
2. Crankshaft area for bushing
SMR2002_073_05_09A.FM 05-09-5
CRANKSHAFT JOURNAL DIAMETER Installation

mm (in) For installation, reverse the removal procedure.
NEW MINIMUM 49.91 mm (1.9650 in) Pay attention to following details.
NOTE: Before installing the crankshaft, make sure
that the timing chain is on the crankshaft and the
SERVICE LIMIT 49.88 mm (1.9637 in) chain tension guide has been installed first. Those
parts cannot be installed as soon as the crankshaft
CRANKSHAFT JOURNAL RADIAL CLEARANCE is in place.
mm (in) CAUTION: Crankshaft has to be aligned with
SERVICE LIMIT 0.07 mm (.0028 in) balance shaft. Grooves on crankshaft and bal-
ance shaft.
Crankshaft Pin
Measure all crankshaft pin diameters. Compare to
inside diameter of connecting rod bushings (else-
where in this section).
1 2
R1503motr17A 1 2
1. Groove on balance shaft
2. Groove on crankshaft
For correct installation of the connecting rods refer

R1503motr14A
to CONNECTING ROD INSTALLATION elsewhere
in this section.
1. Micrometer
2. Crankshaft pin area for bushing CAUTION: It is absolutely necessary to follow
this procedure. Otherwise several engine dam-
CRANKSHAFT PIN DIAMETER age can occur.
mm (in)
CAUTION: Never forget thrust washers no. 4
NEW MINIMUM 45.032 mm (1.7729 in) for axial adjustment on crankshaft center.
CRANKSHAFT PIN RADIAL CLEARANCE

mm (in)
05-09-6 SMR2002_073_05_09A.FM
Insert thrust washers as soon as crankshaft is in Install the crankshaft cover before mounting the
place according to following illustration. engine bracket. Put some oil on O-ring and press
the cover in. The crankshaft cover has to be even
with the engine block surface.
1
R1503motr09A
THRUST WASHER INSERT DIRECTION

1. Thrust washer
CAUTION: Thrust washers has to be even with R1503motr19A 2

the engine block sealing surface.
1. O-ring
1 2. Crankshaft cover
CAUTION: Install crankshaft locking tool (P/N 529

035 821) right away to put crankshaft in TDC
position before installing the camshaft and rock-
2
ers (refer to CYLINDER AND HEAD).
1
R1503motr16A
1. Thrust washer
2. Sealing surface
Install lower engine block half. Refer to ENGINE

BLOCK ASSEMBLY elsewhere in this section for
proper procedure to clean surfaces, apply Loctite
5910 and proper torquing sequence. R1503motr18A
1. Crankshaft locking tool
SMR2002_073_05_09A.FM 05-09-7
TIMING CHAIN CHAIN TENSIONER

Inspection Removal
Check timing chain on camshaft timing gear for ex- NOTE: Removal of the air intake manifold allows
cessive radial play. easier access to the chain tensioner, but is not
Check chain condition for wear and rollers condition. necessary. Refer to AIR INTAKE MANIFOLD RE-
MOVAL in INTAKE section.
Remove:
– chain tensioner plug screw no. 18 with gasket
ring no. 19
– chain tensioner no. 20.
R610motr201A 1 3 2
1. Timing chain
If chain is excessively worn or damaged, replace

it as a set (camshaft timing gear and timing chain).
Removal
Remove:
– engine oil (refer to OIL CHANGE in LUBRICA-
TION section)
– engine from vehicle (refer to REMOVAL AND
INSTALLATION)
MOVAL in CYLINDER HEAD section) R1503motr39A 1
– PTO housing (refer to PTO HOUSING REMOV- 1. Plug screw
AL in PTO HOUSING/MAGNETO section) 2. Gasket ring
3. Chain tensioner
– crankshaft (refer to CRANKSHAFT REMOVAL
elsewhere in this section) Inspection
– timing chain. Check chain tensioner for excessive wear or
cracks. Also check free movement of the chain ten-
Installation sioner piston.
The installation is essentially the reverse of the re-
moval procedure but, pay attention to the follow- Installation
ing details. The installation is essentially the reverse of the re-
Ensure to perform proper valve timing. Lock crank- moval procedure but, pay attention to the follow-
shaft and camshaft at TDC (refer to CYLINDER ing details.
HEAD). Torque chain tensioner plug screw to 18 N•m
Install chain then, install chain tension. (160 lbf•in).
CAUTION: Improper valve timing will damage
engine components.
05-09-8 SMR2002_073_05_09A.FM
BALANCER SHAFT – engine block screws no. 3
Removal
Remove:
– engine oil (refer to OIL CHANGE in LUBRICA-
TION section)
INSTALLATION) 1
R1503motr06A
AL in PTO HOUSING/MAGNETO section) 1. Screws
– starter drive ass’y – bottom engine block half
– oil suction pump with oil separator ass’y (refer – thrust washers no. 6
TION section) 1
– engine mounting brackets
– oil tank plug screws no. 1 with O-ring no. 2
1
R1503motr05A
R1503motr20A
ENGINE UPSIDE DOWN

1. Thrust washer
1. Oil tank plug screw with O-ring
– balance shaft.
SMR2002_073_05_09A.FM 05-09-9
Inspection Installation
Check balancer shaft and replace if damaged. For installation, reverse the removal procedure.
If the gear on the balancer shaft is damaged, re- Pay attention to following detail.
place balancer shaft. CAUTION: Balance shaft has to be aligned with
Check gear(s) on the crankshaft the same time and crankshaft. Grooves on crankshaft and balance
replace crankshaft if necessary (refer to CRANK- shaft.
SHAFT above).
Balance Shaft Bushing Seat Play
Measure all balance shaft bushing seats. Compare
to inside diameter of balance shaft bushings (else-
where in this section).
1
2
R1503motr17A 1 2
1. Groove on balance shaft
2. Groove on crankshaft
CAUTION: Never forget thrust washers no. 6

for axial adjustment on balance shaft PTO side.
R1503motr23A
Insert thrust washers as soon as balance shaft is
1. Micrometer in place according to following illustration.
2. Balance shaft area for bushings
1
BALANCE SHAFT SEAT DIAMETER
mm (in)
BALANCE SHAFT SEAT RADIAL CLEARANCE

mm (in)
R1503motr20B
THRUST WASHER INSERT DIRECTION

1. Thrust washer
05-09-10 SMR2002_073_05_09A.FM
CAUTION: Thrust washers has to be even with CAUTION: Install crankshaft locking tool (P/N
the engine block sealing surface. 529 035 821) right away to put crankshaft in TDC
position before installing the camshaft and rock-
2 ers (refer to CYLINDER AND HEAD).
1
R1503motr22A
1. Thrust washer
2. Sealing surface
R1503motr18A
Install lower engine block half. Refer to ENGINE 1. Crankshaft locking tool
BLOCK ASSEMBLY elsewhere in this section for
proper procedure to clean surfaces, apply Loctite
5910 and proper torquing sequence.
ENGINE BLOCK
Install the crankshaft cover before mounting the Removal
engine bracket. Put some oil on O-ring and press
the cover in. The crankshaft cover has to be even Remove:
with the engine block surface. – engine oil (refer to OIL CHANGE in LUBRICA-
TION section)
1
INSTALLATION)
AL in PTO HOUSING/MAGNETO section)
– starter drive ass’y
– oil suction pump with oil separator ass’y (refer
TION section)
– balance shaft (refer to BALANCE SHAFT RE-
R1503motr19A 2 MOVAL elsewhere in this section)
1. O-ring – crankshaft (refer to CRANKSHAFT REMOVAL
2. Crankshaft cover
elsewhere in this section)
– piston with connecting rod (refer to PISTON RE-
MOVAL elsewhere in this section).
SMR2002_073_05_09A.FM 05-09-11
Bushings – hammer CJ125-6

When bushings need to be removed from the en- – claws CJ93-4.
gine block, mark them to identify the correct posi-
tion at installation. See the following illustration for
an example:
1
F01J0ZA
Close puller claws so that they can be inserted in

end bearing. Holding claws, turn puller shaft clock-
wise so that claws open and become firmly tight
against bearing.
Slide puller hammer outwards and tap puller end.
Retighten claws as necessary to always maintain
them tight against bearing. Continue this way until
bearing completely comes out.
Inspection
Cylinder
R1503motr37A 2
Check cylinder for cracks, scoring and wear ridges
1. Mark on balance shaft bushings on the top and bottom of the cylinder. If so, replace
2. Mark on crankshaft bushings
cylinder.
Starter Drive Bearing
Cylinder Taper
Check bearing no. 21 of starter drive assembly
no. 22 in engine block and replace it if damaged. Measure cylinder bore and if it is out of specifica-
tions, rehone cylinder sleeve and replace piston
ass’y with first oversize.
NOTE: It is not necessary to have all cylinders re-
honed if they are not all out of specification. Mixed
standard size and oversize cylinders are allowed.
Measure cylinder bore at 3 recommended posi-
tions. See the following illustration.
1 B
R1503motr40A 1 3
1. Bearing of starter drive assembly
Starter drive bearing can be easily removed from

lower crankcase half using the following suggest-
R1503motr24A
ed tool or equivalent:
1. First measuring diameter
– Snap-on hammer puller including: 2. Second measuring diameter
3. Third measuring diameter
– handle CJ93-1 A. 60 mm (2.362 in)
B. 110 mm (4.331 in)
05-09-12 SMR2002_073_05_09A.FM
CYLINDER TAPER IN DIAMETER

mm (in)

1
Distance between measurements should not ex-
ceed the service limit mentioned above.
Cylinder Out of Round
Measure cylinder diameter in piston axis direction
from top of cylinder. Take an other measurement
90° from first one and compare.
NOTE: Take the same measuring points like de-
R1503motr33A
scribed in CYLINDER TAPER above.
ENGINE UPSIDE DOWN
1. Radial gauge
CRANKSHAFT BUSHING INSIDE DIAMETER

mm (in)
A
B
R1503motr25A
A. Perpendicular to crankshaft axis

B. Parallel to crankshaft axis
CYLINDER OUT OF ROUND

mm (in)

R1503motr34A 1
ENGINE UPSIDE DOWN
Bushings
1. Radial gauge
To measure the wear of the crankshaft bushings
no. 13 and no. 14 and balance shaft bushings BALANCE SHAFT BUSHING INSIDE DIAMETER
no. 15, both engine block halves with OLD bush- mm (in)
ings have to be screwed together according to SERVICE LIMIT 32.11 mm (1.2642 in)
tightening procedure described below.
Measure the inside diameter of the bushings with Replace bushings if they are out of specifications.
a radial gauge.
SMR2002_073_05_09A.FM 05-09-13
Oil Spray Nozzles Put bushings correctly in place. Top crankshaft

Remove oil spray nozzle no. 16 and banjo screw bushing halves have a bore which has to be placed
no. 17 from engine block. in the upper engine block.
1 2
2 3
R1503motr35A
R1503motr38A
1. Upper engine block half
2. Oil bore in engine block
1. Banjo screw 3. Oil bore in bushing
2. Oil spray nozzle
Bushings have to be even with the engine block
Check free movement of ball inside the banjo
split surface and their protrusions have to fit in the
screw. Clean Nozzle and banjo screw from dirt and
notched areas in the engine block seat.
debris.
1
Installation
Torque oil spray nozzle to 18 N•m (160 lbf•in).
To install starter drive bearing no. 21 of starter
drive assembly, use pusher (P/N 290 876 502) and
handle (P/N 420 877 650).
R1503motr36A
1. Bushing protrusion in engine block notch
2 Apply engine oil on all bushings, in the bottom area

F06D32A of the cylinder bore and also on the band of the
piston ring compressor tool.
1. Handle
2. Pusher For proper installation of pistons, refer to PISTON
Use NEW bushings when diameters are out of INSTALLATION elsewhere in this section.
specification. NOTE: Before installing the crankshaft, make sure
If OLD bushings can be used again, make sure that the timing chain is on the crankshaft and the
they are at the same position as they were before. chain tension guide has been installed first. Those
parts cannot be installed after as the crankshaft is
in place.
05-09-14 SMR2002_073_05_09A.FM
Clean oil passages and make sure they are not

clogged.
Engine block mating surfaces are best cleaned us-
ing a combination of the chisel gasket remover
(P/N 413 708 500) and a brass brush. Brush a first
pass in one direction then make the final brushing
perpendicularly (90°) to the first pass (cross hatch).
CAUTION: Do not wipe with rags. Use a new
clean hand towel only.
IMPORTANT: When beginning the application of
the crankcase sealant, the assembly and the first
torquing should be done within 10 minutes. It is sug-
gested to have all you need on hand to save time.
F12R17A
NOTE: It is recommended to apply this specific
sealant as described here to get an uniform appli- Do not apply in excess as it will spread out inside
cation without lumps. If you do not use the roller crankcase.
method, you may use your finger to uniformly dis-
tribute the sealant (unlike the Drei Bond sealing NOTE: Do not use Loctite Primer N with this seal-
compound, using a finger will not affect the adhe- ant. The sealant curing time is similar to the Loc-
sion). tite 518 without using the Primer N, which is 4 to
24 hours.
Use the silicone-based Loctite 5910 (P/N 293 800
081) on mating surfaces. Tighten engine block screws according to follow-
ing sequence.
CAUTION: Do not use Loctite 515 or 518 to seal
crankcase. Do not use Loctite Primer N with the 6 16 15 14 4 9 2 10 11 12 13 8
Loctite 5910. Using these products or non sili-
cone-based sealant over a previously sealed
crankcase with Loctite 5910 will lead to poor ad-
hesion and possibly a leaking crankcase. These
products are chemically incompatibles. Even af-
ter cleaning, the Loctite 5910 would leave incom-
patible microscopic particles.
Use a plexiglas plate and apply some sealant on it.
Use a soft rubber roller (50 - 75 mm (2 - 3 in))
(available in arts products suppliers for printmak-
ing) and roll the sealant to get a thin uniform coat
on the plate (spread as necessary). When ready,
apply the sealant on crankcase mating surfaces.
5 23 22 3 21 17 18 1 19 20 7
R1503motr06B
Apply Loctite 243 (blue) on threads. Torque engine

block screws no. 3 at first to 40 N•m (29 lbf•ft)
and in a second sequence to 55 N•m (41 lbf•ft).
Torque engine block screws no. 7 to 22 N•m
(17 lbf•ft).
SMR2002_073_05_09A.FM 05-09-15
Before continuing the installation process, the ax- Install the crankshaft cover before mounting the
ial clearance of balance shaft and crankshaft has engine bracket. Put some oil on O-ring and press
to be checked the cover in. The crankshaft cover has to be even
with the engine block surface.
1
1
R1503motr41A 2
1. Dial gauge
2. Crankshaft R1503motr19A 2
1. O-ring
CRANKSHAFT AXIAL CLEARANCE mm (in) 2. Crankshaft cover
NEW MINIMUM 0.08 mm (.003 in) CAUTION: Install crankshaft locking tool (P/N 529
035 821) right away to put crankshaft in TDC
NEW MAXIMUM 0.22 mm (.009 in) position before installing the camshaft and
SERVICE LIMIT 0.35 mm (.014 in) rockers (refer to CYLINDER AND HEAD).
1
1
R1503motr42A 2 R1503motr18A
1. Crankshaft locking tool

1. Dial gauge
2. Balance shaft
Install cylinder head, PTO housing and the other
BALANCE SHAFT AXIAL CLEARANCE mm (in)
parts in accordance with the proper installation
procedures.
05-09-16 SMR2002_073_05_09A.FM
PISTON/CONNECTING ROD 1 2 3
Removal
Disassemble engine block according to ENGINE
BLOCK REMOVAL above.
Remove connecting rod screws.
R1503motr27A
1. Piston
2. Piston pin
3. Circlip
Detach piston no. 10 from connecting rod.
Inspection
Connecting Rod/Piston Pin Clearance
R1503motr08A
Measure piston pin. Compare to inside diameter
1. Connecting rod screws of connecting rod no. 5.
NOTE: Before removing the connecting rod bear-
ing caps, mark them to remember the right posi-
tion when reassembling.
Pull piston with connecting rod out of the cylin-
ders.
Remove one piston circlip no. 8 and discard it.
2
1
R610motr134A 1 R610motr73A
1. Piston circlip 1. Bore gauge

2. Connecting rod
NOTE: The removal of both piston circlips is not
necessary to remove piston pin.
Push piston pin no. 9 out of piston.
SMR2002_073_05_09A.FM 05-09-17
To measure the connecting rod big end diameter,

use the OLD screws no. 11.
Install the OLD bushings no. 12 as they were
mounted initially.
Do the torque procedure as described below.
R610motr137A A
A. Piston pin diameter in the area of the bushing
CONNECTING ROD SMALL END DIAMETER

mm (in)
A
PISTON PIN DIAMETER
mm (in)
NEW MAXIMUM 23.000 mm (.9055 in) R610motr76A
SERVICE LIMIT 22.990 mm (.904 in) A. Connecting rod big end bushing
CONNECTING ROD BIG END DIAMETER

PISTON PIN BORE CLEARANCE
mm (in) mm (in)
SERVICE LIMIT 0.080 mm (.0035 in) SERVICE LIMIT 45.080 mm (1.774 in)
If the connecting rod small end diameter is out of CONNECTING ROD BIG END CLEARANCE
specification, replace connecting rod. mm (in)
Connecting Rod Big End Radial Play SERVICE LIMIT 0.09 mm (.0035 in)
Measure inside diameter of connecting rod big Use NEW bushings no. 12, when connecting rod
end. Compare to crankpin. big end diameter is out of specification.
05-09-18 SMR2002_073_05_09A.FM
Piston With the micrometer set to the dimension, adjust

Inspect piston for scoring, cracking or other dam- a cylinder bore gauge to the micrometer dimen-
ages. Replace piston and piston rings if necessary. sion and set the indicator to 0 (zero).
Using a micrometer, measure piston at 18 mm
(.709 in) perpendicularly (90°) to piston pin axis.
2 1
F00B09A
1. Use the micrometer to set the cylinder bore gauge

2. Dial bore gauge
R610motr136A 1
A. 18 mm (.709 in)
The measured dimension should be as described

in the subsequent table. If not, replace piston.
PISTON MEASUREMENT
mm (in)
99.951 to 99.969 mm
NEW NOMINAL
(3.935 to 3.936 in)
1
F00B0AA
Piston/Cylinder Clearance TYPICAL

1. Indicator set to 0 (zero)
Adjust and lock a micrometer to the piston dimen-
sion. Position the dial bore gauge 62 mm (2.44 in) above
cylinder base, measuring perpendicularly (90°) to
1 piston pin axis.
Read the measurement on the cylinder bore gauge.
The result is the exact piston/cylinder wall clear-
ance.
PISTON/CYLINDER CLEARANCE mm (in)
0.0 24 to 0.056 mm
NEW NOMINAL
(.0009 to .0022 in)
F00B08A
NOTE: Make sure used piston is not worn. See PIS-

1. Micrometer set to the piston dimension
TON MEASUREMENT above.
SMR2002_073_05_09A.FM 05-09-19
If clearance exceeds specified tolerance, rehone Replace connecting rod if diameter of connecting
cylinder sleeve and replace piston ass’y by over- rod small end is out of specifications. Refer to
size. CRANKSHAFT AND BALANCER SHAFT for removal
NOTE: It is not necessary to have all pistons re- procedure of connecting rod.
placed with an oversize if they are not all out of
specification. Mixed standard size and oversize Installation
piston are allowed. For installation, reverse the removal procedure.
NOTE: Make sure the cylinder bore gauge indica- Pay attention to the following details.
tor is set exactly at the same position as with the Apply engine oil on the piston pin.
micrometer, otherwise the reading will be false. Insert piston pin into piston and connecting rod.
Piston Pin Use the piston circlip installer (P/N 529 035 765) to
assemble the piston circlip.
Using synthetic abrasive woven, clean piston pin
from deposits. CAUTION: Secure piston pin with new piston cir-
clips.
Inspect piston pin for scoring, cracking or other dam-
ages. NOTE: Take care that the hook of the piston circlip
is positioned properly.
Measure piston pin. See the following illustration
for the proper measurement positions. 1
Piston Pin/Connecting Rod Bushing Clearance
Measure inside diameter of connecting rod.
2
CONNECTING ROD SMALL END DIAMETER
mm (in)

R1503motr28A
1. Sleeve with piston circlip inside

2. Assembly jig from piston clip installer
2
1
R610motr134B
CORRECT POSITION OF THE PISTON CIRCLIP
R610motr73A
1. Bore gauge
2. Connecting rod
05-09-20 SMR2002_073_05_09A.FM
Using a piston ring compressor plier, such Snap-

3 1 2
ON RC-980, slide piston into cylinder.
R1503motr29A
R610motr79A
1. Half bushing of connecting rod big end

CAUTION: Take care that piston will be in- 2. Split surface of the connecting rod
stalled with the punched arrow on piston top to 3. Protrusion of bushing in line with connecting rod groove
the exhaust side.
Torque NEW connecting rod screws no. 11 as per
1 following procedure:
– Install screws and torque to 45 N•m (33 lbf•ft).
Do not apply any thread locker product.
– Finish tightening the screws with an additional
90° turn using an angle torque wrench.
CAUTION: Failure to strictly follow this proce-
dure may cause screw to loosen and lead to en-
gine damage. Besides, as the screws have been
stretched from the previous installation, it is
very important to use new screws at assembly.
R1503motr30A
1. Arrow should indicate to the exhaust side 1

Put bushings correctly in place and clean the split
surface on both sides (cracked area) carefully.
R1503motr31A
1. Angle torque wrench
SMR2002_073_05_09A.FM 05-09-21
PISTON RINGS Ring End Gap
RING END GAP

Removal mm (in)
Remove piston ass’y as described above.
NEW MINIMUM
Remove rings.
RECTANGULAR 0.15 mm (.006 in)
Inspection
TAPER-FACE 0.15 mm (.006 in)
Ring/Piston Groove Clearance
Using a feeler gauge measure each ring/piston OIL SCRAPER RING 0.15 mm (.006 in)
groove clearance. If the clearance is too large, the NEW MAXIMUM
piston and the piston rings should be replaced.
RECTANGULAR 0.35 mm (.014 in)
RING/PISTON GROOVE CLEARANCE
mm (in) TAPER-FACE 0.35 mm (.014 in)
NEW MINIMUM OIL SCRAPER RING 0.30 mm (.012 in)
RECTANGULAR 0.025 mm (.001 in) SERVICE LIMIT
TAPER-FACE 0.015 mm (.0006 in) ALL 1 mm (.04 in)
OIL SCRAPER RING 0.020 mm (.0008 in) Measure position for ring end gap in the area of 8
NEW MAXIMUM
to 16 mm (.315 to .630 in) from top of cylinder.
NOTE: In order to correctly position the ring in the
RECTANGULAR 0.070 mm (.0028 in) cylinder, use piston as a pusher.
TAPER-FACE 0.060 mm (.0024 in) Using a feeler gauge, check ring end gap. Replace
ring if gap exceeds above described specified tol-
OIL SCRAPER RING 0.055 mm (.0021 in) erance.
SERVICE LIMIT
Installation
ALL 0.15 mm (.006 in) For installation, reverse the removal procedure.
Install the oil scraper ring first, then the taper-face
ring with the word “TO” facing up, then the rectan-
gular ring with the word “T” facing up.
2
1
3
R1503motr32A 1 A31C2NA
1. Rectangular ring
1. Piston
2. Taper-face ring
2. Filler gauge 3. Oil scraper ring
05-09-22 SMR2002_073_05_09A.FM
CAUTION: Ensure that top and second rings are

not interchanged.
NOTE: Use a ring expander to prevent breakage
during installation. The oil ring must be installed by
hand.
Check that rings rotate smoothly after installation.
Space the piston ring end gaps 120° apart and do
not align the gaps with the piston pin bore or the
thrust side axis.
A
A A
A31C2OA
1. DO NOT align ring gap with piston trust side axis

2. DO NOT align ring gap with piston pin bore axis
A. 120°
SMR2002_073_05_09A.FM 05-09-23
Section 06 ENGINE MANAGEMENT (DI)
TABLE OF CONTENTS 0
OVERVIEW............................................................................................................................. 06-02-1
OPERATING PRINCIPLE .................................................................................................... 06-02-2
AIR INDUCTION................................................................................................................. 06-02-2
AIR COMPRESSOR SYSTEM............................................................................................ 06-02-2
FUEL DELIVERY SYSTEM................................................................................................. 06-02-2
BASIC OPERATION ........................................................................................................... 06-02-2
AIR/FUEL RAIL ASSEMBLY .............................................................................................. 06-02-2
FUEL PUMP MODULE....................................................................................................... 06-02-3
ELECTRONIC MANAGEMENT.......................................................................................... 06-02-4
MPEM (multi-purpose electronic module) ...................................................................... 06-02-4
IGNITION SYSTEM............................................................................................................ 06-02-8
COMPONENT INSPECTION AND ADJUSTMENT .............................................................. 06-03-1

GENERAL ........................................................................................................................... 06-03-1
FUEL SYSTEM ................................................................................................................... 06-03-1
ELECTRICAL SYSTEM....................................................................................................... 06-03-2
AMP CONNECTOR PIN-OUT ............................................................................................ 06-03-3
QUICK FUEL PRESSURE TEST ........................................................................................ 06-03-4
AIR INDUCTION SYSTEM................................................................................................. 06-03-5
THROTTLE BODY .............................................................................................................. 06-03-5
AIR COMPRESSOR............................................................................................................ 06-03-8
PRESSURE TEST ............................................................................................................... 06-03-8
REPAIR ............................................................................................................................... 06-03-9
FUEL DELIVERY................................................................................................................. 06-03-12
FUEL PRESSURE REGULATOR ........................................................................................ 06-03-12
FUEL INJECTOR ................................................................................................................ 06-03-14
AIR/FUEL RAIL ................................................................................................................... 06-03-15
DIRECT INJECTOR ............................................................................................................ 06-03-16
FUEL PUMP ....................................................................................................................... 06-03-17
MPEM REPLACEMENT ..................................................................................................... 06-03-21
THROTTLE POSITION SENSOR (TPS) ............................................................................. 06-03-22
CRANKSHAFT POSITION SENSOR (CPS) ....................................................................... 06-03-24
MANIFOLD AIR TEMPERATURE SENSOR (MATS)......................................................... 06-03-26
WATER TEMPERATURE SENSOR (WTS) ........................................................................ 06-03-26
MANIFOLD AIR PRESSURE SENSOR (MAPS) ................................................................ 06-03-27
EXHAUST GAS TEMPERATURE SENSOR (EGT) ............................................................ 06-03-28
KNOCK SENSOR (KS) ....................................................................................................... 06-03-28
RAVE SOLENOID ............................................................................................................... 06-03-29
IGNITION COIL .................................................................................................................. 06-03-30
TDC SETTING .................................................................................................................... 06-03-32
SPARK PLUGS ................................................................................................................... 06-03-35
CRANKING SYSTEM ......................................................................................................... 06-03-36
DI SYSTEM TEST SUMMARY .......................................................................................... 06-03-36
SMR2002-095_06-01ATOC.FM 06-01-1
DIAGNOSTIC PROCEDURES................................................................................................. 06-04-1

GENERAL............................................................................................................................ 06-04-1
DESS SYSTEM ................................................................................................................... 06-04-1
FAULT DETECTION AND COMPENSATORY ACTIONS .................................................. 06-04-3
COMPONENT FAILURE WARNING SYSTEM .................................................................. 06-04-3
VCK (VEHICLE COMMUNICATION KIT) ........................................................................... 06-04-5
DI SYSTEM FAULT CODES ............................................................................................... 06-04-6
06-01-2 SMR2002-095_06-01ATOC.FM
Subsection 02 (OVERVIEW)
OVERVIEW 0
F12F03T
SMR2002-074_06-02A.FM 06-02-1
OPERATING PRINCIPLE
The Orbital Combustion Process (OCP) provides a
stratified combustion process resulting from the
direct injection of a finely atomized fuel spray (less
than 10 microns). This is achieved by using a pneu-
matically assisted direct injection system, a
unique combustion chamber geometry and a pre-
cise control of the combustion process by the
MPEM (Multi-Purpose Electronic Module).
AIR INDUCTION
Air for combustion is drawn directly at the base of
F12D01A
the engine through two 46 mm throttle bodies.
The air flow is controlled by two throttle plates.
The air continues through the reed valves into the FUEL DELIVERY SYSTEM
crankcase.
BASIC OPERATION
When the piston reaches the correct position, the
MPEM opens the fuel injector and fuel is dis-
charged into a cavity inside the direct injector.
Next, the direct injector opens and the fuel is dis-
charged into the combustion chamber by the com-
pressed air which breaks the fuel up into a very
fine mist in the process. This air/fuel mixture is
then ignited by the spark plug.
AIR/FUEL RAIL ASSEMBLY

F12F05A 1 1 2 4 3 2 6
TWIN 46 mm THROTTLE BODIES
1. Throttle position sensor (TPS)
AIR COMPRESSOR SYSTEM

The air compressor supplies the compressed air
required for fuel atomization in the air injector. It is
integrated with the engine and mechanically driv-
en by the counterbalance shaft. It also supplies the
air pressure required to operate the RAVE valves.
F12F06A 5 7 1 8
TYPICAL
1. Air/fuel rail
2. Fuel injector
3. Fuel pressure regulator
4. Air pressure regulator
5. Air inlet hose
6. Fuel inlet
7. Air return
8. Fuel return
06-02-2 SMR2002-074_06-02A.FM
The air/fuel rail assembly is mounted on top of the FUEL PUMP MODULE
cylinder head. It provides support for the air/fuel
injectors and both air and fuel regulators. It also
contains passages for the air and the fuel. The rail
is a small reservoir for the injectors that keeps
enough fluid at the proper pressure to supply the
injectors demand.
Fuel Injector
Fuel injectors are used to provide fuel from the
fuel rail to the to the direct injector.
Fuel Pressure Regulator

A fuel pressure regulator controls the pressure in-
side the fuel rail, and allows the excess of fuel to
return to the fuel tank. The fuel pressure regulator
regulates the fuel pressure at approximately
185 kPa (27 PSI) higher than the air pressure in the
fuel rail. The back side of the diaphragm is ex- F12D0AA
posed to the air rail pressure. As the air pressure

increases in the fuel rail, the fuel pressure needed The fuel pump module is located inside the fuel
to open the regulator will increase equally. tank. The module includes the fuel pump and the
fuel level sensor.
The differential pressure regulation utilizes the air
pressure reference signal to maintain constant Fuel Pump
pressure drop across fuel injector orifice.
It operates at a nominal pressure of approximately
The initial operating pressure of the regulator is 735 kPa (107 PSI).
preset by the manufacturer and is not adjustable.
Fuel Filter
Direct Injector
A mesh filter is located at the bottom of the fuel
Also called air injector, two direct injectors (one pump module inside the fuel tank. An inline fuel
per cylinder) are used to inject air/fuel mixture into filter is also installed on the fuel line going to the
the combustion chamber. fuel rail.
Air Pressure Regulator
An air pressure regulator regulates the pressure of
air delivered by the air compressor.
It regulates the pressure developed inside the air
passage to approximately 550 kPa (80 PSI).
The initial operating pressure of the regulator is
preset by the manufacturer and is not adjustable.
SMR2002-074_06-02A.FM 06-02-3
ELECTRONIC MANAGEMENT The MPEM is directly powered by the battery. It is

responsible for the following engine management/
MPEM electrical functions:
(multi-purpose electronic module) – interpreting information
The electronic fuel injection is equipped with a – distributing information
MPEM. It is also called ECU (Electronic Control – start/stop function
Unit). It is the brain of the electrical system/fuel – timer
injection system.
– DESS (Digitally Encoded Security System)
1 – ignition timing maps
– injection maps (fuel injector and direct injector)
– MPEM contains a total of 34 maps (injection
and ignition) for optimum engine operation in all
conditions
– engine RPM limiter
– etc.
The MPEM features a permanent memory that
will keep the programmed safety lanyard(s) active,
fault codes and other vehicle information, even
when the battery is removed from the watercraft.
MPEM — General Functions

F12D0EA Automatic Power Shut-Down
TYPICAL The MPEM is equipped with an automatic power
1. Multi-purpose electronic module (MPEM) shut-down. This feature prevents the battery from
The MPEM is mounted in the front of the water- losing its charge if the safety lanyard cap is left on
craft. the post when the engine is not running.
After connecting the safety lanyard cap, the
MPEM will remain in standby mode during the
next 10 minutes, waiting for a starting. If the start/
stop button is not depressed, then the MPEM will
be automatically powered down.
Antistart Feature
This system allows starting the vehicle only with
safety lanyard(s) that has been programmed to op-
erate a specific watercraft. This functionality is the
DESS system. See below for details.
Digitally Encoded Security System (DESS)
The following components are specially designed
for this system: Multi-Purpose Electronic Module
(MPEM), safety lanyard cap and safety lanyard
post.
06-02-4 SMR2002-074_06-02A.FM
The safety lanyard cap contains a magnet and a Gauges Current Supply
ROM chip. The magnet actually closes the reed The purpose of this function is to allow reading of
switch inside the post which is the equivalent of a gauges without the engine running. It will give ac-
mechanical ON/OFF switch. The chip has a unique cess to most functions of the information center
digital code. gauge without starting the engine.
The DESS circuitry in the watercraft MPEM is ac- Gauges are supplied with current for 33 seconds
tivated at the factory. Therefore, a safety lanyard when connecting the safety lanyard cap on its post
must be programmed to start the engine. or when pressing the start/stop switch without
NOTE: Actually, it is the memory of the MPEM the safety lanyard on the DESS post.
which is programmed to recognize the digital code NOTE: The fuel pump will be activated for 2 sec-
of the safety lanyard cap. This is achieved with the onds to build up pressure in the fuel injection sys-
MPEM programmer (P/N 529 035 878) or the VCK tem, only when connecting the safety lanyard cap
(Vehicle Communication Kit) (P/N 529 035 844). to the post.
Refer to their operation manual or help system to
program a safety lanyard. Engine Starting
The system is quite flexible. Up to 8 safety lan- If the MPEM recognizes a valid safety lanyard, it
yards may be programmed in the memory of the allows engine to start when the start/stop switch
watercraft MPEM. They can also be erased indi- is pressed.
vidually. If the safety lanyard is left on the DESS post for
The MPEM also offers a special safety lanyard — the more than 10 minutes after stopping the engine,
Sea-Doo LK™ (learning key) — which can be pro- the MPEM may send out 1 long beep when press-
grammed so that the vehicle can be run only at a ing the start/stop switch. The current supply to
limited speed — approximately 48 km/h (30 MPH). gauges will be stopped as explained in the ANTI-
Such feature is ideal for first time riders or renters. START FEATURE section. A light pressure on the
safety lanyard or removing and reinstalling the
 WARNING safety lanyard is required to allow the MPEM to
read and validate the safety lanyard, the engine
When programming a Sea-Doo LK™ (learning
can then be started.
key), use only a lanyard that is identified for
that purpose. Otherwise, a customer could use If start/stop button is held after engine has started,
a vehicle with a greater speed than he was ex- the MPEM automatically stops the starter when
pecting. the engine speed reaches 1000 RPM.
If start button is activated while the throttle lever
NOTE: If desired, a safety lanyard can be used on is depressed more than 70%, the engine will not
other watercraft equipped with the DESS. It only be allowed to start.
needs to be programmed for that watercraft.
Engine RPM Limiter
When connecting a safety lanyard cap on the post,
the DESS is activated and will emit audible signals: The MPEM will limit the maximum engine speed.
– 2 short beeps indicate a working safety lanyard. Engine Stopping
Engine starting can take place. There are 2 ways to stop the engine.
– 1 long beep indicates a wrong safety lanyard is Press and hold start/stop switch or remove the
being used or that something is defective. En- safety lanyard cap from its post.
gine starting is not allowed.
If the engine is stopped by removing the safety lan-
The memory of the MPEM features two self- yard, it is possible to restart the engine as explained
diagnostic modes for the DESS operation. Refer in the ENGINE STARTING section.
to DIAGNOSTIC PROCEDURES subsection for
more information. If safety lanyard cap is reconnected within 6 sec-
onds, the current supply to gauges is cut for a brief
The memory of the MPEM is permanent. If the moment and comes back on with the audible sig-
battery is disconnected, no information is lost. nal of safety lanyard validation.
When ordering a new MPEM from the regular
parts channel, the DESS circuitry will be activated.
SMR2002-074_06-02A.FM 06-02-5
Low-Fuel and Low-Oil Level Warning Device Power Distribution

When the fuel level in the reservoir is low, the fuel The MPEM distributes power from battery to all
level sensor transmits a signal to the MPEM. The accessories. Accessories are protected by fuses
MPEM sends out signals for the beeper and to the integrated in the MPEM. Fuses are identified be-
information center gauge. sides their holder.
When the oil level is low in the reservoir, the IMPORTANT: The sensors and injectors are con-
MPEM sends out a signal to the information center tinuously powered with the supply from the bat-
gauge and the pilot lamp on the gauge will turn on. tery. The MPEM switches the ground to com-
plete the electrical circuits it controls. Take this
into account when troubleshooting the electrical
system.
MPEM — Engine Management Functions
F12D0CS
06-02-6 SMR2002-074_06-02A.FM
This engine management system controls both Flooded Engine (drowned mode)
the fuel injection and the ignition timing. If the engine does not start and it is flooded, pro-
As shown in the DI CONTROL SYSTEM illustra- ceed as follows:
tion, the MPEM is the central point of the fuel in- Remove spark plug cables and connect them on
jection system. It reads the inputs, makes compu- the grounding device.
tations, uses pre-determined parameters and
sends the proper signals to the outputs for proper Remove spark plugs and dry them using a rag.
engine management. Cover spark plug holes with a rag.
The MPEM also stores the fault codes and general While engine is stopped, depress and HOLD the
information such as: operating conditions, vehicle throttle lever at full throttle position for cranking.
hours, serial numbers, customer and maintenance Crank the engine several times.
information.
A 1 second beep every second indicates the drowned
Electronic Fuel Injection mode is active.
The MPEM receives the signals from different sen- NOTE: Proceeding in this order, no fuel is injected,
sors which indicate engine operating conditions at no ignition occurs and the accumulated fuel in the
milli-second intervals. engine will be expelled.
Signals from sensors are used by the MPEM to In case of water-flooded engine, if water does not
determine the injection parameters (fuel maps) re- completely go out, it may be necessary to remove
quired for optimum air-fuel ratio. the air intake silencer then to lean the vehicle so
The CPS and both TPS are the primary sensors that water can flow out from throttle bodies.
used to control the injection and ignition timing. Reinstall spark plugs and connect cables.
Other sensors are used for secondary input.
Start engine normally without applying the throttle.
NOTE: The EGT sensor does not provide control
inputs to the MPEM. Its sole purpose is to protect Monitoring System
the exhaust system components by emitting a The MPEM monitors the electronic components
warning signal in the event of overheating. of the fuel injection system and some compo-
nents of the electrical system. When a fault oc-
Ignition Timing
curs, it sends visual messages through the infor-
The MPEM is programmed with data (it contains mation center and/or audible signals through a
ignition mappings) for optimum ignition timing un- beeper to inform you of a particular condition. Re-
der all operating conditions. Using engine operat- fer to the DIAGNOSTIC PROCEDURES subsec-
ing conditions provided by the sensors, the MPEM tion for the displayed messages and the beeper
controls the ignition timing for optimum engine coded signals chart.
operation.
Limp Home Modes
Knock Sensor
Besides the signals as seen above, the MPEM
A knock sensor is mounted on top of the cylinder may automatically set default parameters to the
head. It detects specific vibration that would be engine management to ensure the adequate op-
typically generated by engine detonation. If deto- eration of the watercraft if a component of the fuel
nation occurs, the knock sensor detects it and the injection system is not operating properly.
MPEM retards the ignition advance temporarily (it
Depending on the severity of the malfunction, the
goes in a specific mode) until detonation stops.
watercraft speed may be reduced and not allowed
Engine Modes of Operation to reach its usual top speed as usual.
The MPEM controls different operation modes of The engine RPM may be limited to idle if some
the engine to allow proper operation for all possi- critical components fail. In this case, removing and
ble conditions: Cranking, flare, idle, warm up, nor- reinstalling the safety lanyard on its post may al-
mal operation, Sea-Doo LK™ (learning key) (limit- low retrieving normal operation.
ed vehicle speed), engine speed limiter, drowned
engine and limp home (see below).
SMR2002-074_06-02A.FM 06-02-7
These performance-reduced modes allow the rid- Ignition Coil

er to go back home which would not be possible
Ignition coil induces voltage to a high level in the
without this advanced system. Refer to the DIAG-
secondary windings to produce a spark at the
NOSTIC PROCEDURES for a complete chart.
spark plug.
If a fault occurs and involves a limp home mode
Two separate ignition coils receive input from the
operation, the DI system will reduce engine RPM
MPEM. Each coil provides high voltage to its cor-
gradually to the proper level.
responding spark plug.
Diagnostic Mode This ignition system allows spark plugs to spark
The malfunctions are recorded in the memory of independently.
the MPEM. The memory of the MPEM can be CAUTION: Do not interchange spark plug ca-
checked using the VCK (Vehicle Communication bles. The white tape on the ignition coil should
Kit) (P/N 529 035 844) to see the fault codes. Refer match the white tape on the high tension cable.
to the DIAGNOSTIC PROCEDURES subsection.
Both coils are located inside the electrical box.
IGNITION SYSTEM 2 1
The ignition system consist of different sub-systems
where some are interrelated.
Unregulated AC current is produced by the mag-
neto. Part of the AC current is rectified and regu-
lated for the charging system.
A 12 volts battery supplies the Multi-Purpose Elec-
tronic Module (MPEM) with DC current.
Refer to CHARGING SYSTEM.
The following type of ignition system is used:
– Digital Inductive System.
Magneto System F12R0UC
The magneto is the primary source of electrical TYPICAL

energy. It transforms magnetic field into electric 1. PTO side ignition coil
2. MAG side ignition coil
current (AC).
The magneto has a 3 phases, delta wound stator
on 18 poles. Capacity is 270 watts.
06-02-8 SMR2002-074_06-02A.FM
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)
COMPONENT INSPECTION AND

ADJUSTMENT 0
GENERAL  WARNING
Engine problems are not necessarily related to the Fuel lines remain under pressure at all times. Al-
electronic fuel injection system. ways proceed with care and use appropriate
It is important to ensure that the mechanical integrity safety equipment when working on pressurized
of the engine/propulsion system is present: fuel system. Wear safety glasses and work in a
well ventilated area. Do not allow fuel to spill on
– good jet pump/drive system operation hot engine parts and/or on electrical connectors.
– good engine compression and properly operat- Proceed with care when removing/installing
ing mechanical components, no leaks etc. high pressure test equipment or disconnecting
– fuel pump connection and fuel lines without leaks. fuel line connections. Use the VCK (Vehicle Com-
munication Kit) to release fuel pressure prior to
Check the chart in TROUBLESHOOTING section removing a hose. Cover the fuel line connection
to have an overview of problems and suggested with an absorbent shop rag. Slowly disconnect
solutions. the fuel hose to minimize spilling. Wipe off any
When replacing a component, always check its fuel spillage in the bilge. Fuel is flammable and
operation after installation. explosive under certain conditions. Always work
in a well ventilated area. Always disconnect bat-
 WARNING tery prior to working on the fuel system. After
Air compressor hose may be hot. Use a rag performing a pressure test, use the valve on the
or gloves or let hose cool down. fuel pressure gauge to release the pressure (if so
equipped).
FUEL SYSTEM – Always disconnect battery properly prior to

working on the fuel system.
 WARNING When the job is done, ensure that hoses from fuel
The fuel system of a fuel injection system holds rail going to fuel pump are properly secured in their
much more pressure than on a carbureted wa- support. Then, pressurize the fuel system. Perform
tercraft. Prior to disconnecting a hose or to re- the high pressure test as explained in this section
moving a component from the fuel system, fol- and pressurize the fuel tank and fuel lines as ex-
low the recommendation described here. Pay plained in FUEL SYSTEM section.
attention that some hoses may have more than Properly reconnect the battery.
one clamp at their ends. Ensure to reinstall the
same quantity of clamps at assembly.  WARNING
Ensure to verify fuel line connections for dam-
– Use the VCK (Vehicle Communication Kit) (P/N 529
age and that NO fuel line is disconnected prior to
035 844) to release the fuel pressure in the sys-
installing the safety lanyard on the DESS post.
tem. Look in the ACTIVATION section of the soft-
Always perform the high pressure test if any
ware B.U.D.S.
component has been removed. A pressure test
must be done before connecting the safety lan-
yard. The fuel pump is started each time the safe-
ty lanyard is installed and it builds pressure very
quickly.
SMR2002-075 _06-03A.FM 06-03-1
CAUTION: Never use injector cleaning products. Pay particular attention to ensure that pins are not
They may contain additive that could damage in- out of their connectors or out of shape. The trou-
jector components. A copper wire brush may be bleshooting procedures cover problems not re-
used to clean the tip of the direct injectors if nec- sulting from one of these causes.
essary.
To check air/fuel rail for leaks, first pressurize the  WARNING
system then spray soapy water on all hose con- Ensure all terminals are properly crimped on
nections, regulators and injectors. Air bubbles will wires and connector housings are properly
show the leaking area. Check also for leaking fuel fastened.
or fuel odor.
Before replacing a MPEM, always check electrical
 WARNING connections. Make sure that they are very tight and
Never use a hose pincher on high pressure they make good contact and that they are corrosion-
hoses. free. A “defective module” could possibly be re-
paired simply by unplugging and replugging the
MPEM. The voltage and current might be too
ELECTRICAL SYSTEM weak to go through dirty wire pins. Check carefully
if posts show signs of moisture, corrosion or if
It is important to check that the electrical system they look dull. Clean pins properly and then coat
is functioning properly: them with silicon-based dielectric grease or other
– battery appropriate lubricant (except if otherwise speci-
– fuses fied) when reassembling them. If the newly re-
placed MPEM is working, try the old one and re-
– DESS check if it works.
– ignition (spark) Ensure that all electronic components are genu-
– ground connections ine — particularly in the ignition system. Installing
– wiring connectors. resistive caps, non-resistive spark plug cables (or
modified length) or non-resistive spark plugs may
It is possible that a component seems to operate lead to generate fault codes or bad operation.
in static condition but in fact, it is defective. In this
case, the best way to solve this problem is to re- NOTE: Diagnostics Communication Kit. See DIAG-
move the original part and replace it with one NOSTIC PROCEDURES section.
which is in good condition. After a problem has been solved, ensure to clear
Never use a battery charger to replace temporarily the fault(s) in the MPEM using the VCK. Refer to
the battery, as it may cause the MPEM to work DIAGNOSTIC PROCEDURES section.
erratically or not to work at all. Check related-circuit
fuse solidity and condition with an ohmmeter. Vi- Communication Errors Between
sual inspection could lead to false results. B.U.D.S. and the MPEM
Remember that if there has not been active com-
 WARNING munication between B.U.D.S. and the MPEM for
All electrical actuators (injectors, fuel pump, more than 10 minutes, the MPEM automatically
RAVE solenoid, ignition coil and starter sole- shuts down. This causes false “communication
noid) are permanently connected to the bat- errors”. This occurs quite frequently and confuses
tery positive terminal, even when the safety many technicians. Whenever this occurs, simply
lanyard is removed. Always disconnect the remove and replace the lanyard to restart the
battery prior to disconnecting any electric or MPEM. In fact, one should get into the habit of
electronic parts. resetting the MPEM with the lanyard whenever
the MPEM does not seem to respond. It must be
To perform verifications, a good quality multimeter kept “awake”.
such as Fluke 111 (P/N 529 035 868) should be
used.
06-03-2 SMR2002-075 _06-03A.FM
Resistance Measurement Also remember this validates the operation of the

sensor at ambient temperature. It does not vali-
When measuring the resistance with an ohmmeter,
date the over temperature functionality. To test it,
all values are given for a temperature of 20°C
the sensor could be removed from the engine/
(69°F). The resistance value of a resistance varies
muffler and heated with a heat gun while it is still
with the temperature. The resistance value for
connected to the harness to see if the MPEM will
usual resistor or windings (such as injectors) in-
detect the high temperature condition and gener-
creases as the temperature increases. However,
ate a fault code.
our temperature sensors are NTC types (Negative
Temperature Coefficient) and work the opposite When working with injectors, the resistance value
which means that the resistance value decreases might test good while the complete current would
as the temperature increases. Take it into account not flow through the wire when pulsating current
when measuring at temperatures different from is supplied to the injector in its normal operation.
20°C (69°F). Use this table for resistance variation A solution would be to use a jumper wire to direct-
relative to temperature for temperature sensors. ly supply the injector from the MPEM. If it now
works, replace the defective wire. A Noid light
TEMPERATURE RESISTANCE (ohms) (available from after-market tool/equipment sup-
°C °F NOMINAL LOW HIGH pliers) may also be used to validate the injector
operation.
- 30 - 22 12600 11800 13400
- 20 -4 11400 11000 11800 AMP CONNECTOR PIN-OUT
- 10 14 9500 8000 11,000
Use this diagram to locate the pin numbers on the
0 32 5900 4900 6900 AMP connector no. 3 and no. 4 of the wiring har-
10 50 3800 3100 4500 ness when performing tests.
20 68 2500 2200 2800
18 19 20 21
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
110 230 145 125 160
120 248 115 100 125
CONVERSION CHART FOR TEMPERATURE SENSORS
F07F15A
The resistance value of a temperature sensor may
AMP CONNECTOR PIN-OUT (WIRING HARNESS SIDE)
test good at a certain temperature but it might be
defective at other temperatures. If in doubt, try a
new sensor.
SMR2002-075 _06-03A.FM 06-03-3
QUICK FUEL PRESSURE TEST

 WARNING
Read PRESSURE TEST under AIR/FUEL RAIL
farther in this section for precautions and
setup to take care of, before performing this
test. The procedure here is a quick summary.
Disconnect outlet hose (the one with the fuel fil-

ter) from fuel pump using tool (P/N 529 035 714).
Connect adapter to pressure gauge as shown.
3
1
1 F12R09A
1. Fuel filter
2. Fuel line going to air/fuel rail
3. Pressure gauge between disconnected hose (inline installation)
Install safety lanyard and observe fuel pressure.

Do not crank engine.
FUEL REGULATOR PRESSURE
(when installing safety lanyard)
2
185 ± 14 kPa (27 ± 2 PSI)
If pressure is within limits, air/fuel rail is working

F12R08A
adequately. Proceed with the fuel pressure test
1. Pressure gauge (P/N 529 035 709) below.
2. T-adapter (P/N 529 035 710)
If pressure is out of limits, go to FUEL DELIVERY
Install pressure gauge between disconnected hose part and proceed with the tests described there.
(inline installation).
Crank or start engine and observe fuel pressure.
FUEL PRESSURE
(when cranking engine
or when engine is running)
738 ± 14 kPa (107 ± 2 PSI)
If pressure is within limits, fuel and air systems are

working adequately. No subsequent tests are nec-
essary for the air/fuel system.
Remove pressure gauge and reinstall fuel hose. At
installation apply engine oil on O-ring.
If pressure is out of limits, proceed with all the tests.
06-03-4 SMR2002-075 _06-03A.FM
AIR INDUCTION SYSTEM Remove TPS, throttle lever, spring and guide from
the old throttle body.
THROTTLE BODY Installation
Mechanical Inspection Reinstall removed parts on the new throttle body.
Check that the throttle plates moves freely and For TPS replacement procedures, refer to THROT-
smoothly when depressing throttle lever. Take this TLE POSITION SENSOR (TPS) in ELECTRONIC
opportunity to lubricate the throttle cable. MANAGEMENT below.
IMPORTANT: The throttle bodies are designed to Properly attach throttle bodies together if previ-
be tamper proof. Changing the idle stop or modi- ously detached.
fying them in any way will not increase perfor-
mance or change the idle speed. Adjustment
Before replacing any parts, check the following as Throttle Body Synchronization
these could be causing the fault. Perform the test NOTE: If both throttle bodies are replaced togeth-
while the engine is not running. er with new ones, no synchronization is required
– Throttle cable adjustment too tight. Not return- as it has already been set at the factory. However,
ing fully to idle stop. proceed with throttle cable and closed TPS adjust-
ments as described below. If only one throttle body
– Throttle body idle set screw is loose or worn.
is replaced, proceed with the complete following
– Throttle linkage between the two throttles has adjustments. Ensure to perform all the adjust-
moved. ments prior to starting the engine. Otherwise, en-
– TPS is loose. gine may run at a limited RPM in limp home mode.
– Corroded or damaged wiring or connectors. IMPORTANT: The throttle body synchronization
is required only when replacing one throttle body.
– Throttle body has been replaced and the closed
Otherwise, do not tamper with it as this is NOT a
TPS reset has not been performed.
regular maintenance procedure.
– MPEM has been replaced and the closed TPS
The master throttle body is the one driven by the
reset has not been performed.
throttle cable. The slave throttle body follows the
master and must me synchronized with the master.
Electrical Inspection
Refer to THROTTLE POSITION SENSOR (TPS) in 1 7
ELECTRONIC MANAGEMENT below.
Replacement
Removal
To remove throttle bodies from engine, proceed
as follows:
– Remove air intake silencer. Refer to AIR INTAKE
section.
– Disconnect TPS connectors.
– Disconnect throttle cable and oil injection pump
cable.
– Detach hoses and remove fasteners retaining 4 5 8 6 2 3
F12R0XA
throttle bodies and pull out together.
1. Throttle cable attachment
If only one throttle body replacement is required, 2. Master throttle body
detach them and remove the sealant on idle set 3. Master throttle plate
4. Slave throttle body
screw head. Gently remove the plastic cap from 5. Slave throttle plate
the synchronization screw. 6. Idle set screw
7. Lock nut
8. Synchronizing screw with its tamper proof cap
SMR2002-075 _06-03A.FM 06-03-5
NOTE: In the following illustrations, the lower link

plate has been removed for clarity purposes only.
It does not have to be removed to perform the
adjustment.
Loosen lock nut of idle set screw.
Unscrew idle set screw so that master throttle
plate completely closes in the throttle body. En-
sure screw end clears the lever stopper.
F12R1BA 2 1
1. Measure resistance between pins 2 and 3
2. Turn screw clockwise to increase resistance
Tighten lock nut.
 WARNING
Do not apply any threadlocker to the screw
F12R0YA 2 1 threads. The threadlocker may leak off the
1. Unscrew until master throttle plate is fully closed in throttle body screw and onto the throttle mechanism and
2. Unscrew here cause the throttle to stick.
3. Gap here
Remove synchronizing screw and spring between Recheck reading and readjust as necessary.
levers. Slave TPS
NOTE: The 175 Ω below is used to open the throt- Install a new synchronizing screw. Screw in and
tle plates the same amount on each throttle body ensure screw end clears the lever stopper. Ensure
to obtain the proper synchronization. It is the also to keep slave throttle plate completely closed
equivalent of using a drill bit in the throttle bore to in the throttle body.
open throttle plate on carburetors.
Master TPS  WARNING
Snap throttle plate a few times to ensure it is com- Ensure to use a new screw which is coated
pletely closed. with the proper threadlocker to avoid further
loosening. Do not use the removed screw
Using an ohmmeter, measure resistance between
even if you were applying any threadlocker.
pins 2 and 3. Note the resistance value. Add
The threadlocker may leak off the screw and
175 Ω to that value.
flow onto the throttle mechanism and cause
Turn idle set screw clockwise until ohmmeter the throttle to stick.
reading reaches the computed value above ± 20 Ω.
06-03-6 SMR2002-075 _06-03A.FM
Ensure spring is still well positioned on stoppers.

2
Properly reinstall the plastic cap to the synchroni-
zation screw.
Apply Loctite 5900 (P/N 293 800 066) flange sealant
on idle set screw head.
1
F12R1DA
1. Gap here
2. Spring removed
Snap throttle plate a few times to ensure it is com-

pletely closed.
Measure resistance between pins 2 and 3. Note
the resistance value. Substract 175 Ω from that
value.
Properly reinstall the spring. Ensure that master
throttle plate is still closed.
Turn synchronizing screw clockwise until read- F12R10A 2
ing reaches the computed value above ± 20 Ω. 1. Plastic cap
2. Wider spaced tabs here
1 3. Loctite 5910 flange sealant
 WARNING
Ensure no Loctite product protrudes screw head.
F12R1CA 2
1. Measure resistance between pins 2 and 3
2. Turn screw clockwise to decrease resistance
SMR2002-075 _06-03A.FM 06-03-7
Throttle Cable Adjustment Closed TPS Adjustment

Mechanically adjust the throttle cable using the ad- Perform the CLOSED TPS ADJUSTMENT as de-
justing device underneath body, below steering. scribed in THROTTLE POSITION SENSOR (TPS)
Slacken lock nut to allow adjuster rotation. Free- in ELECTRONIC MANAGEMENT below.
play on lever should be between 2 and 3.5 mm
Injection Oil Pump Cable Adjustment
(1/16 and 1/8 in). When done, tighten lock nut.
As oil injection cable is throttle dependent, always
proceed with the oil injection pump cable adjust-
1 ment after throttle cable adjustment. Refer to OIL
2 INJECTION PUMP subsection.
CAUTION: Improper oil injection pump synchro-
nization with throttle bodies can cause serious
engine damage.
AIR COMPRESSOR
PRESSURE TEST
The pressure test will show the available pressure
from the air compressor.
First ensure there is no leak from compressor gas-
kets, hoses and fittings. Soapy water can be sprayed
on components. Repair any leak.
Disconnect hose outlet from air compressor.
F12R1GB
1. Slacken nut
2. Turn adjuster
NOTE: On GTX DI models, vent tube removal in

front storage compartment may be necessary to
reach the adjusting device.
CAUTION: Improper cable adjustment will cause
strain on cable and/or damage cable bracket or
throttle lever at handlebar.
Use the vehicle communication kit (VCK) with the F12R02A
B.U.D.S. software to perform this adjustment.
Choose the Monitoring tab. Connect adapters and pressure relief valve to pres-
Press throttle lever to reach full throttle. sure gauge as shown.
Turn cable adjustment until throttle opening meter
indicates between 95% and 99%.
06-03-8 SMR2002-075 _06-03A.FM
If pressure is within limits, air compressor is work-

1
ing adequately.
If pressure is below limits, ensure inlet hose is not
obstructed, bent or kinked. Otherwise, repair the
air compressor.
Remove pressure gauge and reinstall air compres-
sor hose.
REPAIR
Top End
Remove retaining screws.
Lift cover then remove compressor head.
Clean all parts in a solvent and visually inspect for
corrosion damage.
Check reed valve plates for cracks, deformation,
F12R03A 4 3 2 dirt or other defects. The reed plates must lie com-
pletely flat against the reed valve body.
1. Pressure gauge (P/N 529 035 709)
2. Adapter for air compressor (P/N 529 035 712) Inspect plane surfaces for warpage.
3. T-adapter (P/N 529 035 710)
4. Pressure relief valve (P/N 529 035 711) If reed valve is found defective, it is suggested to
replace it then to temporarily reassemble the com-
CAUTION: Ensure to install the pressure relief pressor to then make a pressure test. If it fails,
valve to allow excess pressure to go out. Note check bottom end.
the arrow on the valve. Otherwise, air compres-
sor components might be damaged. When changing reed valve, ensure to position ring
plate opening so that 2 holes align inside the open-
Install pressure gauge to air compressor. ing. Holes must not be obstructed by the opening
NOTE: To prevent fuel to be injected and thus go- edges.
ing out the disconnected hose, use the drowned
engine mode to crank engine. While engine is
stopped, depress and HOLD the throttle lever at
full throttle position for cranking.
Ensure the battery is in good condition to get the
normal cranking speed.
Crank engine and observe air pressure.
NOTE: A 1 second beep every second indicates
the drowned mode is active.
 WARNING
Be careful of pressure relief valve outlet. Com-
pressed air may flow out there.
F12R04A 1 2
MINIMUM AIR PRESSURE (at cranking) 1. Reed valve opening
2. Rotate opening to align 2 holes inside without obstructing the
holes
621 ± 14 kPa (90 ± 2 PSI)
SMR2002-075 _06-03A.FM 06-03-9
Ensure to position O-ring, around top of cylinder Bottom End

sleeve.
To gain access to piston, rings and connecting rod,
engine PTO flywheel must be removed. Refer to
ENGINE section.
Remove engine support and slightly lift engine to
allow access. Block engine in this position.
Remove top end as explained above.
Remove access plug of air compressor connect-
ing rod.
Remove connecting rod retaining screw.
As a puller, use a M7 x 1.0 x 50 mm screw to re-
lease connecting rod “crankpin”.
IMPORTANT: Trace a mark on “crankpin” (bush-
ing) outer end. This is needed for reinstallation.
F12R05A 1
1. O-ring on top of cylinder sleeve
Ensure to position screw from the bottom up as

show. Torque nut to 2.7 N•m (24 lbf•in).
2.7 Nm
(24 lbfin)
F12R06A 1
1. Use a M7 x 1.0 x 50 mm screw as a puller
Push piston upward with or without the cylinder

sleeve.
Remove rubber plug then push piston pin end to
remove from connecting rod.
1
F12D0BA Inspection
1. Screw from bottom up Clean all parts in a solvent and visually inspect for
corrosion damage.
CAUTION: Failure to properly position screw
head will lead piston to hit it. Clean piston ring grooves with a groove cleaner
tool, or a piece of broken ring.
If pressure is still low then continue with BOT-
TOM END. Otherwise, remove components Check bearings and pins for wear and heat discol-
again. Install a new gasket, new O-ring, compres- oration. Check connecting rod for straightness.
sor head and cover. Apply synthetic grease below Replace damaged components.
screw head and Loctite 243 on threads. Install Inspect piston for damage. Light scratches can be
screws then torque to 5 N•m (44 lbf•in) to then sanded with a fine sand paper.
finalize to 11 N•m (97 lbf•in). If you find aluminum dust or debris in this area,
they may have flowed toward the injection oil res-
ervoir. In this case, the oil reservoir and lines must
be flushed and the filter replaced.
06-03-10 SMR2002-075 _06-03A.FM
CAUTION: Failure to properly clean the oil sys- Assembly

tem will result in serious engine damage. Apply injection oil in cylinder and on rings prior to
The inspection of top end should include the fol- installing.
lowing measurements. Install the oil ring with the “TOP” marking on top.
Identify the correct position by looking at beveled
TOLERANCES
ENGINE edge of oil ring and while installation, make sure
MEASUREMENT NEW PARTS WEAR that the beveled edge should be towards the top
(min.) (max.) LIMIT of the piston.
Piston/cylinder wall 0.12 mm 0.2 mm
N.A. 1
clearance (.005 in) (.008 in)
0.1 mm 0.25 mm 0.5 mm

Ring end gap
(.004 in) (.010 in) (.020 in)
N.A.: Not Applicable
Piston/Cylinder Wall Clearance

Clearance can be quickly checked with a feeler
gauge. Insert feeler gauge in cylinder then slide 1
piston (without piston rings installed). If clearance
exceeds tolerance, check cylinder top area with
your finger to feel if there is a ridge. If so, the cyl-
inder sleeve is worn and needs replacement. Oth-
erwise, replace piston.
Ring End Gap F12R1OA
Position ring close to top of cylinder top. 1. Beveled edge

NOTE: In order to correctly position ring in cylin-
Position ring openings 180° apart.
der, use piston as a pusher.
Using a feeler gauge, check ring end gap. If gap 1
exceeds specified tolerance, rings should be re-
placed.
F12R15A 2
1. Ring openings 180° apart
2. TOP marking on this side
F12R07A 2 1
1. Top of cylinder Use ring compressor (P/N 529 035 713) and insert
2. Ring end gap piston in cylinder.
NOTE: Cylinder may be removed from crankcase
to install piston more easily on the bench from the
bottom if desired.
SMR2002-075 _06-03A.FM 06-03-11
When attaching connecting rod to “crankpin”, strict-

ly follow this procedure:
1. Block counterbalance shaft to prevent any rota-
tion.
2. Install the “crankpin” (bushing) with the previ-
ously marked end outside. If the mark is not
present anymore, place a straight edge against
bushing end to find the tapered end (concave).
A very small gap between the edge and the
bushing will identify the tapered end to be in- 1
stalled against the counterweight.
3. Install a NEW screw and torque to 6.5 N•m
(58 lbf•in). Do not apply any thread locker product.
4. Turn the screw clockwise an additional 80 de-
grees ± 5 degrees.
CAUTION: Failure to strictly follow this proce-
dure may cause screw to loosen and lead to 2
engine damage. The bushing tapered end must
be against the counterweight. Besides, as the
“crankpin” screw has been stretched from the
previous installation, it is very important to use F12R08A
a new screw at assembly. Also, the new screw

1. Pressure gauge (P/N 529 035 709)
will have the proper threadlocking coating. 2. T-adapter (P/N 529 035 710)
Ensure to correctly position O-ring on access cov- Install pressure gauge between disconnected hose
er and install cover. (inline installation).
Reinstall remaining removed parts. Ensure to
check engine alignment.
FUEL DELIVERY
FUEL PRESSURE REGULATOR
Pressure Test
The pressure test will show the available pressure
at the air/fuel rail. It validates the pressure regula-
tor and leaks in the system.
IMPORTANT: Before checking air/fuel rail pres-
sure, make sure the fuel pressure from the fuel
pump and the air pressure from the air compres- 2
sor are within specifications. See the procedures
elsewhere in this section.
Also ensure there is no leak from hoses and fit-
tings. Repair any leak.
3
Ensure there is enough gas in fuel tank. 1
Release the fuel pressure in the system.
Disconnect outlet hose (the one with the fuel fil- F12R09A
ter) from fuel pump using tool (P/N 529 035 714).
1. Fuel filter
Connect adapter to pressure gauge as shown. 2. Fuel line going to air/fuel rail
3. Pressure gauge between disconnected hose (inline installation)
06-03-12 SMR2002-075 _06-03A.FM
Install safety lanyard and observe fuel pressure.

Do not crank engine. 1
FUEL REGULATOR PRESSURE

185 ± 14 kPa (27 ± 2 PSI)
If pressure is within limits, fuel pressure regulator

is working adequately.
A rapid pressure drop indicates leakage either
from the air/fuel rail or from the fuel pump check
valve. Check air/fuel rail for leaks. If it is not leaking
then replace fuel pump.
A slow pressure drop indicates leakage either from
the fuel injector or from the fuel pressure regulator.
Check fuel injector for leaks (see below). If it is not
leaking then replace fuel pressure regulator.
NOTE: Fuel in air compressor outlet line is an indica-
tion of a leaking fuel pressure regulator diaphragm.
F12R0DA
Remove pressure gauge and reinstall fuel hose. At
installation apply engine oil on O-ring. 1. Push clip toward injector to release connector
Unscrew rail retaining screws.

 WARNING
Wipe off any fuel spillage in the bilge. Fuel is 1 1
flammable and explosive under certain con-
ditions. Always work in a well ventilated area.
Fuel Pressure Regulator Replacement

Removal
Disconnect spark plug cables from spark plugs.
Disconnect the fuel injector wires, if necessary. F12R19A
1. Retaining screws
SMR2002-075 _06-03A.FM 06-03-13
Gently pull rail up by hand, working each side slight- Electrical Test
ly at a time.
Safety lanyard must be on DESS post.
Pull rail out.
Using the vehicle communication kit (VCK) with
Unscrew retaining plate screws. the B.U.D.S. software, energize the fuel injector
from the ACTIVATION section.
4 2 5
If the injector does not work, disconnect the plug
connector from the injector.
Install a temporary connector to the injector with
wires long enough to make the connection out-
side the bilge and apply voltage (12 V) to this test
harness.
This will validate the injector mechanical and elec-
trical operation.
If it does not work, replace it.
F12R1AA 2 3 1 3 2 Otherwise, check the resistance of the fuel injec-
1. Retaining plate tor circuit.
2. Screws
3. Fuel injector Reconnect the injector and disconnect the AMP
4. Fuel pressure regulator and cover plug connector number 4 on the MPEM.
5. Air pressure regulator
Using a multimeter, check resistance value be-
NOTE: If needed, use a small screwdriver to lift tween terminals as follows.
the fuel pressure regulator.
To remove fuel pressure regulator, pull the fuel COMPONENT CONTACT LOCATION
regulator and the cover out of rail.
Fuel injector MAG 7 and 13
Installation
Fuel injector PTO 8 and 14
For the installation, reverse the removal procedure
but pay attention to the following. The resistance should be between 1.7 and 1.9 Ω.
If the same regulator is reinstalled, it is recommend- If resistance value is correct, try a new MPEM.
ed to change the O-rings. Refer to MPEM REPLACEMENT procedures else-
Insert the fuel pressure regulator into the cover where in this section.
then install both regulators together in place with If resistance value is incorrect, repair the wiring
your hand. Do not use any tool. harness/connectors between AMP plug connec-
NOTE: A thin film of injection oil may be applied tor and fuel injector.
to O-ring to ease insertion in rail.
Apply Loctite 243 on rail retaining screws then Fuel Injector Replacement
torque to 25 N•m (18 lbf•ft). When one fuel injector is defective, both have to
be replaced at the same time. Be sure to check
FUEL INJECTOR the other one. Also replace direct injectors.
Removal
Leakage Test
See FUEL PRESSURE REGULATOR REPLACE-
Testing the fuel injector operation can be per- MENT above for procedure. However, do not re-
formed with the air/fuel rail installed. move any regulator.
The leakage test is validated when performing the To remove fuel injector, pull it out of rail.
FUEL DELIVERY SYSTEM DIAGNOSTIC FLOW
CHART elsewhere in this section.
06-03-14 SMR2002-075 _06-03A.FM
Installation Air/Fuel Rail Replacement

For the installation, reverse the removal proce- Removal
dure. Paying attention to the following details.
If the same injector is reinstalled, it is recommend-
Disconnect air compressor supply hose from rail.
ed to change the O-rings.
Disconnect fuel hoses (supply and return) at their
Insert the fuel injector in place with your hand. Do
inline connectors.
not use any tool.
Temporarily connect those hose ends together to
NOTE: A thin film of injection oil may be applied prevent rail draining.
Disconnect spark plug cables from spark plugs
Apply Loctite 243 on rail retaining screws then torque and fuel injector wires. Cut locking ties of wiring.
AIR/FUEL RAIL 3 1 4 2
Pressure test
FUEL PRESSURE
(when cranking engine or when engine is running)
738 ± 14 kPa (107 ± 2 PSI)
If pressure is within limits, fuel and air systems are

working adequately. No subsequent tests are nec-
essary for the air/fuel system.
Remove pressure gauge and reinstall fuel hose. At F12R0CA
installation apply engine oil on O-ring.
1. Air/fuel rail
If pressure is out of limits, check air/fuel rail for 2. Air supply hose
3. Fuel supply hose
leaks. If it is not leaking then replace air regulator 4. Retaining screws
A higher pressure may be an indication of a
pinched or clogged air regulator outlet line. 1
Air Pressure Regulator Replacement

Removal
See FUEL PRESSURE REGULATOR REMOVAL
above for procedure.
Remove the fuel regulator then the air regulator.
Installation
For the installation, reverse the removal procedure
but pay attention to the following.
NOTE: A thin film of injection oil may be applied
Apply Loctite 243 on rail retaining screws then
torque to 25 N•m (18 lbf•ft).
F12R0DA
1. Push clip toward injector to release connector

SMR2002-075 _06-03A.FM 06-03-15
Gently pull rail up by hand, working each side slight- Leakage Test
ly at a time.
If direct injector leaks through its large top O-ring,
Pull rail out. there will be an air/fuel leak between the injector
Disconnect hose ends at their inline connectors and the air/fuel rail. Replace O-ring of both injectors.
and drain fuel rail. If there is an injector internal leak, the high tempera-
Disconnect air and fuel hoses from rail. ture from the combustion chamber will make visible
overheated area. Replace damaged components.
2 Electrical Test
1 the B.U.D.S. software, energize the direct injector
in the ACTIVATION section.
If the injector does not work, disconnect the plug
harness.
This will validate its mechanical and electrical op-
eration.
If it does not work, replace the direct injector.
Otherwise, check the resistance of the direct in-
jector circuit.
F12R0FA
Reconnect the injector and disconnect the AMP
plug connector number 4 on the MPEM.
1. Air and fuel return hoses
2. Fuel supply hose Using a multimeter, check resistance value be-
tween terminals as follows.
NOTE: When lifting/removing air/fuel rail, we rec-
ommend replacing carbon dams on direct injec- COMPONENT CONTACT LOCATION
tors that have been running for 50 hours or more.
Remove fuel injector, fuel pressure regulator and Direct injector MAG 5 and 15
air pressure regulator. Direct injector PTO 6 and 21
Installation
For installation, reverse the removal process but The resistance should be between 1 and 1.6 Ω.
pay attention to the following. If resistance value is correct, try a new MPEM.
A thin film of injection oil may be applied to O-rings Refer to MPEM REPLACEMENT procedures else-
of fuel injectors to ease rail installation. where in this section.
Apply Loctite 243 on rail retaining screws then torque If resistance value is incorrect, repair the wiring
to 25 N•m (18 lbf•ft). harness/connectors between AMP plug connec-
tor and direct injector.
When installing fuel or air hoses fitting to the air/
fuel rail, use Loctite Krylox (no. 29-719).
Direct Injector Replacement
DIRECT INJECTOR IMPORTANT: Do not remove direct injector need-
lessly. They are sealed with a carbon dam that may
When one direct injector is defective, both have expand when pulled out. A special tool is required
to be replaced at the same time. Be sure to check to compress it prior to reinstalling. Otherwise,
the other one. Also replace fuel injectors. sealing efficiency might be affected.
The direct injectors can be replaced by lifting the Remove air/fuel rail retaining screws. Partially lift
air/fuel rail. rail to allow direct injector removal.
06-03-16 SMR2002-075 _06-03A.FM
Disconnect direct injector connector then pull in- Carbon Dam Replacement
jector out of cylinder head. Remove direct injector. See procedure above.
1 NOTE: When replacing a carbon dam, it is recom-
mended to replace it on both injectors. It is also
recommended to replace all O-rings. When servic-
ing air/fuel rail or direct injectors, we recommend
replacing carbon dams that have been running for
50 hours or more.
CAUTION: Never reuse a carbon dam after it has
been removed from the injector. Always install
a new one.
Remove carbon dam and O-ring using a small pick.
Install seal guide (P/N 529 035 715) on end of injec-
tor. Carefully slide carbon dam in injector groove.
Use carbon dam compressor (P/N 529 035 716) to
compress carbon dam evenly.
2
F12R0GA
FUEL PUMP
1. Air/fuel rail
2. Disconnect and pull injector out
Pressure Test
Compress the carbon dam using tool (P/N 529 035 The pressure test will show the available pressure
716).
from the fuel pump.
Carefully install direct injector in cylinder head pay-
ing attention to carbon dam insertion. Ensure to Ensure there is no leak from hoses and fittings.
position connector pointing toward bottom of cyl- Repair any leak.
inder head. Ensure there is enough gas in fuel tank.
NOTE: A thin film of injection oil may be applied Use the VCK (Vehicle Communication Kit) to re-
to carbon dam if necessary to ease insertion in cyl- lease the fuel pressure in the system. Look in the
inder head. ACTIVATION section of the software B.U.D.S.
Reconnect electrical connector. Disconnect inlet and outlet hoses from fuel pump
using tool (P/N 529 035 714).
2
F12R0HA 1
1. Carefully insert direct injector
2. Connector pointing toward bottom of cylinder head
Reinstall air/fuel rail.
SMR2002-075 _06-03A.FM 06-03-17
Connect adapters and pressure relief valve to

pressure gauge as shown.
2
1
1
3
4
F12R0BA
1. Fuel pump outlet hose (fuel filter side)

F12R0AA 3 2 2. Fuel pump return line
3. Fuel relief valve on the return line side
1. Pressure gauge (P/N 529 035 709) 4. Pressure gauge between disconnected hose (inline installation)
2. T-adapter (P/N 529 035 710)
3. Pressure relief valve (P/N 529 035 711) Install safety lanyard and observe fuel pressure.
CAUTION: Ensure to install the pressure relief MINIMUM FUEL PUMP PRESSURE
valve to allow excess pressure to flow back (when installing safety lanyard)
through return line. Note the arrow on the valve.
Otherwise, fuel pump components might be dam- 721 kPa (105 PSI)
aged.
Install pressure gauge between disconnected If pressure is within limits, fuel pump is working
hoses on fuel pump side (closed-loop installation adequately.
on fuel pump). Make sure the pressure-relief valve If pressure is below limits, ensure fuel filters are
is installed on the fuel pump return line side. not obstructed. There is one in-line fuel filter at the
fuel pump outlet hose and one filter at the inlet
underneath the pump. Otherwise, replace the fuel
pump.
Remove pressure gauge and reinstall fuel hoses.
At installation apply engine oil on O-ring.
06-03-18 SMR2002-075 _06-03A.FM
Electrical Test Disconnect electrical connector.

When connecting the safety lanyard to the DESS Disconnect vent tube from fuel pump.
post, the fuel pump should run for 2 seconds to Release the fuel pressure in the system.
build up the pressure in the system.
Disconnect inlet and outlet hoses from fuel pump
If the pump does not work, disconnect the plug using tool (P/N 529 035 714).
connector from the fuel pump.
Pull fuel pump toward front of vehicle. Wipe off
Install a temporary connector to the fuel pump any fuel spillage in the bilge.
with wires long enough to make the connection
outside the bilge and apply voltage (12 V) to this
test harness.
If pump does not run, replace the fuel pump.
Otherwise, check the continuity of the fuel pump
circuit.
Disconnect the AMP plug connector number 4 on
the MPEM.
Using a multimeter, check continuity between ter-
minals of circuits 24 and 26.
If wiring harness is good, try a new MPEM. Refer
to MPEM REPLACEMENT procedures elsewhere
in this section.
Otherwise, repair the wiring harness/connectors
between AMP plug connector and fuel pump.
F12R0JA 1
Fuel Pump Replacement 1. Pull fuel pump toward front
Removal Installation
Open front storage compartment cover. For installation, reverse the removal process but
Remove the storage basket. pay attention to the following.
Remove glove box (see HULL/BODY section). Tighten fuel pump screws in a criss-cross sequence.i
Remove front vent tubes.
From glove box opening, remove fuel pump retain-
ing nuts.
F12R0IA 1 2
1. Fuel pump
2. Retaining screw
SMR2002-075 _06-03A.FM 06-03-19
FUEL DELIVERY SYSTEM DIAGNOSTIC FLOW CHART
NOTE: The tolerance for the pressure is ± 14 kPa (2 PSI).

Fuel pump runs
Fuel pump does not run Connect safety lanyard for 2 sec. then stops
Check fuses Install fuel pressure gauge on

Check lanyard connection fuel pressure line
Check pump module operation
Repair or replace if necessary
Connect safety lanyard

OK
Fuel pump runs Repair or replace
Fuel pressure Check for

Fuel pressure less more than blocked fuel
than 185 kPa (27 PSI) 185 kPa return line
(27 PSI)
Check fuel lines

Repair or yes for leaks Fuel pressure
replace Check fuel filters is 185 kPa Line OK
(27 PSI)
Replace Perform fuel

fuel pump fails
pump test Crank or start engine
module
Fuel pressure lower

test OK than 735 kPa (107 PSI)
Fast
pressure Replace
drop Perform fuel Check Fuel pressure Fuel pressure
fuel pump fails no yes
pump test for air greater than is 735 kPa
yes module leaks
no leaks 735 kPa (107 PSI)
(107 PSI)
Verify pass
fuel pump Repair
check valve Proceed to air leaks
fails compressor OK Check air Replace fuel
OK fails pressure test return pressure
line for regulator
Ensure Replace blockage
Air pressure less Air pressure more
air/fuel fuel pump than 621 kPa than 621 kPa
rail is not (90 PSI) (90 PSI)
leaking yes
no Check
Repair/replace
air/fuel rail RAVE no Check direct
fails OK line
Check fuel for air leaks injector
leaks OK
injector
Repair Repair air Direct
fails Replace
OK leaks compressor injector direct
OK injector
Replace fuel Replace air
injector pressure System OK
regulator
Check air/fuel rail for leaks OK
Replace fuel
fails
pressure NOTE: The tolerance for the Retest
regulator pressure is ± 14 kPa (2 PSI).
Repair/replace air/fuel rail
F12A06S
06-03-20 SMR2002-075 _06-03A.FM
ELECTRONIC MANAGEMENT Select the Activation tab.

Point the mouse cursor over the PTO TPS. Check
MPEM REPLACEMENT the ADC reading. It must be between 23 and 45.
General 1
Prior to replacing a suspected MPEM, ensure that Activation
all the recommendations in the general introduc-
tion of this section have been followed.
IMPORTANT: When MPEM is replaced, the safe-
ty lanyard(s), the TPS closed position and the TDC
setting must be reprogrammed/reset. Refer to
their specific section for adjustment.
To allow transferring the previous recorded infor-
mation from the old MPEM to the new one, use the
vehicle communication kit (VCK) with the B.U.D.S.
software. Use Replace in the MPEM menu. Follows
instructions in its help system.
NOTE: If the old MPEM is working, it must be read
inside B.U.D.S. prior to removing it from the vehicle
to carry vehicle information and history to the new 30
MPEM. Besides, select the Setting tab and note
the Current Angle in the ignition offset area. When F12R1JA 3 2
installing the new MPEM, re-use this setting as a 1. “Activation” tab
preliminary setting. Then, proceed with the regular 2. Point on PTO TPS
3. ADC reading
procedure for the TDC setting. If the old MPEM is
not working, try to find a previous saved file from Point the mouse cursor over the MAG TPS. Check
B.U.D.S. the ADC reading. It must be between 37 and 59.
If either readings are not within those parameters,
Replacement they are out of range and the MPEM will be unable
Disconnect battery cables. to initialize. Proceed with THROTTLE BODY SYN-
CHRONIZATION as detailed in THROTTLE BODY.
 WARNING If the ADC’s are within range, proceed with the
Battery BLACK negative cable must always required resets.
be disconnected first and connected last. After performing the required resets, ensure to
clear all faults from the newly replaced MPEM.
Disconnect AMP connectors from MPEM. Now, all faults must be inactive (except the Diag-
Remove MPEM. nostic Cap Missing fault).
Install the new MPEM to the vehicle. Start the engine and increase engine speed above
Reconnect AMP connectors to MPEM then bat- 5000 RPM to be sure no fault appears.
tery cables.
Transfer the data from the previous MPEM to the
new one using B.U.D.S. then proceed with the re-
quired resets after the following verification has
been done.
SMR2002-075 _06-03A.FM 06-03-21
THROTTLE POSITION SENSOR NOTE: In this particular case, by comparing the

signals from both sensors, the MPEM will gener-
(TPS) ate a fault code when the TPS is malfunctioning
due to specific “spots”.
General
To isolate the faulty TPS, disconnect one and test
The throttle position sensor (TPS) is a potentiom- the other.
eter that sends a signal to the MPEM which is pro-
portional to the throttle shaft angle. On the DI sys- Voltage Test — Both TPS
tem, two sensors are used for redundancy purposes.
The MPEM compares the signals from both sensors Check the voltage output from MPEM to the desired
and determines if there is an error and uses the most throttle position sensor.
appropriate sensor to operate the system. Disconnect plug connector from throttle position sen-
sor and connect a voltmeter to the wiring harness.
Check the voltage readings on the PTO side as
follows.
CONNECTION VOLTAGE
Pin 1 with engine ground 5V
Pin 2 with engine ground 0 - 0.5 V
Check the voltage readings on the MAG side as

follows.
F12F05A 1 1
CONNECTION VOLTAGE
IMPORTANT: Prior to testing the TPS, ensure that
mechanical components/adjustments are adequate Pin 2 with engine ground 0 - 0.5 V
according to THROTTLE BODY in AIR INDUCTION
Pin 3 with engine ground 4.75 - 5 V
SYSTEM above.
The MPEM may generate two types of fault codes Remove and reinstall the safety lanyard to activate
pertaining to the TPS. Refer to DI SYSTEM FAULT the MPEM. There should be 5 Vdc in each test.
CODES in DIAGNOSTIC PROCEDURES section If voltage test is good, replace the TPS.
for more information.
If voltage test is not good, check the resistance of
Wear Test the TPS circuit.
While engine is not running, activate throttle and Resistance Test
pay attention for smooth operation without physi-
cal stops of the cable. Reconnect the TPS.
Using the vehicle communication kit (VCK) with the NOTE: Resistance values are different at idle on
B.U.D.S. software, use the THROTTLE OPENING each TPS.
display under Monitoring. MAG Side
Slowly and regularly depress the throttle. Observe Disconnect the AMP plug connector number 3 on
the needle movement. It must change gradually the MPEM.
and regularly as you move the throttle. If the nee-
dle “sticks”, bounces, suddenly drops or if any dis- Using a multimeter, check resistance value be-
crepancy between the throttle movement and the tween terminal 10 and 14.
needle movement is noticed, it indicates a worn The resistance should be 1600 - 2400 Ω.
TPS that needs to be replaced. Check the resistance between terminal 5 and ter-
minal 14 with the throttle plate in idle position.
06-03-22 SMR2002-075 _06-03A.FM
The resistance should be 2500 Ω.

1 2
Check the resistance between terminal 5 and ter-
PTO Side
the MPEM.
tween terminal 3 and 18.
The resistance should be 1600 - 2400 Ω.
minal 18 with the throttle plate in idle position. F12R0LA
The resistance should be 2500 Ω. MAG SIDE THROTTLE BODY

1. Allen screws
Test Results — Both TPS 2. Throttle position sensor (TPS)
If resistance values are correct, try a new MPEM. Re- Apply Loctite 243 on screw threads, install the
fer to MPEM REPLACEMENT procedures else- new TPS.
where in this section.
NOTE: Both TPS do not need to be replaced at the
If resistance values are incorrect, repair the wiring same time.
harness/connectors between AMP plug connec-
Reinstall remaining removed parts.
tor and the TPS.
Proceed with the CLOSED TPS ADJUSTMENT.
Replacement See below.
Remove the air intake silencer. Closed TPS Adjustment
Remove the air duct.
NOTE: Although this operation is called “adjust-
Disconnect the connector of the TPS. ment”, it is not really an adjustment. Rather, it per-
Loosen two Allen screws retaining the TPS. forms a reset of the values in the MPEM.
Remove TPS. This reset is very important. The setting of the TPS
will determine the basic parameters for all fuel
mapping and several MPEM calculations.
NOTE: Reset must be done each time the throttle
position sensor (TPS) is loosened or removed or
throttle body(ies) is(are) replaced or MPEM is re-
placed.
SMR2002-075 _06-03A.FM 06-03-23
CAUTION: An improperly adjusted TPS may Otherwise, validate the information center is
lead to poor engine performance and emission working by activating the tachometer using the
compliance could possibly be affected. software B.U.D.S. under Activation (first ensure
information center is in tachometer mode). If it
Use the vehicle communication kit (VCK) with the does not display 3000 RPM, the information cen-
B.U.D.S. software to perform this adjustment. ter may be faulty and needs to be tested.
Ensure the throttle body plate stop lever rest against If the information center correctly displayed 3000
its stopper. Open throttle approximately one quarter RPM, perform the following tests.
then quickly release. Repeat 2 - 3 times to settle
throttle plate. If stopper does not rest against its NOTE: Take into account that a CPS fault can be
stop lever, perform throttle cable adjustment. Refer triggered by bent or missing encoder wheel teeth.
to THROTTLE BODY in AIR INDUCTION SYSTEM Check the teeth condition. Also, bad connections
above. in magneto connector could generate electrical
noise that would make you wrongly think the CPS
Push the Reset button in the SETTING section of is faulty. Check pins and wires.
B.U.D.S.
NOTE: There is no idle speed adjustment to per- Encoder Wheel Inspection
form. The MPEM takes care of that. If TPS are not
To check the encoder wheel for bent teeth, pro-
within the allowed range while resetting the
ceed as follows.
closed TPS, the MPEM will generate a fault code
and not accept the setting. Remove magneto cover. Refer to MAGNETO SYS-
TEM in ENGINE section.
Start engine and make sure it operates normally
through its full engine RPM range. If fault codes ap- Install a dial indicator on crankcase casting. Posi-
pear, refer to DI SYSTEM FAULT CODES in DIAG- tion the gauge on a tooth and set it to zero (0).
NOSTIC PROCEDURES section for more informa- Rotate flywheel and check needle movement. The
tion. maximum allowed difference between teeth is
0.15 mm (.006 in). Otherwise, straighten the tooth
CRANKSHAFT POSITION or replace the encoder wheel.
SENSOR (CPS)
2 1
2
F12R1HA
F12R0OA
1. Magneto cover 1. Encoder wheel

2. CPS connector 2. Dial indicator
Check for RPM display at the information center Properly reinstall cover.
while cranking engine (first ensure information The encoder wheel for bent teeth can also be in-
center is in tachometer mode). If it displays ap- spected by the following alternative method.
proximately 300 RPM, the CPS circuitry is properly Remove magneto cover. Refer to MAGNETO SYS-
working. TEM in ENGINE section.
06-03-24 SMR2002-075 _06-03A.FM
Install a pointed wire on one of the threaded hole Voltage Test

of crankcase with the screw as shown in the fol-
Unplug magneto connector.
lowing illustration.
Check connector pins for corrosion or damage.
1 2 Remove and reinstall the safety lanyard to activate
the MPEM.
Check the voltage readings on the harness side as
follows:
CONNECTION VOLTAGE
0 V ± a small mV
Pin 4 with engine ground
tolerance
Pin 5 with engine ground 12 V
If voltage tests good, the CPS is defective and

needs replacement.
F12R1MA If voltage does not test good, perform the follow-
ing tests.
1. Pointed wire
2. Screw on the threaded hole
Resistance Test
Rotate the flywheel one time and adjust the point-
er so that it slightly touches the highest tooth. Us- Check the continuity of the wiring harness.
ing a feeler gauge, check and measure the clear- Disconnect the AMP plug connector number 2 on
ance between each tooth and pointer. the MPEM.
Using a multimeter, check continuity of circuits 6,
7 and 14.
If wiring harness is good, it could be either the CPS
or the MPEM. Try a new part one at a time. When
trying a new MPEM, refer to MPEM REPLACE-
MENT procedures elsewhere in this section.
2 1 between AMP plug connector and the CPS.
Replacement
Remove tuned pipe.
Unscrew front engine support and slightly lift en-
gine to have access to magneto cover screws.
Block engine in this position.
Disconnect connector and remove magneto cover.
F12R1NA
1. Pointed wire
2. Feeler gauge
The maximum allowed difference between teeth

is 0.15 mm (.006 in). Otherwise, straighten the
tooth or replace the encoder wheel.
Properly reinstall cover.
SMR2002-075 _06-03A.FM 06-03-25
Remove CPS. If resistance tests good, reconnect the MATS and

disconnect the AMP plug connector number 4 on
the MPEM.
Using a multimeter, recheck resistance value be-
tween terminals 16 and 19.
If resistance value is correct, try a new MPEM. Re-
fer to MPEM REPLACEMENT procedures else-
If resistance value is incorrect, repair the wiring
tor and the MATS.
Replacement
Remove the air intake silencer.
F12R0NA 1
Disconnect the connector of the MATS.
1. CPS inside magneto cover
Pull MATS out while turning right and left.
Apply Loctite 243 on screw threads then install the Install the new MATS.
new CPS.
MANIFOLD AIR TEMPERATURE WATER TEMPERATURE SENSOR

SENSOR (MATS) (WTS)
F12R0MA 1 F12R0PA 1
PTO SIDE THROTTLE BODY 1. Water temperature sensor (WTS)

1. Manifold air temperature sensor (MATS)
Resistance Test
Resistance Test Disconnect the plug connector from the WTS and
Disconnect the plug connector from the MATS check the resistance of the sensor itself.
and check the resistance of the sensor itself. The resistance should be between 2280 Ω and
The resistance should be between 2280 Ω and 2740 Ω.
2740 Ω. Otherwise, replace the WTS.
Otherwise, replace the MATS. If resistance tests good, reconnect the WTS and
disconnect the AMP plug connector number 4 on
the MPEM.
06-03-26 SMR2002-075 _06-03A.FM
Using a multimeter, recheck resistance value be- Ensure sensor is correctly installed elbow adaptor.
tween terminals 9 and 11. Otherwise, the MAPS could generate a fault code
If resistance value is correct, try a new MPEM. Re- for an unexpected sensor range at idle when it
fer to MPEM REPLACEMENT procedures else- reads the atmospheric pressure. Ensure the cor-
where in this section. rect connector is plugged and not mixed with the
MAG TPS. Remove sensor and check for oil or dirt
If resistance value is incorrect, repair the wiring on its end and if problem persists, check throttle
harness/connectors between AMP plug connec- plate condition/position and the wiring harness.
tor and the WTS. Perform the following tests.
Replacement Voltage Test
Remove air/fuel rail retaining screws. Check the voltage output from MPEM to the mani-
Cut locking ties as necessary to allow lifting of fold air pressure sensor (MAPS).
air/fuel rail in order to give access to the tempera- Disconnect plug connector from throttle position
ture sensor. sensor and connect a voltmeter between pin 1 and
Disconnect WTS connector and remove WTS. 3 and also between pin 1 and 2 of wiring harness.
Apply Loctite 518 on threads of the WTS then in- Remove and reinstall the safety lanyard to activate
stall. the MPEM. There should be 5 Vdc in each test.
Reinstall remaining removed parts. If voltage test is good, replace the MAPS.
If voltage test is not good, check the continuity of
MANIFOLD AIR PRESSURE the MAPS circuit.
SENSOR (MAPS)
Resistance Test
the MPEM.
Using a multimeter, check continuity of circuits 3-3,
3-6 and 3-7.
If wiring harness is good, try a new MPEM. Refer
to MPEM REPLACEMENT procedures elsewhere
in this section.
between AMP plug connector and the MAPS.
Replacement
Remove the air intake silencer.
Disconnect MAPS connector and remove the MPAS.
F12R0LB 1
Install the new MAPS paying attention to index its
MAG SIDE THROTTLE BODY tab into the adaptor notch.
1. Manifold air pressure sensor (MAPS)
NOTE: This sensor is a dual function device. When
engine is started and it runs at idle speed, the sen-
sor takes the atmospheric pressure and stores it in
the MPEM. Thereafter, it takes the manifold air
pressure at operating RPMS.
SMR2002-075 _06-03A.FM 06-03-27
EXHAUST GAS TEMPERATURE KNOCK SENSOR (KS)

SENSOR (EGT)
1
F12R0QA 1
1. Knock sensor (KS)
F12R0SA 2
1. Muffler Dynamic Test
2. Exhaust gas temperature sensor (EGT)
Resistance Test the B.U.D.S. software, monitor the knock sensor
using the FAULTS section.
Disconnect the plug connector from the EGT and
check the resistance of the sensor itself. Start the engine and bring engine RPM above
4500 RPM. If no fault code occurs, the knock sen-
The resistance should be between 2280 Ω and sor is good.
2740 Ω.
Otherwise, do the following.
Otherwise, replace the EGT.
Ensure sensor and head contact surfaces are clean
If resistance tests good, reconnect the EGT and and mounting bolt and washer are correct and prop-
disconnect the AMP plug connector number 4 on erly torqued down.
the MPEM.
Check the knock sensor resistance.
tween terminals 10 and 12. Disconnect the AMP plug connector number 4
from the MPEM module.
If resistance value is correct, try a new MPEM. Re-
fer to MPEM REPLACEMENT procedures else- Static Resistance Test
Using a multimeter, check the resistance between
terminal 2 and terminal 17 on the plug connector.
tor and the EGT. The resistance should be approximately 5 MΩ.
Otherwise, check the continuity of the knock sen-
Replacement sor circuit 4-2 and 4-17.
Disconnect EGT connector and remove EGT. If wiring harness is good, try a new MPEM. Refer
Apply Loctite 518 on threads of the EGT then in- to MPEM REPLACEMENT procedures elsewhere
stall. in this section.
Replug connector. Otherwise, repair the wiring harness/connectors
between AMP plug connector and knock sensor.
06-03-28 SMR2002-075 _06-03A.FM
Replacement Install leak test pump (P/N 529 021 800) on hose end
and pressurize air line to 69 - 103 kPa (10 - 15 PSI).
Unscrew and remove knock sensor.
Wait some time to see if pressure drops. If so,
Clean contact surface, apply Loctite 243 in thread- check line for leaks. Otherwise, the solenoid is de-
ed hole then install the new knock sensor. fective and needs to be replaced.
Torque screw to 20 N•m (15 lbf•ft). Using the vehicle communication kit (VCK) with
CAUTION: Improper torque might prevent sen- the B.U.D.S. software, energize the RAVE sole-
sor to work properly and lead engine to severe noid from the ACTIVATION section.
damage of internal components. The pressure should drop when the solenoid is ac-
Re-plug connector. tivated. If the solenoid does not work, disconnect
the plug connector from the solenoid.
RAVE SOLENOID Install a temporary connector to the solenoid with
A quick check can be done as follows. When engine side the bilge and apply voltage (12 V) to this test
is being stopped, the RAVE valves will open and harness.
close. This can be heard or seen by carefully remov-
ing the cap and feeling the movement with a hand. If it does not work, replace the solenoid. Other-
wise, proceed with the resistance test below.
Another test can be done using the vehicle com-
munication kit (VCK) with the B.U.D.S. software, Reconnect hose to compressor.
using the MONITORING section. Start engine and Unplug the outlet hose from RAVE solenoid.
bring its RPM to approximately 6000 and look at
the RAVE solenoid LED. It should turn on, indicat- 4
ing the RAVE system is working on the electronic
side. However, pneumatic test still have to be per-
formed to validate the mechanical operation.
Leakage/Voltage Test
NOTE: The solenoid activates both RAVE valves
at the same time.
Unplug the RAVE solenoid supply hose from air
compressor.
F12R0TA 3 1 2
1. RAVE solenoid
2. Supply hose from air compressor
3. Check valve
4. Outlet hose to RAVE valves
Install leak test pump on hose end and apply pres-

sure. If pressure can not be held, check hoses for
leaks. If hoses test good, connect pump directly
to each RAVE valve nipple and pressurize. If pres-
sure drops, replace the defective seal inside RAVE
valve.
Take into account that the RAVE may be mechani-
F12R0RA 1 2 cally stuck in the cylinder slot. Open the RAVE and
check for free operation. Refer to ENGINE section
1. Air compressor
2. Disconnect RAVE supply hose and look in TOP END subsection.
SMR2002-075 _06-03A.FM 06-03-29
Pressure Relief Circuit IGNITION COIL

When RAVE valve is released, the pressure es-
NOTE: The MPEM energizes the primary side of
cape from this vented hose. If the RAVE valves
each ignition coil individually. It can detect open
does not return when the solenoid is released, en-
and short circuit in the primary winding but it does
sure the return spring is in good condition, this
not check the secondary winding.
hose is not kinked or plugged and the solenoid al-
lows pressure to bleed there. Using the vehicle communication kit (VCK) with
the B.U.D.S. software, energize the ignition coil
Although it is not related with RAVE operation, we
from the ACTIVATION section.
suggest to verify the check valve operation which
prevent the pressure going down to crankcase. In- You should hear the spark occurring. In doubt, use an
stall a hose pincher after the T-fitting to adequately inductive spark tester or a sealed tester — available
pressurize the check valve portion. from after-market tool/equipment suppliers — to pre-
vent spark occurring in the bilge. Otherwise, perform
3 2 the following checks.
 WARNING
Never make a spark test with spark plug re-
moved. Flammable vapors may be present in
the bilge and ignited which could cause an
explosion.
Primary Winding
Disconnect the plug connector from the ignition
coil and check the resistance of the primary circuit.
F12R0TB 1
1. RAVE solenoid
2. Pressure relief hose
3. Install hose pincher here
Resistance Test
Reconnect the solenoid and disconnect the AMP
plug connector number 4 on the MPEM.
If resistance value is correct, try a new MPEM. Refer F12R0UA 3 1
to MPEM REPLACEMENT procedures elsewhere in 1. PTO side ignition coil
2. Mag side ignition coil
this section. 3. Primary winding connector
tor and solenoid.
06-03-30 SMR2002-075 _06-03A.FM
The resistance should be between .45 - .55 Ω at Dynamic Test

20°C (68°F). Use an ignition coil tester, available from after-market
Otherwise, replace the ignition coil. tool/equipment suppliers.
If resistance tests good, reconnect the ignition
coil connector and disconnect the AMP plug con-  WARNING
nector number 3 on the MPEM. Do NOT use coil tester on metal work bench.
Using a multimeter, recheck resistance value be- Follow manufacturer instructions.
tween terminals 21 and 22 for MAG side and ter-
minals 20 and 23 for PTO side. 1. With ignition coil removed from craft, hook high
tension leads from tester to ignition coil high
If resistance value is correct, try a new MPEM. Re- tension cables.
fer to MPEM REPLACEMENT procedures else-
where in this section. 2. Connect 2 smaller tester leads to primary of ig-
nition coil.
harness/connectors between AMP plug connec- 1
tor and the ignition coil.
Secondary Winding
Static Test
NOTE: An ignition coil with good resistance mea-
surement can still be faulty. Voltage leak can occur
at high voltage level which is not detectable with
an ohmmeter. A dynamic test is more effective.
Remove high tension lead from ignition coil.
Using a multimeter, check the resistance between 2
the terminals C and the coil post.
F12H0UA
The resistance should be between 6800 and
10200 Ω at 20°C (68°F). TYPICAL
1. Lead to secondary
If not within specification, replace the ignition coil. 2. Leads to primary
Otherwise, perform the DYNAMIC TEST below.
3. Turn power switch to 12 volts and you should
Measure resistance of the high tension leads. observe spark jumping at a predetermined gap
They must be as follows. Otherwise, replace the of 7 to 8 mm (.276 to .311 in).
lead.
If there is no spark, if it is weak or intermittent, the
NOTE: It is not necessary to remove the spark coil is defective and should be replaced.
plug cap.
IMPORTANT: Always replace leads with genuine  WARNING
parts. Otherwise, fuel injection system operation Always reconnect spark plug cables at the same
may be impaired. spark plugs where they come from. The cable
coming out the edge of the electrical box must
MODEL SIDE VALUE OHM
be connected to the MAG side spark plug. Oth-
MAG 5700 erwise, severe backfire may occur with possible
GTX DI
PTO 4900 damage to exhaust system components. The
white tape on the ignition coil should match the
Check continuity between ignition coil ground cir- white tape on the high tension cable.
cuits and engine.
SMR2002-075 _06-03A.FM 06-03-31
Normally TDC setting should not be required. It

2 3 1 has been set at factory and it should remain cor-
rectly set since every part is fixed and not adjust-
able. The only time the TDC setting might have to
be changed would be when replacing the crank-
shaft, the magneto rotor, the CPS, the encoder
wheel or the MPEM. If the TDC setting is found
to be incorrect, you should first check for proper
crankshaft alignment. This might be the indication
of a twisted crankshaft.
With this ignition system, the TDC setting can be
checked with either the engine hot or cold. Also,
the TDC setting is to be checked at any RPM with
the timing light. The TDC setting is best checked
F12R0UB
at idle speed as it is more accurate and easier than
at higher speed, also it will keep the engine tem-
1. MAG side ignition coil at bottom
2. Mag side ignition coil wire on edge of electrical box perature lower for a longer time. Ensure to prop-
3. Edge of electrical box erly cool the engine through the flushing fitting.
NOTE: If PTO ignition coil is replaced, ensure to NOTE: When checking the TDC setting, the spark
reinstall the white tape on the new coil on if it is advance has to be locked to allow proper verifica-
not present. tion of the TDC marks. See TDC SETTING below.
TDC SETTING Static Test

1. Disconnect MAG side spark plug wire and con-
General nect wire to grounding device then remove spark
Before checking TDC setting with a stroboscopic plug.
timing light (dynamic test), it is mandatory to CAUTION: Never crank engine with spark plugs
scribe a timing mark on the PTO flywheel (static removed unless spark plug cables are connect-
test) corresponding to the specific engine. ed to the grounding device.
Also, the mark scribed on the PTO flywheel can 2. Remove PTO flywheel guard.
be used to troubleshoot a broken magneto woo- 3. Remove middle screw securing the engine to
druff key. the rear engine mount. Reinstall screw with tim-
CAUTION: The relation between the PTO flywheel ing mark pointer tool.
mark position and crankshaft position may
change as the PTO flywheel might move on crank- 1
shaft when engine is ran. This will result in a false
ignition timing reading. Always verify PTO fly-
wheel mark position before checking ignition tim-
ing with an appropriate timing light. If mark does
not align with tool, repeat static test to ensure fly-
wheel has not moved before changing the ignition
timing.
NOTE: Do not use the factory mark found on the
PTO flywheel to check TDC setting or troubleshoot
any problems.
F12R1IA
1. Timing mark pointer tool (P/N 295 000 135)
06-03-32 SMR2002-075 _06-03A.FM
4. Install and adjust a TDC gauge (P/N 295 000 143) NOTE: This specification is of the type “indirect
in MAG side spark plug hole. measurement” relative to the piston movement
5. Ensure to install its roller to allow proper reading since we are measuring at a 45° angle through the
of the gauge. Proceed as follows: spark plug hole.
– Rotate magneto flywheel clockwise until pis- 7. Scribe a thin mark on PTO flywheel aligned with
ton is just Before Top Dead Center. timing mark pointer tool.
NOTE: This mark becomes the reference when
1 2 3 using the stroboscopic timing light.
CAUTION: The static test cannot be used as a
TDC setting procedure, therefore, always check
the TDC setting with a stroboscopic timing light.
8. Remove TDC gauge.
9. Reinstall spark plug and connect wire.
Dynamic Test
To check TDC setting, use Bombardier timing light
(P/N 529 031 900).
F12R0VA 5 4
1. Outer ring
2. Adaptor lock nut
3. Adaptor
4. Roller
5. Roller lock nut
– Install roller on dial gauge end. Ensure to posi-

tion roller edge parallel with the dial gauge A00B4FA
face. Secure in this position by tightening roller

lock nut. This will keep the roller in the proper 10. Connect timing light pick-up to MAG side spark
axis for measurement accuracy. plug wire.
– Loosen adaptor lock nut then holding gauge 1
with dial face directed toward you when you
are in line with the crankshaft, screw adaptor
in spark plug hole.
– Slide gauge far enough into adaptor to obtain
a reading then finger tighten adaptor lock nut.
– Since we are working with an indirect mea-
surement, ensure that dial gauge face is po-
sitioned in the same direction as the connect-
ing rod.
– Rotate magneto flywheel clockwise until pis-
ton is at Top Dead Center.
– Unlock outer ring of dial and turn it until “0”
(zero) on dial aligns with pointer. F00H1QA
– Lock outer ring in position. TYPICAL

1. Timing light pick-up
6. From this point, rotate magneto flywheel back 1/4
turn then rotate it clockwise to reach 7.87 mm
(.310 in).
SMR2002-075 _06-03A.FM 06-03-33
IMPORTANT: To check the TDC setting, the spark CAUTION: If the TDC setting is adjusted too ad-
advance curve must be locked first. This allows to vanced, this will cause serious damage to the
perform TDC setting at any RPM by keeping the engine.
ignition timing “frozen” so that it does not vary
Adjustment
with engine RPM. See TDC SETTING below for
more information. In this operation, the ignition timing light and
B.U.D.S. are used to synchronize the MPEM TDC
CAUTION: If the spark advance curve is not
reference with the engine crankshaft. This timing
locked using B.U.D.S. then a wrong ignition tim-
adjustment will affect the timing of ignition as well
ing will be seen as the ignition curve does not
as direct injector timings. The aim of the adjust-
match the locked ignition timing.
ment is to align the mark on the flywheel with the
11. Start engine and check marks at idle speed. pointer at idle using the timing light and B.U.D.S.
Point beam of timing light straight in line with When this is achieved, then the MPEM TDC refer-
timing mark pointer. ence is synchronized with the engine crankshaft.
NOTE: Look at the mark at the same angle as it
was scribed so that parallax error is minimized. 1
1
2
4
3 5
F12R0WA
F06H07A
1. “Setting” tab
2. Ignition offset section
3. “Locked” box
1. Timing light straight in line with pointer
4. Current angle in MPEM
5. Arrows to change the angle
CAUTION: If engine is to be run more than a few
seconds, engine must be cooled using the flush 1. Choose the Setting tab and look under IGNI-
kit. TION OFFSET.
NOTE: If mark on PTO flywheel is perfectly align- 2. Check the Locked box to “freeze” the timing at
ed with timing mark pointer, no adjustment is re- the correct value.
quired. If mark does not align with pointer, recheck 3. The VCK displays the number that is stored in
PTO flywheel mark before performing the TDC the MPEM.
setting to ensure PTO flywheel has not loosen or
tightened. 4. Now click the up or down arrow to change the
number of the current angle so that the TDC
TDC Setting setting marks align when checking with the tim-
ing light. Each step makes an adjustment of 1/4
General degree.
To correct the TDC setting, the data of the MPEM NOTE: Each time the setting is changed on the
is changed using the VCK (Vehicle Communication screen, the new value is also changed in the
Kit) (P/N 295 035 844). Look in SETTING section MPEM, so there may be a slow response, do not
of the software B.U.D.S. make changes too quickly.
NOTE: For more information on the VCK, refer to
its online help. The MPEM programmer will not
work to perform this operation on the DI engines.
06-03-34 SMR2002-075 _06-03A.FM
5. When marks align, uncheck the Locked box to Safety Lanyard Removed
finish. Connect test probes to switch BLACK and BLACK/
NOTE: This will write the new value immediately YELLOW wires. Measure resistance, there should
to the MPEM. There is no need to write the doc- be NO continuity (open circuit).
ument to the MPEM for the TDC setting unless Connect one test probe to the WHITE/GRAY wire
other changes were made. However, we recom- and the other test probe to the switch terminal.
mend to reset the service hours when you per- Measure resistance, it must be close to 0 ohm.
form a service action such as the TDC setting.
Connect one test probe to the BLACK wire and the
NOTE: The MPEM features a permanent (non- other test probe to the switch ring. Measure resis-
volatile) memory and keeps the TDC setting pro- tance, it must be close to 0 ohm.
grammed even when the watercraft battery is dis-
connected. Safety Lanyard on Switch
Connect test probes to switch BLACK and BLACK/
Engine Start/Stop Switch Verification YELLOW wires. Measure resistance, it must be
A quick operation test can be done using the vehi- close to 0 ohm.
cle communication kit (VCK) with the B.U.D.S. soft-
ware, using the MONITORING section. Press the SPARK PLUGS
start button and look at the Start button LED. It
should turn on, indicating the starting system is Disassembly
working on the input side (start button, MPEM and First unscrew the spark plug one turn.
wiring). You know now the problem is on the output
side (MPEM output signal to starting solenoid, wir- Clean the spark plug and cylinder head with pres-
ing harness going to the solenoid, starter motor. Re- surize air then completely unscrew.
fer to STARTING SYSTEM for testing procedures).
Otherwise, check the input side as follows. Heat Range
Disconnect the YELLOW/RED wire of the start/ The proper heat range of the spark plugs is deter-
stop switch. Using an ohmmeter, connect test mined by the spark plugs ability to dissipate the
probes to YELLOW/RED wire and to ground. heat generated by combustion.
Measure resistance, it must be an open circuit The longer the heat path between the electrode tip
(switch is normally open). Depress and hold switch, to the plug shell, the hotter the spark plug operat-
the ohmmeter should read close to 0 ohm. Other- ing temperature will be — and conversely, the
wise, replace switch. shorter the heat path, the colder the operating tem-
perature will be.
If the switch tests good, check continuity of cir-
cuits 2-8 and 2-11 using a multimeter. A “cold” type plug has a relatively short insulator
nose and transfers heat very rapidly into the cylin-
If wiring harness tests good, it could be the MPEM.
der head.
Try a new MPEM referring to MPEM REPLACE-
MENT procedures elsewhere in this section. Such a plug is used in heavy duty or continuous
high speed operation to avoid overheating.
Safety Lanyard Switch Verification
If 2 short beeps are not heard when installing the
safety lanyard, refer to DIAGNOSTIC PROCEDURES.
The following continuity tests can also be per-
formed using an ohmmeter:
Disconnect switch wires.
SMR2002-075 _06-03A.FM 06-03-35
The “hot” type plug has a longer insulator nose 3. Hand screw spark plug into cylinder head. Then,
and transfers heat more slowly away from its firing tighten the spark plug clockwise an additional
end. It runs hotter and burns off combustion de- 1/4 turn with a proper socket.
posits which might tend to foul the plug during
prolonged idle or low speed operation.
1 2
1 2
A00E0BA
1. Proper socket
A00E09A 2. Improper socket
1. Cold
2. Hot SPARK GAP
ENGINE TORQUE
PLUG mm (in)
CAUTION: Severe engine damage might occur
if a wrong heat range plug is used. NGK Hand tighten 1.1
DI + 1/4 turn with
A too “hot” plug will result in overheating and pre- ZFR4F-11 a socket (.043)
ignition, etc.
A too “cold” plug will result in fouling or may cre- CRANKING SYSTEM
ate carbon build up which can heat up red-hot and
cause pre-ignition or detonation. See above for start/stop switch and the DESS post
testing. Refer to STARTING SYSTEM section for
Fouling other tests.
Fouling of the spark plug is indicated by irregular
running of the engine, decreased engine speed DI SYSTEM TEST SUMMARY
due to misfiring, reduced performance, and in-
creased fuel consumption. This is due to a loss of Pressure Tests
compression. Other possible causes are: pro-
longed idling, or running on a too rich mixture or VALUE
COMPONENT
incorrect fuel. The plug face of a fouled spark plug kPa (PSI)
has either a dry coating of soot or an oily, glossy Air compressor 621 ± 14 (90 ± 2) at cranking
coating given by an excess either of oil or of oil
with soot. Such coatings form a conductive con- Fuel pressure 185 ± 14 (27 ± 2)
nection between the center electrode and ground. regulator when installing safety lanyard
738 ± 14 (107 ± 2)
Spark Plug Installation Fuel pressure inline test at cranking or
Prior to installation make sure that contact surfac- when engine is running
es of the cylinder head and spark plug are free of
grime. Fuel pump 721 (105) minimum at cranking
1. Using a wire feeler gauge, set electrode gap ac-
cording to the following chart.
2. Apply anti-seize lubricant over the spark plug
threads to prevent possible seizure.
06-03-36 SMR2002-075 _06-03A.FM
Electrical Tests
TERMINAL
COMPONENT CONNECTOR WIRE COLOR VALUE
NUMBER
26 and pin B PU/PK
Fuel pump AMP no. 4 0 ohm (continuity)
24 and pin D BK/PK
Fuel injector MAG 7 and 13 BL/PU and BL/BK
AMP no. 4 1.7 - 1.9 ohms
Fuel injector PTO 8 and 14 GY/PU and GY/BK
Direct injector MAG 5 and 15 BL/BW and BL/PK
AMP no. 4 1 - 1.6 ohms
Direct injector PTO 6 and 21 GY/BW and GY/PK
1 and engine ground PU/BW 5V
TPS 2 and engine ground BK/BW 0 - 0.5 V
Throttle position 3 and engine ground PU/BW 4.75 - 5 V
sensor MAG
(TPS) 10 and 14 PU/BW and BK/BW 1600 - 2400 ohms
AMP no. 3 5 and 14 WH/BW and BK/BW 2500 ohms at idle
5 and 10 WH/BW and PU/BW 1200 ohms at idle
1 and engine ground PU/RD 5V
TPS 2 and engine ground BK/RD 0 - 0.5 V
Throttle position 3 and engine ground WH/RD 0V
sensor PTO
(TPS) 3 and 18 BK/RD and PU/RD 1600 - 2400 ohms
AMP no. 4 1 and 3 WH/RD and BK/RD 1000 ohms at idle
1 and 18 WH/RD and BK/RD 2500 ohms at idle
0 V (with a small mV
Pin 4 and ground BK
CPS tolerance)
(Deutsche
Pin 5 and ground GY/RD 12 V
connector)
Pin 6 and ground GY/YL 5V
Crankshaft position
sensor Pin 7 and
GY/YL
(CPS) pin 6 of CPS
Pin 6 and
AMP no. 2 GY/RD 0 ohm (continuity)
pin 5 of CPS
Pin 14 and
BK
pin 4 of CPS
Manifold air
temperature sensor AMP no. 4 16 and 19 WH/GY and BK/WH 2280 - 2740 ohms
(MATS)
Water temperature
AMP no. 4 9 and 11 TA/OR and BK/OR 2280 - 2740 ohms
sensor (WTS)
Pin 3 and
PU/BL
pin 1 of MAPS
Manifold air
Pin 6 and
pressure sensor AMP no. 3 WH/BL 0 ohm (continuity)
pin 3 of MAPS
(MAPS)
Pin 7 and
BK/BL
pin 2 of MAPS
Exhaust gas
AMP no. 4 10 and 12 TA/GY and BK/TA 2280 - 2740 ohms
temperature (EGT)
SMR2002-075 _06-03A.FM 06-03-37
TERMINAL
COMPONENT CONNECTOR WIRE COLOR VALUE
NUMBER
Knock sensor (KS) AMP no. 4 2 and 17 BK/BL and YL/BL 5 M ohms
Rave solenoid (RS) AMP no. 4 20 and 23 PU/GY and BK/GY 24 ohms
.45 - .55 ohms
AMP no. 3 21 and 22 RE/GN and WH/GN
primary winding
Ignition coil MAG 6800 - 10200 ohms
Coil terminal C
— — secondary winding w/o
and coil post
high tension leads
.45 - .55 ohms
AMP no. 3 20 and 23 RE/BL and WH/BL
primary winding
Ignition coil PTO 6800 - 10200 ohms
Coil terminal C
— — secondary winding w/o
and coil post
high tension leads
High tension leads MAG — — 5700 ohms lead alone
GTX DI models PTO — White tape 4900 ohms lead alone
06-03-38 SMR2002-075 _06-03A.FM
Subsection 04 (DIAGNOSTIC PROCEDURES)
DIAGNOSTIC PROCEDURES 0
GENERAL
Here is the basic order suggested to diagnose a suspected fuel injection related problem:
– Check the chart in TROUBLESHOOTING section to have an overview of problems and suggested
solutions.
– Check if there is a MAINT signal reported by the vehicle information center. If so, use the VCK (Vehicle
Communication Kit) and look for fault codes to diagnose the trouble.
– Check all fuses.
– Check air/fuel rail pressure.
– Check spark plugs condition.
– Check RAVE valves if stuck.
– Check fuel pump pressure.
– Check air compressor pressure.
DESS SYSTEM
Basic Self-Diagnostic Mode
It is self-activated when the safety lanyard cap is being installed on the watercraft post. It gives immediate
monitoring. Some codes may occur only when pressing the start/stop button. Refer to the following chart.
SIGNAL CAUSE REMEDY
2 short beeps • Safety lanyard is recognized • Ignition is authorized, engine can be started normally.
(while installing safety by the MPEM.
lanyard on watercraft • Good contact between safety
post) lanyard cap and DESS post.
1 long beep • Bad connection between safe- • Remove and replace the safety lanyard on the post
(while installing safety ty lanyard cap and post. until 2 short beeps are heard to indicate the system
lanyard on watercraft is ready to allow engine starting.
post or when pressing
start/stop button) • Unprogrammed or defective • Use the safety lanyard that has been programmed for
safety lanyard. the watercraft. If it does not work, check safety lan-
yard condition with the programmer. Replace safety
lanyard if reported defective. If it still does not work,
enable advanced diagnostic mode to obtain more de-
tails about the failure.
• Salt water or dirt in safety • Clean safety lanyard cap to remove dirt or salt water.
lanyard cap.
• Improper operation of MPEM • Enable advanced diagnostic mode to obtain more de-
or defective wiring harness. tail about the failure.
8 short beeps • Defective MPEM • Replace MPEM.

(memory).
Other beeps • Refer to COMPONENT FAILURE WARNING SYSTEM

below.
SMR2002-076 _06-04A.FM 06-04-1
Advanced Self-Diagnostic Mode

It needs to be enabled manually. Proceed as follows:
1. Remove safety lanyard cap from watercraft post.
2. Press 5 times on the watercraft start/stop button.
NOTE: 1 short beep and 1 long beep must be heard. They validate beginning of diagnostic mode.
3. Install safety lanyard on watercraft post.
4. Press the watercraft start/stop button again.
NOTE: If everything is correct, engine will start. Otherwise, refer to the following chart.
SIGNAL CAUSE REMEDY
No beep • Engine actually starts. • Everything is correct.
1 long and • No safety lanyard has ever been pro- • Use MPEM programmer or the VCK
1 short beeps grammed in watercraft MPEM. and program a safety lanyard. This
code can occur only when you receive
a new MPEM from the factory and no
key has ever been programmed.
2 short beeps • MPEM can not read the digital code of • Check safety lanyard cap condition
the safety lanyard cap or the magnet is with the MPEM programmer or the
defective. VCK. Replace safety lanyard if report-
ed defective.
• Mixed wires at safety lanyard post • Check post wiring harness.

connectors or bad connections.
2 long beeps • Wrong safety lanyard or bad connec- • Use the safety lanyard that has been
tion of the DESS wires. programmed for the watercraft. If the
problem is not resolved, check safety
lanyard cap condition with the MPEM
programmer or the VCK. Replace safe-
ty lanyard if reported defective.
3 short beeps • Wiring harness of DESS post is ground- • Check wiring harness and safety lan-
ed or there is a short circuit. yard post.
If you need to listen again to the coded beeps, remove safety lanyard and repeat the procedure to activate
the diagnostic mode.
If there is more than one problem, the MPEM will send only one error code. When the problem is solved,
the MPEM will send a second code and so on until all problems are resolved.
06-04-2 SMR2002-076 _06-04A.FM
FAULT DETECTION AND COMPENSATORY ACTIONS

For a basic overview of the monitoring system and the limp home modes, see OVERVIEW section.
COMPONENT FAILURE WARNING SYSTEM

Sensor Failures
Refers to open or short circuit failures on sensors, drivers, injectors or ignition.
BUZZER LIMP HOME MODE
PROBLEM INFO CENTER RED LED BUZZER
CODE ➀
Manifold air
pressure sensor “MAINT” ON OFF 6 Limited RPM
(MAPS)
Manifold air
temperature sensor “MAINT” ON OFF 6 Limited RPM
(MATS)
Limited RPM
Throttle position
“MAINT” ON ON 4 (idle speed if both
sensor (single TPS)
TPS’s fail)
Limited RPM
Water temperature
“MAINT” ON OFF/(ON) 6/(4) (code 4 if EGT also
sensor (WTS)
fails)
Direct injector
“MAINT” ON OFF 6 Limited RPM
(single injector)
Fuel injector
(single injector)
Ignition
(no firing on one “MAINT” ON OFF 6 Limited RPM
cylinder)
RAVE solenoid “MAINT” ON OFF 6 Limited RPM
Starter solenoid “MAINT” ON OFF 6 Engine may not start.
Fuel pump “MAINT” ON OFF 6 Limited RPM
Exhaust gas Limited RPM
temperature sensor “MAINT” ON OFF/(ON) 6/(4) (code 4 if WTS
(EGT) also fails)
Fuel level sensor “MAINT” ON OFF 6 None
Diagnostic cap fault “MAINT” ON OFF 6 None
Knock sensor “MAINT” ON OFF 6 Limited RPM
Engine drowned
Engine will not run.
mode activated None None ON 2
Release throttle.
(it is not a fault)
SMR2002-076 _06-04A.FM 06-04-3
System Failures
Refers to operating conditions outside normal and/or safe ranges such as demand system failures, ex-
treme voltages, over temperature conditions or low fuel/oil levels.
BUZZER LIMP HOME MODE
PROBLEM INFO CENTER RED LED BUZZER
CODE ➀
Manifold air pressure
sensor (MAPS),
ATM fault (bad “MAINT” ON OFF 6 Limited RPM
atmospheric
pressure reading)
Throttle position
“MAINT” ON ON 3 Limited RPM
sensor (single TPS)
Throttle position
“MAINT” ON ON 4 Idle RPM
sensor (dual TPS)
Throttle position
sensor None OFF OFF 6 None
(single adaption fault)
Throttle position
sensor “MAINT” ON OFF 6 Limited RPM
(dual adaption fault)
Limited RPM
Sensor supply fault
“MAINT” ON ON/OFF 4/(6) (code 6 and idle RPM
(TPS and MAPS)
if both in fault)
Encoder (CPS) fault
(bad pattern)
Low battery
“12 V LOW” ON OFF 6 None
voltage
Very low battery “12 V LOW”
ON ON 4 Limited RPM
voltage “MAINT”
High battery
“MAINT” ON OFF 6 None
voltage
Very high battery
“MAINT” ON OFF 6 Idle RPM
voltage
High water
“HI-TEMP” ON ON 1 None
temperature
Exhaust
“HI-TEMP” ON ON 3 None
over temperature
Low oil level “OIL-LOW” ON ON 5 None
Low fuel level “FUEL-LO” ON ON 4 None
Setup fault
(TDC or TPS not set “MAINT” ON OFF 6 Idle RPM
on a new MPEM)
MPEM fault “MAINT” ON OFF 6 Engine will not start.
➀ To see how the normal operation is recovered from the limp home mode, see the DI FAULT CODES
chart elsewhere in this section. Look in column “Normal operation resumes if fault removed and...”.
06-04-4 SMR2002-076 _06-04A.FM
Buzzer Code
BUZZER BUZZER PATTERN NOTE

CODE
ON
6 OFF Always OFF
2 SEC. 15 MIN.
5 ON
2 second beep every 15 minutes
OFF
2 SEC. 58 SEC.
4 ON
2 second beep every 58 seconds
OFF
2 SEC. 2 SEC.
3 ON 2 second beep every 2 seconds

OFF
1 SEC. 1 SEC.
2 ON 1 second beep every second
OFF
1 ON Always ON (continuously beep)

OFF
F12H13S
VCK  WARNING
(vehicle communication kit) If the computer you are using is connected to
The VCK (Vehicle Communication Kit) (P/N 529 the 110 Vac power outlet, there is a potential
035 844) is the primary tool to diagnose fuel injec- risk of electrocution when working in contact
tion related problems. with water. Be careful not to touch water
while working with the VCK.
B.U.D.S. is designed for the DI model to allow sen-
sor inspection, diagnostic options and adjustment IMPORTANT: When using the software B.U.D.S.,
such as the Throttle Position Sensor (TPS) and the with the DI engines, ensure that the protocol “947
TDC setting. DI” is properly selected in “MPI” under “Choose
For more information pertaining to the use of the protocol”.
software B.U.D.S., use its help which contains de- Refer to the tables below for the fault codes you
tailed information on its functions. will find in the B.U.D.S.
SMR2002-076 _06-04A.FM 06-04-5
DI SYSTEM FAULT CODES – Electrical noise might also lead engine to occa-
sional cutout without generating a fault code
General when engine is restarted. When looking at the
fault code, pay attention to the “count” value in
The faults registered in the MPEM are kept when the software B.U.D.S. A value between 1 and 9
the battery is disconnected. confirms an electrical noise problem. A value of
Be aware that a red light blinking with the MAINT 10 and above will generate a fault code.
message may not be for a fault code. It may be a – When installing a new MPEM. It is not properly
maintenance inspection reminder. Press and hold programmed from the factory. The MPEM must
the SET button of the information center for 2 sec- be returned to be properly “activated”.
onds. If the blinking continues, it is a fault code.
Use the VCK (Vehicle Communication Kit) to see – If everything is in good condition, replace the
it. Otherwise, it was a maintenance reminder. MPEM.
IMPORTANT: After a problem has been solved, When using the service action suggested in the Fault
ensure to clear the fault(s) in the MPEM using the section of B.U.D.S., the system circuits are referred
VCK. This will properly reset the appropriate as 4-23 for instance. It means AMP connector no. 4
counter(s). This will also records that the problem and the circuit wire no. 23 as found in the wiring dia-
has been fixed in the MPEM memory. gram.
Many fault codes at the same time is likely to be TPS (Throttle Position Sensor) Faults
burnt fuse(s). Faults which are reported in B.U.D.S. fall into two
For more information pertaining to the code faults groups TPS faults and adaption faults. These are
(state, count, first etc.) and report, refer to B.U.D.S. displayed on the B.U.D.S. system as TPS OUT OF
online help. RANGE and TPS ADAPTION FAILURE.
Supplemental Information for Some

Specific Faults
ECU fault code P0606: This code may occur in
the following situations:
– Electrical noise is picked up by the MPEM. Ensure
that all connections are in good condition, also
grounds (battery, MPEM, engine and ignition sys-
tem), they are clean and well tightened and that all
electronic components are genuine — particularly
in the ignition system. Installing resistive caps,
non-resistive spark plug cables (or modified
length), non-resistive spark plugs or knock sensor
wiring/routing may lead to generate this fault code.
06-04-6 SMR2002-076 _06-04A.FM
TPS “OUT OF RANGE” Fault

It is caused by the sensor reading going out of its allowable range. This fault can occur during the whole
range of movement of the throttle.
To diagnose this fully, it is recommended to operate the throttle through its full range. It is also recom-
mended to release the throttle quickly as this may also show up a fault that is intermittent.
POSSIBLE CAUSES RESULT ACTION

Check if wrong connector is connected to TPS. Yes • Fix.
Check if sensor is loose. Yes • Fix and reset closed TPS.
Inspect sensor for damage or corrosion. Yes • Replace and reset closed TPS.
Inspect wiring (voltage test). Failed • Repair.

• If bad wiring, repair.
Inspect wiring and sensor (resistance test). Failed
• If bad TPS, replace and reset closed TPS.
Test sensor operation (wear test). Failed • Replace and reset closed TPS.
TPS “ADAPTATION FAILURE” Fault

It is caused by the idle position moving out of an acceptable range.

Sensor has been replaced and TPS closed
Yes • Reset closed TPS.
position not reset.
Throttle body has been replaced and TPS

closed position not reset.
MPEM has been replaced and TPS closed

position not reset.
Throttle cable too tight. Yes • Fix and reset closed TPS.
Sensor is loose. Yes • Fix and reset closed TPS.
Throttle bracket is loose. Yes • Fix and reset closed TPS.

Idle screw or synchronization screw worn
Yes • Fix and reset closed TPS.
or loose.
SMR2002-076 _06-04A.FM 06-04-7
DI System Fault Code Chart
NORMAL OPERATION
RESUMES IF FAULT
FAULT DETECTED
FAULT DETECTED
SENSOR/CIRCUIT
REMOVED AND...
WHILE ENGINE
WHILE ENGINE
ECU INTERNAL
NOT RUNNING
COMPONENT/
FAULT CODE
DIAGNOSED
DETECTED
RUNNING
SERVICE ACTION
NAME
FAULT
AND
POSSIBLE CAUSES
Service action:
Check for 1 - 1.6 ohm resistance between system circuits 4-15
Direct Open or and 4-5. Check for + 12 volts on pin A of injector connector (color).
P1100 injector AIR_INJ_1 short Yes No Return to
MAG circuit idle Possible causes:
Damaged injector, damaged circuit wires, damaged connector,
damaged ECU output pins. ECU failure.
Service action:
Check for 1 - 1.6 ohm resistance between system circuits 4-21
Direct Open or Return to and 4-6. Check for + 12 volts on pin A of injector connector (color).
P1101 injector PTO AIR_INJ_2 short Yes No idle
circuit Possible causes:
Service action:
Check for 1.7 - 1.9 ohm resistance between system circuits 4-13
Open or and 4-7. Check for + 12 volts on pin A of injector connector (color).
P0201 Fuel injector FUEL_INJ_1 short Yes No Return to
MAG circuit idle Possible causes:
Service action:
Check for 1.7 - 1.9 ohm resistance between 4-14 and 4-8. Check
Open or for + 12 volts on pin A of injector connector (color).
P0202 Fuel injector FUEL_INJ_2 short Yes No Return to
PTO circuit idle Possible causes:
Open or Service action:
Ignition coil, short Check for .45 - .55 ohm resistance between system circuits 3-21
primary circuit on Return to and 3-22. Check for + 12 volts on pin A of coil connector (color).
P0351 winding IGN_CYL_1 ignition Yes No idle Possible causes:
MAG primary Damaged coil, damaged circuit wires, damaged connector, dam-
circuit aged ECU output pins. ECU failure.
Open or Service action:
short Check for .45 - .55 ohm resistance between system circuits 3-20
Ignition coil, and 3-23. Check for + 12 volts on pin A of coil connector (color).
P0352 primary IGN_CYL_2 circuit on Yes No Return to
winding PTO ignition idle Possible causes:
primary Damaged coil, damaged circuit wires, damaged connector, dam-
circuit aged ECU output pins. ECU failure.
Service action:
Check for 12 volts on pin 5 and 5 volts on 6 and 0 volts on pin 4 of
Wrong encoder harness connector. Check system circuits 2-6, 2-7, 2-14.
P0335 Encoder Encoder pattern Yes No Return to
(CPS) idle Possible causes:
sensed Damaged sensor, damaged circuit wires, damaged connector,
damaged ECU pins. ECU failure. Damaged tooth wheel. Check
correct rectifier regulator operation.
06-04-8 SMR2002-076 _06-04A.FM
NORMAL OPERATION
RESUMES IF FAULT
FAULT DETECTED
FAULT DETECTED
SENSOR/CIRCUIT
REMOVED AND...
WHILE ENGINE
WHILE ENGINE
ECU INTERNAL
NOT RUNNING
COMPONENT/
FAULT CODE
DIAGNOSED
DETECTED
RUNNING
SERVICE ACTION
NAME
FAULT
AND
POSSIBLE CAUSES
Service action:
Check for 5 volts on pin 1 and 0-0.5 volts on pin 3 and 0 volts on
pin 2. Check system circuits 4-1, 4-2, 4-18. Check with throttle
closed the resistance between 1 and 2 is 2000 ohms and between
2 and 3 is 1000 ohms and between 1 and 3 2500 ohms. Check for
Sensor out Return to linear resistance rise when opening throttles. Check physical stops
P0120 TPS, PTO TPI_1 of range Yes No idle for wear.
Possible causes:
Damaged Sensor, damaged circuit wires, damaged connector,
damaged ECU pins, ECU failure, damaged or out of alignment
throttle bodies or sensor.
Service action:
Check for 5 volts on pin 1 and 4.75-5.0 volts on 3 and 0volts on pin
2. Check system circuits 3-5, 3-10, 3-14. Check with throttle closed
the resistance between 1 and 2 is 2500 ohms and between 2 and
3 is 2500 ohms and between 1 and 3 1200 ohms. Check for linear
P0220 TPS, MAG TPI_2 Sensor out Yes No Return to resistance rise when opening throttles. Check physical stops for
of range idle wear.
Possible causes:
Damaged Sensor, damaged circuit wires, damaged connector,
damaged ECU pins, ECU failure, damaged or out of alignment
throttle bodies or sensor.
Service action:
Throttle Check cable adjustment. Check Idle stop for wear check throttle
Full reset. angles at idle.
P1102 TPS, PTO TPI_1_ADAP position Yes No Key off
adaption and on Possible causes:
failure No initialisation after throttle body or ECU changes throttle idle
stop drifted.
Service action:
Throttle Check cable adjustment. Check Idle stop for wear. Check throttle
position Full reset. angles at idle.
P1103 TPS, MAG TPI_2_ADAP adaption Yes No Key off
and on Possible causes:
failure No initialisation after throttle body or ECU changes throttle idle.
Stop drifted.
Service action:
Check for resistance approx. 2280 ohms to 2736 ohms at temper-
ature of 19 to 21°C (66 to 70°F) between system circuits 4-9 and
Sensor out Return to 4-11.
P0116 WTS COOL_SENS of range Yes No idle
Possible causes:
Damaged sensor, damaged circuit wires, damaged connector,
damaged ECU pins. ECU failure.
Service action:
Check for debris or blockage in cooling system. Check for resis-
Overheat As soon as tance approx. 2280 ohms to 2736 ohms at temperature of 19 to
P0217 WTS COOL_RED warning Yes No fault is not 21°C (66 to 70°F) between system circuits 4-9 and 4-11.
present
Possible causes:
Engine overheated, damaged sensor.
Service action:
P0110 MATS MCT_SENS of range Yes No idle
Possible causes:
SMR2002-076 _06-04A.FM 06-04-9
NORMAL OPERATION
RESUMES IF FAULT
FAULT DETECTED
FAULT DETECTED
SENSOR/CIRCUIT
REMOVED AND...
WHILE ENGINE
WHILE ENGINE
ECU INTERNAL
NOT RUNNING
COMPONENT/
FAULT CODE
DIAGNOSED
DETECTED
RUNNING
NAME SERVICE ACTION
FAULT
AND
POSSIBLE CAUSES
Service action:
Check system circuits 3-3, 3-6, 3-7. Check sensor connector for 5
volts on pin 1 and 0 volts on pin 3 and 0 volts on pin 2. Check
Sensor out Return to Sensor housing is correctly inserted into manifold.
P0106 MAPS MAP Yes No
of range idle Possible causes:
Check sensing port for dirt or blockage. Sensor failure, unexpect-
ed reading at idle. Sensor fallen out of housing. Leaking Inlet
system, ECU failure.
Service action:
Check system circuits 3-3, 3-6, 3-7. Check sensor connector for 5
Bad Full reset. volts on pin 1 and 0 volts on pin 3 and 0 volts on pin 2.
P0105 MAPS MAP_ATM atmospheric Yes No Key off Possible causes:
reading and on Check sensing port for dirt or blockage, damaged sensor, dam-
aged circuit wires, damaged connector, damaged ECU pins. ECU
failure.
Service action:
P1400 EGT EXH_SENS of range Yes No idle
Possible causes:
Service action:
Check for debris or blockage in cooling system. Check tune pipe
Overheat As soon as injection valve.
P1401 EGT EXH_RED warning Yes No fault is not
present Possible causes:
Exhaust system overheated, damaged sensor damaged circuit
wires.
Service action:
As soon as TBD.
Fuel level Sensor out
P0460 sensor FUEL_SENS of range Yes No fault is not Possible causes:
present Damaged sensor, damaged circuit wires, damaged connector,
Service action:
Check for resistance of 6-8 ohms between system circuits 4-24
Open or Yes, Yes, Return to and 4-26.
P0230 Fuel pump FUEL_PUMP short short open idle
circuit circuit circuit Possible causes:
Damaged pump, damaged circuit wires, damaged connector,
Service action:
Yes, Check for resistance of 30 ohms between system circuits 4-23
Open or open Yes, and 4-20.
P0475 RAVE RAVE short and open Return to
solenoid circuit short circuit idle Possible causes:
circuit Damaged solenoid, damaged circuit wires, damaged connector,
Service action:
Starting Yes, Check for resistance of 6ohms between system circuits 3-19 and
system Open or open Yes, As soon as 3-15.
P1300 solenoid CRANK short and open fault is not
circuit short circuit present Possible causes:
(winding) Damaged solenoid, damaged circuit wires, damaged connector,
circuit
Battery Battery As soon as Possible causes:
P0563 voltage BV_HI_WARN voltage Yes Yes fault is not Battery failure, rectifier failure, battery terminal connection.
high present
06-04-10 SMR2002-076 _06-04A.FM
NORMAL OPERATION
RESUMES IF FAULT
FAULT DETECTED
FAULT DETECTED
SENSOR/CIRCUIT
REMOVED AND...
WHILE ENGINE
WHILE ENGINE
ECU INTERNAL
NOT RUNNING
COMPONENT/
FAULT CODE
DIAGNOSED
DETECTED
RUNNING
SERVICE ACTION
NAME
FAULT
AND
POSSIBLE CAUSES
Battery Battery Full reset. Possible causes:

P1500 voltage BV_HI_RED voltage Yes Yes Key off and Battery failure, rectifier failure, battery terminal connection.
very high on
Service action:
Check fuse.
Battery As soon as Check system circuits 3-25 to battery + terminal, 2-26 to regulator
P0562 Battery BV_LO_WARN voltage Yes Yes fault is not 2 pin connector pin A, 2-25 to regulator 2 pin connector pin B.
voltage low present Possible causes:
Battery failure, rectifier failure, damaged circuit wires, battery
terminal connection, damaged magneto, damaged connectors.
Service action:
Check fuse, check system circuits 3-25 to battery + terminal, 2-26
Battery to regulator 2 pin connector pin A, 2-25 to regulator 2 pin connec-
Battery Return to tor pin B.
P1501 voltage BV_LO_RED voltage Yes Yes idle
very low Possible causes:
Battery failure, rectifier failure, damaged circuit wires, battery
terminal connection, damaged magneto, damaged connectors.
Service action:
Sensor Sensor Check for shorts to ground or corrosion on the following system
supply (TPS, 5 volt Return to circuits 3-10 or 3-3.
P0122 MAG and XDRP_1 supply Yes Yes idle Possible causes:
MAPS) failure Damaged circuit wires, associated sensor failure (TPI 2 or MAP),
ECU fault.
Service action:
Sensor Check for shorts to ground or corrosion on system circuit 4-18.
Sensor 5 volt Return to
P0222 supply (TPS, XDRP_2 supply Yes Yes idle Possible causes:
PTO) failure Damaged circuit wires, associated sensor failure (TPI 1), ECU
fault.
Service action:
TDC and Reinitialise Initialize ECU.
P1600 ECU SETUP ECU not Yes Yes from
initialised B.U.D.S. Possible causes:
ECU not initialised, TDC not setup, throttle sensors not initalised.
Service action:
Internal Full reset. Check ignition leads, coils and correct spark plugs, replace ECU.
P0606 ECU ECU_FAULT ECU faults Yes Yes Key off Possible causes:
and on Incorrect software, ignition noise causing errors, internal EE-
PROM failure.
Service action:
Bring engine to 4500 RPM. If fault code appears, check for resis-
Knock Knock Yes, Return to tance approx. 4.8 ohms between system circuits 4-2 and 4-17.
P0325 sensor KNOCK_SENS sensor over No idle
failure 4500 Possible causes:
Diagnostic Service action:
Diagnostic cap is not As soon as Reinstall cap on wiring harness.
P1601 cap COMMS_CAP installed Yes Yes fault is not
on wiring present Possible causes:
harness Cap is not installed on wiring harness.
SMR2002-076 _06-04A.FM 06-04-11
Section 07 ENGINE MANAGEMENT (4-TEC)
TABLE OF CONTENTS 0
OVERVIEW............................................................................................................................. 07-02-1
COMPLETE ELECTRICAL SYSTEM OVERVIEW .............................................................. 07-02-2
MAGNETO SYSTEM AND POWER SUPPLY ................................................................... 07-02-3
OPERATING PRINCIPLE OF ENGINE MANAGEMENT ................................................... 07-02-3
AIR INDUCTION................................................................................................................. 07-02-4
FUEL DELIVERY SYSTEM................................................................................................. 07-02-4
BASIC OPERATION ........................................................................................................... 07-02-4
INTAKE MANIFOLD........................................................................................................... 07-02-4
FUEL PUMP MODULE....................................................................................................... 07-02-5
EMS (engine management system) ................................................................................ 07-02-5
EMS — GENERAL FUNCTIONS ....................................................................................... 07-02-6
EMS — ENGINE MANAGEMENT FUNCTIONS............................................................... 07-02-8
MPEM - MULTI-PURPOSE ELECTRONIC MODULE ........................................................ 07-02-11
COMPONENT INSPECTION AND ADJUSTMENT .............................................................. 07-03-1

GENERAL ........................................................................................................................... 07-03-1
FUEL SYSTEM ................................................................................................................... 07-03-1
ELECTRICAL SYSTEM....................................................................................................... 07-03-2
ENGINE CONNECTOR PIN-OUT ...................................................................................... 07-03-3
CONNECTORS ON ENGINE ............................................................................................. 07-03-4
AIR INDUCTION SYSTEM................................................................................................. 07-03-5
THROTTLE BODY .............................................................................................................. 07-03-5
FUEL DELIVERY................................................................................................................. 07-03-8
FUEL PUMP ....................................................................................................................... 07-03-9
FUEL RAIL .......................................................................................................................... 07-03-11
FUEL INJECTOR ................................................................................................................ 07-03-11
EMS ECU AND MPEM REPLACEMENT ........................................................................... 07-03-13
ENGINE WIRING HARNESS ............................................................................................. 07-03-14
THROTTLE POSITION SENSOR (TPS) ............................................................................. 07-03-16
IDLE BYPASS VALVE ........................................................................................................ 07-03-18
CRANKSHAFT POSITION SENSOR (CPS) ....................................................................... 07-03-19
CAMSHAFT POSITION SENSOR (CAPS) ......................................................................... 07-03-20
MANIFOLD AIR TEMPERATURE SENSOR (MATS)......................................................... 07-03-21
COOLANT TEMPERATURE SENSOR (CTS)..................................................................... 07-03-22
MANIFOLD AIR PRESSURE SENSOR (MAPS) ................................................................ 07-03-23
EXHAUST GAS TEMPERATURE SENSOR (EGT) ............................................................ 07-03-23
KNOCK SENSOR (KS) ....................................................................................................... 07-03-24
OIL PRESSURE SWITCH (OPS) ........................................................................................ 07-03-25
OIL SEPARATOR PRESSURE SWITCH (OSPS) ............................................................... 07-03-25
TOPS VALVE (BLOW-BY) .................................................................................................. 07-03-27
SMR2002-095_07-01ATOC.FM 07-01-1
IGNITION COILS................................................................................................................. 07-03-29

TDC SETTING (TOP DEAD CENTER)................................................................................. 07-03-30
ENGINE START/STOP SWITCH VERIFICATION ............................................................... 07-03-30
SAFETY LANYARD SWITCH VERIFICATION.................................................................... 07-03-30
SPARK PLUGS.................................................................................................................... 07-03-31
CRANKING SYSTEM.......................................................................................................... 07-03-31
DIAGNOSTIC PROCEDURES................................................................................................. 07-04-1

GENERAL............................................................................................................................ 07-04-1
SELF-DIAGNOSTIC MODE ................................................................................................ 07-04-3
VCK (vehicle communication kit) ..................................................................................... 07-04-4
4-TEC SYSTEM FAULT CODES......................................................................................... 07-04-4
07-01-2 SMR2002-095_07-01ATOC.FM
OVERVIEW 0
ENGINE MANAGEMENT SYSTEM OVERVIEW
ROTAX 4-TEC 1503
Cyl. 1 Cyl. 2 Cyl. 3
Con. B
MAGNETO Con. A
KS MAPS
CPS MATS
OPS TPS
CTS
CAPS EMS IDLE BYPASS VALVE
INJECTOR 1, 2, 3 ECU TOPS SWITCH

TOPS VALVE
OSPS
IGNITION COIL 1, 2, 3
EGT
MUFFLER
BATTERY ENGINE POWER SUPPLY
REGULATOR/
MPEM
RECTIFIER EMS ECU Engine Management System
Electronic Control Unit
MPEM Multi-Purpose Electronic Module
KS Knock Sensor
CPS Cranshaft Position Sensor
OSPS Oil Separator Pressure Sensor
CTS Coolant Temperature Sensor
CAPS Camshaft Position Sensor
EGT Exhaust Gas Temperature
MAPS Manifold Air Pressure Sensor
MATS Manifold Air Temperature Sensor
TOPS Tip-Over Protection System
Con. A Connector for Engine Wiring Harness
R1503motr212S Con. B Connector for MPEM Connection
SMR2002-077_07-02A.FM 07-02-1
COMPLETE ELECTRICAL SYSTEM OVERVIEW
- COMPASS
WH/RE INFORMATION - OUTSIDE AIR
WH/BK CENTER TEMPERATURE
SENSOR
COMMUNICATION LINK
COMMUNICATION
LINK
- TPS - POWER TO
WH/BK
- MAPS EMS ECU MPEM EMS ECU
WH/RE
- MATS - INFORMATION
- CTS CENTER
- EGT - SET AND MODE
- KS SWITCHES
- OPS - SPEED SENSOR
- OSPS - FUEL LEVEL
- CPS SENDER
- DESS - BEEPER
- IDLE
BYPASS
VALVE COMMUNICATION LINK
- START/STOP WH/BK VCK

SWITCH WH/RE (COMMUNICATION
- STARTING PORT)
SOLENOID
- FUEL PUMP
- FUEL INJECTORS
- IGNITION COILS
- TOPS VALVE
- TOPS SWITCH
- CAPS
EMS
COLOUR CODE
These components are shared between the MPEM and the WH = WHITE
EMS ECU. The MPEM supplies the power while the EMS ECU BK = BLACK
F18L2WS controls and completes the circuit by switching it to the ground. RE = RED
07-02-2 SMR2002-077_07-02A.FM
The complete electrical system is managed by OPERATING PRINCIPLE OF

micro-controllers working together. Overall, the
MPEM (multi-purpose electronic module) manag-
ENGINE MANAGEMENT
es the vehicle electrical system, the EMS (engine A highly advanced engine management system
management system) controls the engine man- (EMS) has been used to ensure a high power out-
agement and the information center is used to dis- put with cleanest combustion. The EMS calcu-
play information that comes both from MPEM and lates the proper air/fuel mixture and ignition timing
EMS. for each cylinder separately. The fuel is injected
A communication link is used between the elec- into the intake port of each cylinder.
tronic modules to communicate each other. It con- NOTE: On the 1503, PTO and magneto (MAG) are
sists of a twisted pair of wires (WHITE/RED and on the same engine side (rear). Each cylinder is
WHITE/BLACK). referenced as 1, 2 and 3 instead of PTO, CENTRE
For communication link troubleshooting, refer to and MAG. The numbers are stamped on the valve
INSTRUMENTS AND ACCESSORIES in ELECTRI- cover.
CAL section.
1 2 3
The communication link is also used to communi-
cate informative messages, monitoring and diag-
nostic codes to the information center and to the
VCK (vehicle communication kit) where B.U.D.S.
(Bombardier utility and diagnostic system) is used
for diagnosing and troubleshooting the system.
The fault code can be seen from either the infor-
mation center or B.U.D.S. Refer to DIAGNOSTIC
PROCEDURES section.
MAGNETO SYSTEM AND

POWER SUPPLY
The magneto is the primary source of electrical
R1503motr218A
energy. It transforms magnetic field into electric
current (AC). 1. Cylinder 1
2. Cylinder 2
The magneto has a 3 phases, delta wound stator 3. Cylinder 3
NOTE: “EMS” stands for engine management
It supplies DC current to battery after being trans- system. “EMS” includes an ECU (electronic control
formed by the voltage regulator/rectifier. Refer to unit), sensors, injectors, electromagnetic valves
CHARGING SYSTEM. and ignition system.
The battery then supplies all the electrical system
with regulated 12 Vdc.
SMR2002-077_07-02A.FM 07-02-3
AIR INDUCTION INTAKE MANIFOLD

Air for combustion is drawn directly at the front of
3 2
the engine through one 52 mm throttle body. The 5
air flow is controlled by a throttle plate and an idle
bypass valve respectively. The air continues
1
through the intake manifold, which contains the
flame arrester and goes into the cylinder head.
2
R1503motr214B
6 7 4
INTAKE MANIFOLD
1. Electronic Control Unit (EMS ECU)
2. Fuel rail
3. Injector
4. Throttle body
5. Ignition coil
R1503motr216A 1 6. Manifold air pressure sensor (MAPS)
52 mm THROTTLE BODY
1. Idle bypass valve The intake manifold is mounted on the engine block
2. Throttle position sensor (TPS) on the vehicle starboard side. It provides support
for the fuel injectors, the fuel rail, the EMS ECU, the
FUEL DELIVERY SYSTEM flame arrester and the throttle body. The air intake
manifold is a resonator between the throttle body
BASIC OPERATION and the air intake at the cylinder head with the
When the intake valve reaches the correct posi- flame arrester.
tion, the EMS ECU (Electronic Control Unit) opens
the fuel injector and fuel is discharged into the in- Fuel Rail
take port at the air intake manifold by the high fuel The fuel rail is a small tube on which the three
pressure inside the fuel rail. The air/fuel mixture injectors are mounted. It ensures all the time, that
enters then the combustion chamber through the enough fuel at the right pressure can be delivered
open intake valve. This mixture is then ignited by to the fuel injectors. The fuel rail is fed by the fuel
the spark plug. pump with a fuel pressure of approximately
303 kPa (44 PSI).
Fuel Injector
Three fuel injectors (one per cylinder) are used to
inject fuel into the intake port of the cylinder head.
Flame Arrester
The flame arrester is a tube inside the air intake
manifold. It prevents flames leaving through the
intake system if the engine backfires.
07-02-4 SMR2002-077_07-02A.FM
Throttle Body ELECTRONIC MANAGEMENT

It is a 52 mm throttle body mounted on intake
manifold. Fitted on the throttle body, there is the EMS
TPS and the idle bypass valve which allows the (engine management system)
EMS ECU to control the RPM while the throttle The engine management system is controlled by
plate is closed. the EMS ECU.
FUEL PUMP MODULE 1
R1503motr215A
1. EMS ECU
EMS ECU
The EMS ECU is mounted on the intake manifold.
It controls all engine management functions, by
R1503motr217A processing the information given by various sen-
sors.
The fuel pump module is located inside the fuel
tank. The module includes fuel pump, fuel pres-
sure regulator and fuel level sensor.
1
Fuel Pump
It provides fuel pressure and flow rate to the system.
Fuel Pressure Regulator

A fuel pressure regulator controls the pressure in
the system and allows the excess of fuel to return
to the fuel tank. The fuel pressure regulator regu-
lates the fuel pressure at approximately 303 kPa
(44 PSI).
R1503motr214A
Fuel Filter
1. EMS ECU on intake manifold
A mesh filter is located at the bottom of the fuel
pump module inside the fuel tank.
SMR2002-077_07-02A.FM 07-02-5
EMS — GENERAL FUNCTIONS

Safety Lanyard Reminder
If engine is not started within 5 seconds after in-
stalling the safety lanyard on its post, 2 very short
beeps every 3 second interval will sound for ap-
proximately 4 hours to remind you to start the en-
gine or to remove safety lanyard. Afterwards, the
beeps will stop. The same will occur when safety
lanyard is left on its post 5 seconds after engine is
stopped.
CAUTION: Leaving the safety lanyard on its
post when engine is not running will slowly dis-
charge battery.
Antistart Feature
This system allows starting the vehicle only with
R1503motr219A safety lanyard(s) that has been programmed to op-
erate a specific watercraft. This functionality is the
The EMS ECU gets its power by the MPEM which DESS system. See below for details.
is directly powered by the battery. It is responsible
for the following engine management/electrical Digitally Encoded Security System
functions:
(DESS)
– interpreting information
The following components are specially designed
– distributing information for this system: Multi-Purpose Electronic Module
– start/stop function (MPEM), EMS ECU, safety lanyard cap and safety
lanyard post.
– timer
The safety lanyard cap contains a magnet and a
– DESS (Digitally Encoded Security System)
ROM chip. The magnet actually closes the reed
– ignition timing control switch inside the post which is the equivalent of a
– injection control mechanical ON/OFF switch. The chip has a unique
digital code.
– The EMS ECU applies the proper map (injection
and ignition) for optimum engine operation in all The DESS circuitry in the EMS ECU is activated at
conditions. the factory. Therefore, a safety lanyard must be
programmed to start the engine.
– engine RPM limiter
NOTE: Actually, it is the memory of the EMS ECU
– etc.
which is programmed to recognize the digital code
The EMS ECU features a permanent memory that of the safety lanyard cap. This is achieved with the
will keep the programmed safety lanyard(s) active, VCK (Vehicle Communication Kit) P/N 529 035
fault codes and other engine information, even 844. Refer to B.U.D.S. help system to program a
when the battery is removed from the watercraft. safety lanyard.
The system is quite flexible. Up to 8 safety lan-
yards may be programmed in the memory of the
watercraft MPEM. They can also be erased indi-
vidually.
07-02-6 SMR2002-077_07-02A.FM
The EMS ECU also offers a special safety lanyard Engine RPM Limiter
— the Sea-Doo LK™ (learning key) — which can
The EMS ECU will limit the maximum engine
be programmed so that the vehicle can be run only
speed.
at a limited speed — approximately 55 km/h
(35 MPH). Such feature is ideal for first time riders
or renters.
Engine Stopping
There are 2 ways to stop the engine.
 WARNING Press and hold start/stop switch or remove the
When programming a Sea-Doo LK™ (learning safety lanyard cap from its post.
key), use only a lanyard that is identified for If the engine is stopped by removing the safety lan-
that purpose. Otherwise, a customer could yard, it is possible to restart the engine as explained
use a vehicle with a greater speed than he was in the engine starting section.
expecting.
If safety lanyard cap is reconnected within 6 sec-
NOTE: If desired, a safety lanyard can be used on onds, the current supply to gauges is cut for a brief
other watercraft equipped with the DESS. It only moment and comes back on with the audible sig-
needs to be programmed for that watercraft. nal of safety lanyard validation.
When connecting a safety lanyard cap on the post, Low-Oil Pressure Warning Device
the DESS is activated and will emit audible signals:
When the oil pressure falls under a certain level,
– 2 short beeps indicate a working safety lanyard. the EMS ECU sends out a signals for the beeper
Engine starting can take place. and to the information center gauge. Additionally
– 1 long beep indicates a wrong safety lanyard is the engine goes in limp home mode.
being used or that something is defective. En-
gine starting is not allowed. High Coolant Temperature and EGT
The memory of the EMS ECU features a self- Warning Device
diagnostic mode for the DESS operation. Refer to When the coolant temperature or the exhaust gas
DIAGNOSTIC PROCEDURES section for more in- temperature is getting to high, the EMS ECU
formation. sends out signals to the beeper.
The memory of the EMS ECU is permanent. If the
battery is disconnected, no information is lost.
When ordering a new EMS ECU from the regular
parts channel, the DESS circuitry will be activated.
Engine Starting
If the EMS ECU recognizes a valid safety lanyard,
it allows engine to start when the start/stop switch
is pressed.
If start/stop button is held after engine has started,
the EMS ECU automatically stops the starter
when the engine speed reaches 1600 RPM.
If start button is activated while the throttle lever
is depressed more than 65%, the engine will not
be allowed to start.
SMR2002-077_07-02A.FM 07-02-7
EMS — ENGINE MANAGEMENT FUNCTIONS
R1503motr220S
07-02-8 SMR2002-077_07-02A.FM
This engine management system controls both All three ignition coils are located on the cylinder
the fuel injection and the ignition timing. head directly on the spark plugs.
As shown in the 1503 4-TEC CONTROL SYSTEM
1
illustration, the EMS ECU is the central point of the
fuel injection system. It reads the inputs, makes
computations, uses pre-determined parameters
and sends the proper signals to the outputs for
proper engine management.
The EMS ECU also stores the fault codes and gen-
eral information such as: operating conditions, ve-
hicle hours, serial numbers, customer and mainte-
nance information.
Electronic Fuel Injection

The EMS ECU reads the signals from different sen-
sors which indicate engine operating conditions at R1503motr213A
milli-second intervals.
1. Ignition coils
Signals from sensors are used by the EMS ECU to
determine the injection parameters (fuel maps) re- Ignition Timing
quired for optimum air-fuel ratio. The EMS ECU is programmed with data (it con-
The CPS, the MATS, the MAPS and the TPS are tains ignition mappings) for optimum ignition tim-
the primary sensors used to control the injection ing under all operating conditions. Using engine
and ignition timing. Other sensors (like tempera- operating conditions provided by the sensors, the
ture sensors, etc.) are used for secondary input. EMS ECU controls the ignition timing for optimum
NOTE: The EGT, OPS and OSPS sensors does not engine operation.There is no mechanical adjust-
provide control inputs to the EMS ECU. Their sole ment to perform.
purpose is to protect the engine components by
emitting a warning signal and/or a fault code in the Knock Sensor
event of overheating or low oil pressure or TOPS A knock sensor is mounted on the engine block
valve fault. behind the air intake manifold. It detects specific
vibration that would be typically generated by en-
Ignition System gine detonation. If detonation occurs, the knock
The ignition system is a digital inductive type. The sensor detects it and the EMS ECU retards the
EMS ECU control the ignition system parameters, ignition advance temporarily (it goes in a specific
such as spark timing, duration and firing in order mode) until detonation stops. The EMS ECU is
to achieve the proper engine requirements. able to evaluate the knocking cylinder and modi-
fies the ignition advance just on the detonating
Ignition Coils one.
Three separate ignition coils induce voltage to a Engine Modes of Operation
high level in the secondary windings to produce a
spark at the spark plug. The EMS ECU controls different operation modes
of the engine to allow proper operation for all pos-
The ignition coils receive input from the EMS ECU. sible conditions: Cranking, start-up, idle, warm up,
Each coil provides high voltage to its correspond- part load, full load, Sea-Doo LK™ (learning key, lim-
ing spark plug. ited vehicle speed), engine speed limiter, drowned
This ignition system allows spark plugs to spark engine and limp home (see below).
independently.
NOTE: Ignition coil cables are not interchangeable
due to different lengths.
SMR2002-077_07-02A.FM 07-02-9
Flooded Engine (drowned mode) The following components failure will trigger a
limp home mode: CTS, EGT, OPS, OSPS and
If engine is fuel-flooded and does not start, this
TOPS.
special mode can be activated to prevent fuel in-
jection and ignition while cranking. Proceed as fol- When minor fault occurs, the fault and message/
lows to activate it. beeper will disappear automatically, if the condi-
tion does not exist anymore.
With safety lanyard on its post while engine is
stopped, press and HOLD throttle lever. Releasing throttle and letting the engine returning
at idle speed may allow normal operation to come
Press the start/stop button. The mode is now on.
back. If it does not work, try removing and rein-
Releasing throttle lever will bring back to its nor- stalling the safety lanyard on its post.
mal mode.
Depending on the malfunction, the watercraft
If engine does not start, it may be necessary to speed may be reduced and not allowed to reach
remove spark plugs and crank engine with rags its usual top speed. The engine speed will be lim-
over spark plug holes. Refer to COMPONENT IN- ited to 2500 or 5000 RPM.
SPECTION AND ADJUSTMENT subsection.
These performance-reduced modes allow the rid-
 WARNING er to go back home which would not be possible
without this advanced system. Refer to the DIAG-
When disconnecting coil from spark plug, al- NOSTIC PROCEDURES for a complete chart.
ways disconnect coil from main harness first.
If a fault occurs and involves a limp home mode
operation, the engine management system will re-
open coil and/or spark plug in the engine
duce engine RPM gradually to the proper level.
compartment as spark may cause fuel vapor
to ignite.
Diagnostic Mode
If engine is water-flooded, refer to WATER The malfunctions are recorded in the memory of
FLOODED ENGINE in MAINTENANCE section. the EMS ECU. The memory of the EMS ECU can
be checked using the VCK (Vehicle Communica-
Limp Home Modes tion Kit) (P/N 529 035 844) to see the fault codes.
Besides the signals as seen above, the EMS ECU The EMS ECU and the VCK are able to communi-
may automatically set default parameters to the cate through a connector on the vehicle. Refer to
engine management to ensure the adequate op- the D IA GN OSTIC PR OCE DUR ES section.
eration of the watercraft if a component of the fuel B.U.D.S. Version 1.1 and up must be used for this
injection system is not operating properly. system.
07-02-10 SMR2002-077_07-02A.FM
MPEM - MULTI-PURPOSE ELECTRONIC MODULE

Power Distribution
The MPEM distributes power from battery to all accessories and the EMS ECU. Accessories are protected
by fuses integrated in the MPEM. Fuse ratings is identified besides their holder.
T.O.P.S.
Bilge pump (optional)
Spare Beeper diagnostic,
10A 3A connector
Cylinder 3 2A 5A
ignition coil and injection 10A 10A Spare fuse
1A 2A Electric starter,
10A 7.5A fuel pump
Information center 10A 5A
MPEM
Cylinder 2
ignition coil and injection VTS (optional)
Cylinder 1 EMS
ignition coil and injection start/stop circuit
F18H07S
IMPORTANT: Some components are continu- Monitoring System

ously powered with the supply from the battery
The EMS ECU monitors the electronic compo-
through MPEM. The EMS ECU switches the
nents of the fuel injection system and also the en-
ground to complete the electrical circuits it con-
gine components of the electrical system.The
trols. Take this into account when troubleshooting
MPEM monitors the vehicle electrical system and
the electrical system. Refer to the illustration at
the accessories. When a fault occurs, it sends vi-
the beginning of this section.
sual messages through the information center
and/or audible signals through a beeper to inform
Gauges Current Supply you of a particular condition. Refer to the DIAG-
The purpose of this function is to allow reading of NOSTIC PROCEDURES section for the displayed
gauges without the engine running. It will give ac- messages and the beeper coded signals chart.
cess to functions of the information center gauge
without starting the engine. Addition of Accessories
Gauges are supplied with current whenever the Every time an accessory is added such as an elec-
safety lanyard cap is installed on its post. tric bilge pump or a VTS for instance, it must be
NOTE: The fuel pump will be activated for 2 sec- “registered” using B.U.D.S. to activate it in the
onds to build up pressure in the fuel injection sys- MPEM. Otherwise, the accessory will not work.
tem, only when connecting the safety lanyard cap Use the Options area in the Setting tab in B.U.D.S.
to the post.
Low-Fuel Level Warning Device

When the fuel level in the reservoir is low, the fuel
level sensor transmits a signal to the MPEM. The
MPEM sends out signals for the beeper and to the
information center gauge.
SMR2002-077_07-02A.FM 07-02-11
COMPONENT INSPECTION AND

ADJUSTMENT 0
GENERAL  WARNING
Engine problems are not necessarily related to the Fuel lines remain under pressure at all times.
electronic fuel injection system. Always proceed with care and use appropriate
It is important to ensure that the mechanical integ- safety equipment when working on pressurized
rity of the engine/propulsion system is present: fuel system. Wear safety glasses and work in a
well ventilated area. Do not allow fuel to spill on
– good jet pump/drive system operation hot engine parts and/or on electrical connectors.
– good engine compression and properly operat- Proceed with care when removing/installing
ing mechanical components, no leaks etc. high pressure test equipment or disconnecting
– fuel pump connection and fuel lines without leaks. fuel line connections. Use the VCK (Vehicle
Communication Kit) to release fuel pressure
Check the chart in TROUBLESHOOTING section prior to removing a hose. Cover the fuel line
to have an overview of problems and suggested connection with an absorbent shop rag. Slowly
solutions. disconnect the fuel hose to minimize spilling.
When replacing a component, always check its Wipe off any fuel spillage in the bilge. Fuel is
operation after installation. flammable and explosive under certain condi-
Whenever watercraft is out of water and engine is tions. Always work in a well ventilated area. Al-
running, ensure to supply water through the con- ways disconnect battery prior to working on the
nector on jet pump support to cool down exhaust fuel system. After performing a pressure test,
system. use the valve on the fuel pressure gauge to re-
lease the pressure (if so equipped).
water to the exhaust cooling system when wa- – Always disconnect battery properly prior to
tercraft is out of water. working on the fuel system. Refer to BATTERY
section.
FUEL SYSTEM When the job is done, ensure that hoses from fuel
rail going to fuel pump are properly secured in their
 WARNING supports. Then, pressurize the fuel system. Per-
The fuel system of a fuel injection system holds form the high pressure test as explained in this
much more pressure than on a carbureted wa- section and pressurize the fuel tank and fuel lines
tercraft. Prior to disconnecting a hose or to reas explained in FUEL SYSTEM section.
moving a component from the fuel system, fol- Properly reconnect the battery.
low the recommendation described here. Pay
attention that some hoses may have more than
one clamp at their ends. Ensure to reinstall the
 WARNING
Ensure to verify fuel line connections for dam-
same quantity of clamps at assembly.
age and that NO fuel line is disconnected prior
– Use the VCK (Vehicle Communication Kit) (P/N 529 to installing the safety lanyard on the DESS
035 844) to release the fuel pressure in the sys- post. Always perform the high pressure test if
tem. Look in the Activation section of the soft- any component has been removed. A pressure
ware B.U.D.S. test must be done before connecting the safety
lanyard. The fuel pump is started each time the
safety lanyard is installed and it builds pressure
very quickly.
SMR2002-078 _07_03A.FM 07-03-1
To check fuel rail for leaks, first pressurize the sys- Pay particular attention to ensure that pins are not
tem then spray soapy water on all hose connec- out of their connectors or out of shape. The trou-
tions, regulators and injectors. Air bubbles will bleshooting procedures cover problems not re-
show the leaking area. Check also for leaking fuel sulting from one of these causes.
or fuel odor.
 WARNING
 WARNING Ensure all terminals are properly crimped on
Never use a hose pincher on high pressure wires and connector housings are properly
hoses. fastened.
Before replacing a MPEM or EMS ECU, always

ELECTRICAL SYSTEM check electrical connections. Make sure that they are
It is important to check that the electrical system very tight and they make good contact and that they
is functioning properly: are corrosion-free. Particularly check MPEM and
EMS ECU ground connections. Ensure that con-
– battery tacts are good and clean. A “defective module”
– fuses could possibly be repaired simply by unplugging
– DESS and replugging the MPEM or EMS ECU. The volt-
age and current might be too weak to go through
– ignition (spark) dirty wire pins. Check carefully if pins show signs
– ground connections of moisture, corrosion or if they look dull. Clean
– wiring connectors. pins properly and then coat them prior to assem-
bling as follows:
It is possible that a component seems to operate
in static condition but in fact, it is defective. In this AMP connectors, EMS ECU connectors, OPS
case, the best way to solve this problem is to re- and OSPS connectors: Apply a thin coat of DEOX-
move the original part and replace it with one IT contact lubricant (P/N 293 550 015)
which is in good condition. Other connectors: Apply a silicon-based dielectric
Never use a battery charger to substitute tempo- grease or other appropriate lubricant. If the newly
rarily the battery, as it may cause the MPEM/EMS replaced MPEM or EMS ECU is working, try the
ECU to work erratically or not to work at all. Check old one and recheck if it works.
related-circuit fuse solidity and condition with an Ensure that all electronic components are genuine
ohmmeter. Visual inspection could lead to false re- — any modification on the wiring harness may
sults. lead to generate fault codes or bad operation.
NOTE: For diagnostics purposes, use Vehicle
 WARNING Communication Kit (VCK). See DIAGNOSTIC
All electrical actuators (idle bypass valve, PROCEDURES subsection.
TOPS valve, injectors, fuel pump, ignition coils After a problem has been solved, ensure to clear
and starter solenoid) are permanently sup- the fault(s) in the EMS ECU using the VCK. Refer
plied by the battery when the safety lanyard is to DIAGNOSTIC PROCEDURES subsection.
installed. Always disconnect the battery prior
to disconnecting any electric or electronic
parts.
To perform verifications, a good quality multimeter

such as Fluke 111 (P/N 529 035 868) should be
used.
07-03-2 SMR2002-078 _07_03A.FM
Resistance Measurement NOTE: In case of overheating, EGT and CTS do

not generate codes. No message will be displayed
When measuring the resistance with an ohmmeter,
on the information center. The beeper will be acti-
all values are given for a temperature of 20°C
vated and the EMS will be set in limp home mode.
(69°F). The resistance value of a resistance varies
with the temperature. The resistance value for
usual resistor or windings (such as injectors) in- ENGINE CONNECTOR PIN-OUT
creases as the temperature increases. However,
our temperature sensors are NTC types (Negative Connector Position
Temperature Coefficient) and work the opposite
which means that the resistance value decreases
as the temperature increases. Take it into account
when measuring at temperatures different from
20°C (69°F). Use this table for resistance variation
relative to temperature for temperature sensors.
TEMPERATURE RESISTANCE (ohms)
°C °F NOMINAL LOW HIGH
- 30 - 22 12600 11800 13400
- 20 -4 11400 11000 11800
- 10 14 9500 8000 11,000
0 32 5900 4900 6900
R1503motr166A 1 2
10 50 3800 3100 4500
1. EMS ECU connector A
20 68 2500 2200 2800 2. Engine connector
30 86 1700 1500 1900 EMS ECU Connector

40 104 1200 1080 1320
50 122 840 750 930 EMS ECU connector A of the wiring harness when
60 140 630 510 750 performing tests.
70 158 440 370 510
13 1
80 176 325 280 370
90 194 245 210 280
28
100 212 195 160 210 14
110 230 145 125 160
120 248 115 100 125
41 29
CONVERSION CHART FOR TEMPERATURE SENSORS
R1503motr176A
The resistance value of a temperature sensor may

EMS ECU CONNECTOR PIN-OUT (WIRING HARNESS SIDE)
test good at a certain temperature but it might be
defective at other temperatures. If in doubt, try a CAUTION: Probe on top of terminal only. Do
new sensor. not try to probe inside terminal or to use a pa-
Also remember this validates the operation of the per clip to probe inside terminal, it can damage
sensor at ambient temperature. It does not vali- the square-shaped terminal.
date the over temperature functionality. To test it, CAUTION: Do not disconnect the EMS ECU con-
the sensor could be removed from the engine/ nector needlessly. They are not designed to be
muffler and heated with a heat gun while it is still disconnected/reconnected repeatedly.
connected to the harness to see if the EMS ECU
will detect the high temperature condition and
generate a fault code.
SMR2002-078 _07_03A.FM 07-03-3
Engine Connector 3 2
Engine connector of the wiring harness when per-
forming tests.
1 4
2 3
R1503motr192A
ENGINE CONNECTOR PIN-OUT (WIRING HARNESS SIDE)

F18Z0KA 1
CONNECTORS ON ENGINE 1. Engine connector bracket
2. Deutsch connector
3. Flat screwdriver
Removal
To disconnect two connectors slide a flat screw-
To remove connectors from engine connector driver between each other to disengage, press the
bracket, slide a flat screwdriver between the con- release button and disconnect them.
nector bracket and the connectors and remove
connectors. 1
F18Z0LA 2
F18Z0JA 1 1. Flat screwdriver

2. Connectors
1. Engine connector bracket
2. Connectors
07-03-4 SMR2002-078 _07_03A.FM
2 AIR INDUCTION SYSTEM

THROTTLE BODY
6
5
F18Z0MA 1 2 2
1. Release button
2. Connectors R1503motr160A 1 3
1. Throttle body
2. Throttle cable attachment
3. Throttle plate
4. TPS
5. Idle bypass channel
6. Idle bypass valve
Mechanical Inspection
Check that the throttle plate moves freely and
smoothly when depressing throttle lever. Take this
opportunity to lubricate the throttle cable.
IMPORTANT: The throttle body is designed to be
tamper proof. Changing the idle stop or modifying it
in any way will not increase performance or change
the idle speed but may cause poor startability and
F18Z0NA 2 1 erratic idling.
1. Connectors Before replacing any part, check the following as
2. Press release button these could be causing the fault. Perform the test
while the engine is not running.
– Throttle cable adjustment too tight. Not return-
ing fully to idle stop.
– Throttle body idle set screw is loose or worn.
– TPS is loose.
– Idle bypass valve is loose.
– Corroded or damaged wiring or connectors.
– Throttle body has been replaced and the Closed
Throttle and Idle Actuator reset has not been
performed.
– EMS ECU has been replaced and the Closed
Throttle and Idle Actuator reset has not been
performed.
SMR2002-078 _07_03A.FM 07-03-5
Electrical Inspection Adjustment

Refer to THROTTLE POSITION SENSOR (TPS) and
1
IDLE BYPASS VALVE in ELECTRONIC MANAGE-
MENT below.
Replacement
Removal
To remove the throttle body from engine, proceed
as follows:
– Disconnect air intake silencer from throttle body.
Move boot away.
– Remove retaining screws of throttle body.
R1503motr161A
THROTTLE BODY
2 1. Idle stop screw
CAUTION: It is not allowed to perform any

change on the idle stop screw.
The adjustment of the idle stop screw is optimized
by the throttle body manufacturer and locked to
prevent any modification.
CAUTION: Never attempt to adjust the idle
speed through the throttle body tamper proof
screw. If so, it would impair the idle speed sta-
R1503motr205A 1 2 bility. Besides, no adjustment could be per-
1. Throttle body formed by the dealer nor the factory to correct
2. Screws the idle speed. The throttle body would need to
– Slightly pull throttle body out. be replaced. Also take into account that might
change the engine emission level and the en-
– Disconnect connectors from idle bypass valve, gine might not meet the EPA/CARB require-
and TPS. ments.
– Disconnect throttle cable. CAUTION: Do not alter or tamper with throttle
Installation cable adjustment or routing. It may cause poor
Installation of the new throttle body is the reverse startability and erratic idling.
of the removal procedure. The only thing that has to be performed when the
For TPS and idle bypass valve replacement proce- throttle body has been replaced is the Closed
dures, refer to the respective paragraph in ELEC- Throttle and Idle Actuator reset. Refer to THROT-
TRONIC MANAGEMENT below. TLE POSITION SENSOR (TPS) in ELECTRONIC
MANAGEMENT below.
07-03-6 SMR2002-078 _07_03A.FM
Throttle Cable Adjustment To adjust, loosen jam nut then turn adjustment nut
Mechanically adjust the throttle cable. as necessary.
Lubricate cable with BOMBARDIER LUBE lubricant.
When throttle is released, cable must have a free
play of 0.5 - 4 mm (1/64 - 5/32 in).
Besides, throttle lever must reach handlebar grip
without causing strain to cable or brackets. Ensure
throttle lever fully closes on it’s stopper.
F18F07A 3 2 1
1
F01K08A 1. Adjustment nut
2. Jam nut
1. Must touch handlebar grip 3. Throttle lever stopper
Ensure throttle body is fully open at full throttle po- Tighten jam nut and recheck adjustment.
sition. At this position, throttle lever stopper is al-
most in contact with throttle body.
 WARNING
NOTE: Apply a light pressure on the throttle plate, a Make sure idle speed stopper contacts throt-
slight play should be obtained. tle cam when throttle lever is fully released at
CAUTION: If there is no free-play at idle posi- handlebar.
tion, it may cause poor idling and startability.
Improper cable adjustment will cause strain on Closed Throttle and Idle Actuator Reset
cable and/or damage cable bracket or throttle
lever at handlebar. Perform the Closed Throttle and Idle Actuator re-
set as described in THROTTLE POSITION SENSOR
(TPS) in ELECTRONIC MANAGEMENT below.
SMR2002-078 _07_03A.FM 07-03-7
FUEL DELIVERY
4-TEC FUEL DELIVERY SYSTEM DIAGNOSTIC FLOW CHART
Fuel pump does not run Connect safety lanyard Fuel pump runs
for 2 sec. then stops
Check fuses Install fuel pressure gauge

Check safety lanyard connection on fuel pressure line
Check fuel pump operation
Repair or replace if necessary Replace fuel
pump module
Connect safety lanyard
Fuel pump runs
Repair or Fuel pressure less Fuel pressure is Fuel pressure more

replace than 303 kPa (44 PSI) 303 kPa (44 PSI) than 303 kPa (44 PSI)
Fails
Check fuel line /
rail for leaks
OK
Fails Crank or start
Perform fuel pump test engine
OK
Fast Fuel pressure less Fuel pressure more Fuel pressure is

pressure drop than 303 kPa (44 PSI) than 303 kPa (44 PSI) 303 kPa (44 PSI)
No
Yes
Check
OK fuel line /
Verify fuel
pump check rail for leaks Repair or
valve Fails
replace FUEL SYSTEM OK
Fails OK
Fails
OK
Check fuel Perform fuel Replace fuel
injector pump test pump module Retest
OK
R1503motr209S
07-03-8 SMR2002-078 _07_03A.FM
FUEL PUMP
Before proceeding to the pressure test ensure the
battery is fully charged. Battery voltage must be
over 12 volts.
Release the fuel pressure in the system using
B.U.D.S. Look in the Activation tab.
 WARNING
The fuel hose may be under pressure. Cover
the fuel line connection with an absorbent
shop rag. Slowly disconnect the fuel hose to
release the pressure. Wipe off any fuel spill-
age inside bilge. F18R08A 2 1
1. Hose disconnected from fuel pump
The pressure test will show the available pressure 2. In-line installation of fuel pressure gauge
at the fuel pump outlet. It validates the pressure
regulator, the fuel pump and leaks in the system. Install safety lanyard and observe fuel pressure. Do
not crank engine. Repeat twice. Release pressure
Remove glove box to have access to fuel pump.
using B.U.D.S. between tests so that the gauge is
Refer to HULL/BODY section.
“reset” to zero (0).
Remove air vent tube from front storage area.
FUEL PRESSURE
Ensure there is no leak from hoses and fittings.
Repair any leak.
Ensure there is enough gas in fuel tank. 303 kPa (44 PSI)
Disconnect outlet hose from fuel pump.
Install fuel pressure gauge (P/N 529 035 591) be- The fuel pressure should be the same as above.
tween disconnected hose (inline installation).
If pressure is within limits, fuel pump and pressure
regulator are working adequately.
A rapid pressure drop indicates leakage either from
the fuel rail or from the fuel pump check valve.
Check fuel rail for leaks. If it is not leaking then re-
place fuel pump.
A slow pressure drop indicates leakage either from
the fuel injector or from the fuel pressure regulator.
Check fuel injector for leaks (see below). If it is not
leaking then replace fuel pump module.
Release fuel pressure in the system using B.U.D.S.
Look in the Activation tab.
Remove pressure gauge and reinstall fuel hose.
 WARNING
F02B0BA Wipe off any fuel spillage in the bilge. Fuel is
flammable and explosive under certain con-
FUEL PRESSURE GAUGE (P/N 529 035 591)
ditions. Always work in a well ventilated area.
Reinstall removed parts.
SMR2002-078 _07_03A.FM 07-03-9
Electrical Test
When connecting the safety lanyard to the DESS
post, the fuel pump should run for 2 seconds to
build up the pressure in the system.
If the pump does not work, disconnect the plug
connector from the fuel pump.
Install a temporary connector to the fuel pump
with wires long enough to make the connection
outside the bilge and apply voltage (12 V) to this
test harness.
If pump does not run, replace the fuel pump module.
Otherwise, probe terminals A and D of fuel pump
F18R09A
connector on vehicle harness side. When installing
safety lanyard, you should read battery voltage for Pull fuel pump out from glove box opening.
approximately 2 seconds (then voltage will drop to
approximately 11 V). If battery voltage is read, the Installation
problem can be in harness or in fuel pump connec- For installation, reverse the removal process but
tor. Repair or replace appropriate part. pay attention to the following.
If battery voltage is not read, probe pin A and bat- Align tab of gasket with tank neck and then align
tery ground. arrow of fuel pump with tab of gasket.
a. If battery voltage is read, check continuity of cir- Refer to following illustration for tightening se-
cuit B-29 going towards EMS ECU. If it is good, quence. Torque 1 to 4 at 1 N•m (9 lbf•in) and then
try a new EMS ECU. 5 to 13 at 2 N•m (18 lbf•in).
b. If battery voltage is not read, check continuity
of circuit 1-26 going towards MPEM. If it is 1
good, try a new MPEM. 6 3 7
Fuel Pump Replacement
1 5 8
Removal
Open front storage compartment cover.
Remove the storage basket (if so equipped).
13 2 9
Remove front access panel (see HULL/BODY sec-
tion).
Remove front vent tubes. 4 12 10
Remove glove box (see HULL/BODY section). 11
Disconnect electrical connector.
F18R0AA 2
Disconnect vent tube from fuel pump.
TIGHTENING SEQUENCE
Release the fuel pressure in the system using 1. Fuel tank neck
B.U.D.S. Look in the Activation tab. 2. Align
Disconnect inlet hose from fuel pump. Perform a pressure test on fuel tank. Refer to FUEL
From glove box opening, remove fuel pump retain- SYSTEM section.
ing nuts.
07-03-10 SMR2002-078 _07_03A.FM
FUEL RAIL Disconnect wiring harness from the three fuel in-
jectors.
Pressure at fuel rail is supplied and controlled by Cut tie raps and remove the wiring harness from
the fuel pump module. Refer to FUEL PUMP for the fuel rail.
pressure test.
Fuel Rail Replacement Gently pull rail up by hand, working each side slight-
Removal ly at a time.
Pull rail out with fuel injectors.
Remove fuel rail cover from the engine.
Release the fuel pressure in the system using If necessary remove fuel injectors as described be-
B.U.D.S. Look in the Activation tab. low.
Insert pointed tools each side. Installation
Disconnect fuel hose at the connector. For installation, reverse the removal process but
pay attention to the following.
1 A thin film of injection oil should be applied to
O-rings of fuel injectors to ease installation in in-
take manifold.
Apply Loctite 243 on rail retaining screws then torque
When installing fuel line connector to the fuel rail,
put some oil on the O-ring to ease installation.
 WARNING
Perform a fuel pressure test and ensure that
there is no leak. Refer to FUEL PUMP above.
Run engine and check for leaks.
R1503motr162A FUEL INJECTOR

1. Insert pointed tools each side
Leakage Test
Wrap a rag around the hose end to prevent rail drain- To perform a leakage test, the injectors and fuel
ing. rail have to be removed from the engine. Refer to
REMOVAL in FUEL RAIL REPLACEMENT for the
procedure.
NOTE: Do not detach injectors from the fuel rail.
Reconnect the fuel line and the wiring harness.
Place each injector in a clean bowl.
Install the safety lanyard cap on the DESS post to
activate the fuel pump.
Check for fuel leakage from the injector nozzle.
There should be less than 1 drop per minute. Per-
form the test for 2 minutes.
If not within specification, replace the fuel injector(s).
The leakage test is validated when performing the
R1503motr163A 1
FUEL DELIVERY SYSTEM DIAGNOSTIC FLOW
1. Fuel injector connectors CHART elsewhere in this section.
SMR2002-078 _07_03A.FM 07-03-11
Electrical Test
Safety lanyard must be on DESS post.
Using the vehicle communication kit (VCK) with 1 4
the B.U.D.S. software, energize the fuel injector
from the Activation section.
If the injector does not work, disconnect the plug 2 3
R1503motr192A
wires long enough to make the connection out- ENGINE CONNECTOR
harness. 15 14
This will validate the injector mechanical and elec-
trical operation.
If it does not work, replace it.
Using B.U.D.S., activate injector while probing pin
2 (of injector on harness side) and battery ground.
a. If 12 V is read, check continuity of circuit as per
following table. If it is good, try a new EMS ECU.
CIRCUIT NUMBER
(EMS ECU INJECTOR NUMBER R1503motr193A
33
CONNECTOR “A“)
EMS ECU CONNECTOR
A-15 1
A-33 2 COMPONENT CONTACT LOCATION
A-14 3 1 (Engine Connector)
Fuel injector cylinder 1 and A-15 (EMS ECU
b. If it does not read 12 V, check continuity of cir- Connector)
cuit as per following table. If it is good, try a new
MPEM. 2 (Engine Connector)
Fuel injector cylinder 2 and A-33 (EMS ECU
CIRCUIT NUMBER Connector)
INJECTOR NUMBER
(AMP CONNECTOR # 2)
3 (Engine Connector)
2-16 1 Fuel injector cylinder 3 and A-14 (EMS ECU
2-17 2 Connector)
2-18 3 The resistance should be between 11.4 and 12.6 Ω.

Otherwise, check the resistance of the fuel injec- If resistance value is correct, try a new EMS ECU.
tor circuit. Refer to EMS ECU REPLACEMENT procedures
Reconnect the injector and disconnect the EMS
ECU connector A EMS ECU. If resistance value is incorrect, repair the wiring
harness/connectors or replace the wiring harness
Using a multimeter, check resistance value be- between EMS ECU plug connector and fuel injec-
tween terminals as follows. tor.
07-03-12 SMR2002-078 _07_03A.FM
Fuel Injector Replacement IMPORTANT: When the EMS ECU is replaced,

the safety lanyard(s) and the Closed Throttle and
Removal Idle Actuator must be reprogrammed/reset. Re-
Before removing the injectors, the fuel rail has to fer to their specific section for adjustment.
be removed from the engine. Refer to REMOVAL To allow transferring the previous recorded informa-
in FUEL RAIL REPLACEMENT for the procedure. tion from the old EMS ECU or MPEM to the new
3 2 one, use the vehicle communication kit (VCK) with
the B.U.D.S. software. Use Replace EMS or MPEM
in the ECU menu. Follows instructions in its help sys-
tem.
NOTE: If the old EMS ECU or MPEM is working, it
must be read inside B.U.D.S. prior to removing it
from the vehicle to carry vehicle information and his-
tory to the new EMS ECU or MPEM.
EMS ECU Replacement

R1503motr164A 1 Disconnect battery cables.
FUEL RAIL ASS’Y
1. Fuel injector
2. Injector clip
 WARNING
3. O-ring Battery BLACK negative cable must always
be disconnected first and connected last.
Then remove the injector clip. Now the fuel injec-
tor can be easily pulled out of the fuel rail. Disconnect both EMS ECU connectors from EMS
Installation ECU.
For the installation, reverse the removal proce- 2 1
dure. Paying attention to the following details.
Install new O-rings, if you reinstall a used injector
then insert the fuel injector in place with your hand.
Do not use any tool. Ensure clip and injector are
properly installed.
NOTE: A thin film of engine oil should be applied
to O-rings to ease insertion in rail.
Apply Loctite 243 on rail retaining screws then torque
 WARNING
Perform a fuel pressure test and ensure that
there is no leak. Refer to FUEL PUMP above.
Run engine and check for leaks.
R1503motr180A 2
ELECTRONIC MANAGEMENT 1. EMS ECU
2. Retaining screws
EMS ECU AND MPEM Unscrew all retaining screws and remove the en-
REPLACEMENT gine EMS ECU from intake manifold.
General Install the new EMS ECU to the engine.
Prior to replacing a suspected EMS ECU or MPEM, Reconnect EMS ECU connectors to EMS ECU then
ensure that all the recommendations in the general battery cables.
introduction of this section have been followed.
SMR2002-078 _07_03A.FM 07-03-13
Transfer the data from the previous EMS ECU to ENGINE WIRING HARNESS
the new one using B.U.D.S. then proceed with the
required resets and reprogram safety lanyard (s), 3 4 5 6 7 8 10 9 11 12
if you were unable to transfer the data.
NOTE: If data cannot be transferred, manually en-
ter information in Vehicle tab.
After performing the required resets, ensure to
clear all faults from the newly replaced EMS ECU.
Start the engine and increase engine speed above
5000 RPM to be sure no fault appears.
MPEM Replacement
Disconnect battery cables.
 WARNING
Battery BLACK negative cable must always
be disconnected first and connected last.
Disconnect AMP connectors from MPEM. Re-

move retaining nuts on top.
2 1 19 20 18 17 16 15 14 13
Pull MPEM out. R1503motr199A
Install the new MPEM in vehicle. Reconnect AMP 1.EMS ECU connector
2.CTS connector
connectors to MPEM. 3.EGT connector
4.CAPS connector
Transfer the data from the previous MPEM to the 5.Fuel injector connector (cylinder 1)
new one using B.U.D.S. 6.Ignition coil connector (cylinder 1)
7.Fuel injector connector (cylinder 2)
NOTE: If data cannot be transferred, manually ac- 8.Ignition coil connector (cylinder 2)
9.Fuel injector connector (cylinder 3)
tivate the options installed in vehicle under the 10. Ignition coil connector (cylinder 3)
Setting tab. If an option is installed but not 11. TOPS valve connector
12. OSPS connector
checked in B.U.D.S., the information center will 13. TPS connector
not display that option. If an option is checked in 14. Idle bypass valve connector
15. MATS connector
B.U.D.S. but not installed in vehicle, a fault code 16. Engine connector
will be generated. 17. MAPS connector
18. OPS connector
Ensure to clear all faults from the newly replaced 19. KS connector
20. CPS connector
MPEM.
Start engine and ensure no fault is active. Resistance Test
Check continuity of the circuits according to the
wiring diagram in the WIRING DIAGRAMS section
of this manual.
If wiring harness is good, check the respective
sensor/actuator as described in this section.
Otherwise, repair the connectors, replace the wir-
ing harness or the EMS ECU/MPEM as diagnosed.
07-03-14 SMR2002-078 _07_03A.FM
Removal Lead the cable bundle with the injector and igni-
tion coil connectors to the fuel rail and fix it also by
Remove fuel rail cover.
using 4 locking ties.
Disconnect the wiring harness from all sensors/
actuators. 1 1
Disconnect the EMS ECU connector from the EMS
ECU.
Cut all tie raps which are holding the wiring harness
in position.
R1503motr202A
1. Locking ties
Connect the fuel injectors, ignition coils, CAPS, CTS

and EGT to the wiring harness.
 WARNING
1 Pay attention not to mix injectors or ignition
R1503motr200A
coils wires between cylinders. The location of
the splice connectors indicate which cylinder
1. Wiring harness
wires belong to.
Remove complete wiring harness.
Install the engine connector on the appropriate
Installation bracket on the wiring support.
First connect the EMS ECU connector A to the Then fix the other bundle on the appropriate sup-
EMS ECU and fix the harness on the wiring supports on the wiring support and the EMS ECU brack-
port with a locking tie. et with locking ties.
1
R1503motr203A
R1503motr201A 1
1. Locking ties
1. Locking tie
SMR2002-078 _07_03A.FM 07-03-15
Connect the CPS, KS, OPS, and the MAPS to the IMPORTANT: Prior to testing the TPS, ensure that
wiring harness. mechanical components/adjustments are adequate
Also connect now the MATS, TPS, OSPS, idle by- according to THROTTLE BODY in AIR INDUCTION
pass and TOPS valve to the wiring harness. SYSTEM above.
Fix the wiring for the MATS with a locking tie to The EMS may generate several fault codes pertain-
support the cables. ing to the TPS. Refer to SYSTEM FAULT CODES in
DIAGNOSTIC PROCEDURES section for more in-
formation.
Wear Test
While engine is not running, activate throttle and
pay attention for smooth operation without physi-
cal stops of the cable.
the B.U.D.S. software, use the Throttle Opening
display under Monitoring.
Slowly and regularly depress the throttle. Observe
the needle movement. It must change gradually
and regularly as you move the throttle. If the nee-
dle “sticks”, bounces, suddenly drops or if any dis-
R1503motr204A 1 crepancy between the throttle movement and the
needle movement is noticed, it indicates a worn
1. Locking tie
TPS that needs to be replaced.
Install all remaining parts, which has been removed.
Voltage Test
THROTTLE POSITION SENSOR Check the voltage output from EMS ECU to the de-
(TPS) sired throttle position sensor.
General
The throttle position sensor (TPS) is a potentiom-
eter that sends a signal to the EMS ECU which is
proportional to the throttle shaft angle.
3
1
R1503motr167A
TPS
R1503motr165A
07-03-16 SMR2002-078 _07_03A.FM
Disconnect plug connector from throttle position Check the resistance between terminal A-24 and
sensor. To unlock connector, insert a small screw- A-25 with throttle plate in idle position.
driver between the folded tab. To see the connec- The resistance should be 1000 - 1100 Ω.
tor pin-out, temporarily remove the connector
shield joining the harness, to expose the pin num- Now check the resistance with the throttle plate
bers. Connect a voltmeter between pin 1 and 3 in wide open position.
and also between pin 1 and 2 in the wiring har- The resistance should be 2600 - 2700 Ω.
ness. NOTE: When measuring between pins A-24 and
Remove and reinstall the safety lanyard to activate A-39, resistance value decreases while depress-
the EMS ECU. ing throttle lever. when measuring between pins
Check the voltage readings as follows. A-24 and A-25, resistance value increases while
depressing throttle lever. The resistance value
CONNECTION VOLTAGE should change smoothly and proportionally to
Pin 1 with engine ground 0V throttle movement. Otherwise, replace TPS.
Pin 2 with engine ground 5V If resistance values are correct, try a new EMS ECU.
Refer to EMS ECU REPLACEMENT procedures
Pin 3 with engine ground 4.75 - 5 V elsewhere in this section.
If voltage test is good, replace the TPS. If resistance values are incorrect, repair connector
or replace the wiring harness between EMS ECU
If voltage test is not good, check the resistance of connector and the TPS.
the TPS circuit.
Replacement
Resistance Test
Remove the throttle body as described above.
Reconnect the TPS.
Loosen two screws retaining the TPS.
Disconnect the EMS ECU connector A on the EMS
ECU. Remove TPS.
25 24
R1503motr191A
39
R1503motr168A 2
tween terminal A-25 and A-39. THROTTLE BODY
The resistance should be 1600 - 2400 Ω. 2. Screws
Check the resistance between terminal A-24 and Apply Loctite 243 on screw threads, install the new
terminal A-39 with the throttle plate in idle posi- TPS.
tion.
The resistance should be approximately 2500 Ω.
Proceed with the Closed Throttle and Idle Actu-
Check the resistance between terminal A-24 and ator Reset. See below.
terminal A-39 with the throttle plate in wide open
position.
The resistance should be 1000 - 1100 Ω.
SMR2002-078 _07_03A.FM 07-03-17
Closed Throttle and Idle Actuator Reset IDLE BYPASS VALVE

NOTE: This operation performs a reset of the val- An idle bypass valve with good resistance mea-
ues in the EMS ECU. surement can still be faulty. It is also possible that
This reset is very important. The setting of the TPS a mechanical failure occurs which is not detect-
will determine the basic parameters for all fuel able without measuring the air flow. Replacing the
mapping and several EMS ECU calculations and idle bypass valve may be necessary as a test.
the setting of the idle bypass valve will determine
the basic parameters for the idle speed control of Resistance Test
the engine. Disconnect idle bypass valve from the wiring har-
NOTE: Reset must be done each time the throttle ness.
position sensor (TPS) or the idle bypass valve is Using a multimeter, check the resistance in both
loosened or removed or throttle body is replaced windings.
or EMS ECU is replaced.
Check the resistance between pin A and pin D and
CAUTION: An improperly set TPS or idle by- also between pin C ad pin B of the idle bypass
pass valve may lead to poor engine perfor- valve.
mance and emission compliance could possi-
bly be affected. The resistance in each winding should be approx-
imately 50 Ω at 23°C (73°F).
Use the vehicle communication kit (VCK) with the
B.U.D.S. software to perform this adjustment. If the resistance of one or both windings is not
good, replace the idle bypass valve.
Ensure the throttle body plate stop lever rest
against its stopper. Open throttle approximately If resistance test of valve windings is good, check
one quarter then quickly release. Repeat 2 - 3 times continuity of circuits A-35, A-36, A-37, A-38.
to settle throttle plate. If stopper does not rest Visual Inspection
against its stop lever, perform throttle cable ad-
justment. Refer to THROTTLE BODY in AIR IN- Remove idle bypass valve from throttle body.
DUCTION SYSTEM above. Check the piston and bypass channel for dirt/de-
Push the Reset button in the Setting section of posits which can cause a sticking piston.
B.U.D.S. CAUTION: Do not try to operate the piston of
NOTE: No message will be displayed if operation the idle bypass valve when it is dismounted.
is good. If operation is wrong, an error message Also do not move the piston by hand. The
will be displayed. screw drive is very sensitive and will be de-
stroyed.
NOTE: There is no idle speed adjustment to per-
form. The EMS ECU takes care of that. If TPS is Clean the parts and install the idle bypass valve on
not within the allowed range while resetting the the throttle body.
Closed Throttle and Idle Actuator, the EMS ECU Proceed with the Closed Throttle and Idle Actu-
will generate a fault code and will not accept the ator Reset. See above.
setting.
Start engine and make sure it operates normally
through its full engine RPM range. If fault codes ap-
pear, refer to SYSTEM FAULT CODES in DIAGNOS-
TIC PROCEDURES section for more information.
07-03-18 SMR2002-078 _07_03A.FM
CRANKSHAFT POSITION
5
SENSOR (CPS)
1
R1503motr182A
19

If resistance value is correct, try a new EMS ECU.
R1503motr169A
If resistance value is incorrect, repair the connec-
1. CPS connector tors or replace the wiring harness between EMS
Ensure that information center works. Needles ECU connector and the MATS.
will sweep, LED and LCD segments will turn on
when the safety lanyard is installed. Check for Replacement
RPM display at the information center while crank- Disconnect connectors and remove the PTO cov-
ing in engine drowned mode. Press and HOLD er. Refer to PTO HOUSING/MAGNETO in ENGINE
throttle lever then press start/stop button. 800- section.
1000 RPM should display. Otherwise perform the Remove CPS.
following tests.
NOTE: Take into account that a CPS fault can be 1
triggered by bent or missing encoder wheel teeth.
First check fault codes then check the teeth con-
dition if necessary. See below.
Disconnect CPS wiring harness connector. Probe
terminals coming from CPS while cranking en-
gine. Voltage should be within 1-2 Vac. Otherwise,
inspect wiring and replace CPS if wiring is good.
Resistance Test
Disconnect the CPS plug connector from the wir-
ing harness and check the resistance of the sensor
itself.
The resistance should be between 190 Ω and 290
R1503motr170A
Ω.
1. CPS inside PTO cover
Otherwise, replace the CPS.
If resistance tests good, reconnect the CPS and Apply Loctite 243 on screw threads then install the
disconnect the EMS ECU connector A on the EMS new CPS. Torque to 10 N•m (89 lbf•in).
ECU. Reinstall remaining removed parts.
SMR2002-078 _07_03A.FM 07-03-19
Encoder Wheel Inspection Voltage Test (harness)

To check the encoder wheel for bent teeth, pro- Disconnect the connector from the wiring harness.
ceed as follows. To see the connector pin-out, temporarily remove
Remove PTO cover. Refer to PTO HOUSING/ the connector shield joining the harness, to ex-
MAGNETO in ENGINE section. pose the pin numbers.
Install a dial indicator on crankcase casting. Posi- Remove and reinstall safety lanyard to activate the
tion the gauge on a tooth and set it to zero (0). system.
Rotate flywheel and check needle movement. The Probe pin 3 of CAPS connector (wiring harness
maximum allowed difference between teeth is side) and battery ground.
0.15 mm (.006 in). Otherwise, straighten the tooth
or replace the encoder wheel. a. If 12 V is read, check continuity of circuits A-20
and A-34. If they test good, perform the CAPS
2 voltage test as explained below. If CAPS tests
good, try a new EMS ECU.
20
R1503motr183A
34
EMS ECU CONNECTOR

R1503motr177A 1
b. If 12 V is not read, check continuity of circuit 2-19
1. Encoder wheel from MPEM to the CAPS. If it tests good, try a
2. Dial indicator
new MPEM. Otherwise, repair wiring harness.
Properly reinstall cover. Remove the CAPS from the cylinder head.
CAMSHAFT POSITION SENSOR
(CAPS)
R1503motr178A 1
1. CAPS
07-03-20 SMR2002-078 _07_03A.FM
Set up the following electric circuit to perform the

voltage test. 2 V
3 2 1
1 Pin 1 Pin 2 Pin 3

R1503motr207A 1200 W resistor
R1503motr184A
1. CAPS
2. Conductor
CAPS PIN-OUT
If the voltage is not good, replace the CAPS.
1200 W Voltmeter
V Replacement
Unscrew the retaining screw and replace the
CAPS. Ensure to reinstall O-ring.
+ Apply Loctite 243 (blue) on thread and torque to
3 2 1
6 N•m (53 lbf•in).
12 V CAPS MANIFOLD AIR TEMPERATURE
SENSOR (MATS)
-
R1503motr208A
Touch the CAPS with a conductor (ex.: screwdriv-

er) and look if the voltage at the multimeter
switches from 12 V to less than 1 V.
R1503motr171A 1
INTAKE MANIFOLD
SMR2002-078 _07_03A.FM 07-03-21
Resistance Test COOLANT TEMPERATURE

Disconnect the plug connector from the MATS SENSOR (CTS)
and check the resistance of the sensor itself.
The resistance should be between 2280 Ω and
2740 Ω at 20°C (68°F).
Otherwise, replace the MATS.
If resistance tests good, reconnect the MATS and
disconnect the EMS ECU connector A on the EMS
ECU.
R1503motr172A 1
1. Coolant temperature sensor (CTS)
Resistance Test
R1503motr186A
21 Disconnect the plug connector from the CTS and
check the resistance of the sensor itself.
tween terminals 7 and 21. The resistance should be between 2280 Ω and
2740 Ω at 20°C (68°F).
Refer to EMS ECU REPLACEMENT procedures Otherwise, replace the CTS.
elsewhere in this section. If resistance tests good, reconnect the CTS and
If resistance value is incorrect, repair the connec- disconnect the EMS ECU connector A on the EMS
tors or replace the wiring harness between EMS ECU.
ECU connector and the MATS.
11
Replacement
Disconnect the connector of the MATS.
Screw MATS out and install the new one. Torque
to 18 N•m (159 lbf•in).
R1503motr187A
27

tors or replace the wiring harness between EMS
ECU connector and the CTS.
07-03-22 SMR2002-078 _07_03A.FM
Replacement Remove and reinstall the safety lanyard to activate

the EMS ECU. There should be 5 Vdc in each test.
Unlock expansion tank and temporarily move
away to gain access. If voltage test is good, replace the MAPS.
Remove the fuel rail cover. If voltage test is not good, check the continuity of
the MAPS circuit.
Disconnect CTS connector and remove CTS.
Install the new CTS and torque to 18 N•m (159 Resistance Test
lbf•in).
Disconnect the EMS ECU connector A on the EMS
Reinstall remaining removed parts. ECU.
Using a multimeter, check continuity of circuits 12,
MANIFOLD AIR PRESSURE 28 and 40.
SENSOR (MAPS) If wiring harness is good, try a new EMS ECU.
Otherwise, repair the connectors or replace the
wiring harness between EMS ECU connector and
the MAPS.
Replacement
Disconnect MAPS connector and remove the MAPS.
Install the new MAPS paying attention to index its
tab into the adaptor notch. Apply Loctite 243 (blue)
on screw then torque to 10 N•m (89 lbf•in).
EXHAUST GAS TEMPERATURE

R1503motr173A 1 SENSOR (EGT)
1. Manifold air pressure sensor (MAPS)
1 2
NOTE: This sensor is a dual function device. When
engine is started and it runs at idle speed, the sen-
sor takes the atmospheric pressure and stores it in
the EMS ECU. Thereafter, it takes the manifold air
pressure at operating RPMs.
Ensure sensor is correctly installed on intake man-
ifold. Otherwise, the MAPS could generate a fault
code for an unexpected sensor range at idle when
it reads the atmospheric pressure. Remove sensor
and check for oil or dirt on its end and if problem
persists, check throttle plate condition/position
and the wiring harness. Perform the following
tests.
F18D2IA
Voltage Test 1. Muffler

2. Exhaust gas temperature sensor (EGT)
Check the voltage output from EMS ECU to the man-
ifold air pressure sensor (MAPS).
Disconnect plug connector from maps and con-
nect a voltmeter between pin 1 and 3 and also
between pin 1 and 2 of wiring harness.
SMR2002-078 _07_03A.FM 07-03-23
Resistance Test Start the engine and bring engine RPM above
5000 RPM. If no fault code occurs, the knock sen-
Disconnect the plug connector from the EGT and
sor is good.
check the resistance of the sensor itself.
Otherwise, do the following.
The resistance should be between 2280 Ω and
2740 Ω at 20°C (68°F). Ensure sensor and head contact surfaces are clean
and mounting bolt and washer are correct and prop-
Otherwise, replace the EGT.
erly torqued down.
If resistance tests good, reconnect the EGT and
NOTE: It is necessary to remove intake manifold
disconnect the EMS ECU connector A on the EMS
to inspect contact surfaces. Refer to INTAKE SYS-
ECU.
TEM section.
Check the knock sensor resistance.
Disconnect the connector from knock sensor har-
ness.
Refer to EMS ECU replacement procedures else-
Static Resistance Test
tor or replace the wiring harness between EMS Using a multimeter, check the resistance between
ECU connector and the EGT. both terminals on the knock sensor harness side.
The resistance should be approximately 5 MΩ.
Replacement If resistance is not good, replace knock sensor.
Disconnect EGT connector and remove EGT. If resistance is good, reconnect the knock sensor
Apply Loctite 518 on threads of the EGT then in- connector and disconnect the EMS ECU connec-
stall. tor A from the EMS ECU.
Replug connector.
9
KNOCK SENSOR (KS)
R1503motr188A
23

If wiring harness is good, try a new EMS ECU. Re-
fer to EMS ECU REPLACEMENT procedures else-
R1503motr174A 1
Otherwise, repair the connector or replace the wir-
1. Knock sensor (KS) ing harness between EMS ECU connector and
knock sensor.
Dynamic Test
the B.U.D.S. software, monitor the knock sensor
using the Faults section.
07-03-24 SMR2002-078 _07_03A.FM
Replacement When engine is stopped the resistance is infinitely

high (normally open switch).
Remove the intake manifold. Refer to INTAKE
MANIFOLD REPLACEMENT in INTAKE section. When engine is running and the oil pressure reach-
es 180 - 220 kPa (26 - 32 PSI), the resistance of
Unscrew and remove knock sensor.
the OPS is close to 0 Ω.
Clean contact surface, apply Loctite 243 in thread-
If resistance values are incorrect, replace OPS.
ed hole then install the new knock sensor.
If the values are correct, check the continuity of
Torque screw to 24 N•m (18 lbf•ft).
the wiring harness.
CAUTION: Improper torque might prevent sen-
Disconnect the EMS ECU connector A from the
sor to work properly and lead engine to severe
EMS ECU and check continuity of circuit 6.
damage of internal components.
Replug connector. 6
OIL PRESSURE SWITCH (OPS)
R1503motr195A
If wiring harness is good, try a new EMS ECU. Re-

fer to EMS ECU REPLACEMENT procedures else-
ing harness between EMS ECU connector and
OPS.
R1503motr194A 1
1. OPS
OIL SEPARATOR PRESSURE
SWITCH (OSPS)
Oil Pressure Test
To check the function of the oil pressure switch,
an oil pressure test has to be performed. Refer to
OIL PRESSURE TEST in LUBRICATION SYSTEM
section.
If the engine oil pressure is out of specifications,
check the points described in TROUBLESHOOT-
ING section.
If the engine oil pressure is good, check the resis-
tance of the OPS while engine is off and while
engine is running.
Resistance Test 1
Disconnect the plug connector from the OPS and

use a multimeter to check the resistance between
OPS pin and engine ground while engine is
stopped (without oil pressure) and while engine is R1503motr189A
running (with oil pressure). 1. OSPS
SMR2002-078 _07_03A.FM 07-03-25
TOPS Pressure Test When engine is stopped and the blow-by pressure
is released, the resistance of the OPS is close to
 WARNING 0 Ω (normally closed switch).
The TOPS system might be pressurized. When engine is running and the blow-by pressure
When the TOPS valve is disconnected from exceeds 40 kPa (6 PSI), the resistance is infinitely
the wiring harness, never open the oil filler high.
cap. Stop the engine and wait at least 30 sec- If resistance values are incorrect, replace OSPS.
onds before opening it, to release the pres-
If the values are correct, check the continuity of
sure.
the wiring harness.
To check the function of the oil separator pressure Disconnect the EMS ECU connector A from the
switch, disconnect the TOPS valve and perform a EMS ECU and check continuity of circuit 31.
TOPS pressure test. Refer to TOPS PRESSURE
TEST in LUBRICATION SYSTEM section.
If the engine blow-by pressure does not reach
40 kPa (6 PSI), check the points described in the
following illustration.
Otherwise, check the resistance of the OSPS
while engine is off and while engine is running.
Resistance Test
Disconnect the plug connector from the OSPS and R1503motr198A
31
use a multimeter to check the resistance between
OSPS pin and engine ground while engine is If wiring harness is good, try a new EMS ECU. Re-
stopped (without blow-by pressure) and while en- fer to EMS ECU REPLACEMENT procedures else-
gine is running (with blow-by pressure). where in this section.
ing harness between EMS ECU connector and OPS.
07-03-26 SMR2002-078 _07_03A.FM
TOPS VALVE (blow-by)
TOPS DIAGNOSTIC FLOW CHART

Connect safety
lanyard
Repair or
replace
TOPS valve opens No Check

(short knocking noise) TOPS switch Fails
Yes OK
Install oil pressure gauge Check Fails

on oil dipstick tube wiring harness
OK
Lower than 8 V
Check output voltage
Start engine on wiring harness
Greater than 8 V
No
Pressure drops Pressure stays below
down directly after 40 kPa (5.8 PSI) for 10 min. Replace
TOPS valve Try a new MPEM
reaching 40 kPa (5.8 PSI) (TOPS valve is open)
(TOPS valve opens again)
Yes Retest
No
Yes No
Working ?
Check OK
OSPS Yes Try a new
EMS ECU
Fails
Fails
Replace TOPS OK
Retest OK Retest
OSPS
R1503motr206S
The valve is turned on as soon as safety lanyard is The OSPS monitors the pressure to detect a mal-
installed on its post. The valve opening allows ven- function of this valve. If pressure rises above a pre-
tilation of crankcase. set threshold, the valve is re-energized again and
if it fails, a fault code is generated.
SMR2002-078 _07_03A.FM 07-03-27
The TOPS switch (mercury type), located besides

the MPEM (on MPEM bracket), monitors the wa-
tercraft position. If the watercraft rolls above a
present threshold (or tips over) the switch opens
and the EMS ECU closes the valve to prevent oil
in engine crankcase to flow towards intake mani-
fold. Besides, the engine RPM will be gradually
reduced then it will be stopped.
1
1
2
3
R1503motr181A 4
1. Solenoid valve
2. Spring
3. Valve disc
4. Retaining washer
 WARNING
The spring on the TOPS valve is tensioned and
can shoot away the valve disc. Hold the valve
disc with fingers while removing the washer.
Remove the valve disc and the spring on the bot-

tom of the TOPS valve after removing the retain-
R1503motr179A
ing washer.
1. TOPS valve
Unscrew and remove the TOPS valve.
Install the new valve with new gasket. Apply Loc-
Resistance Test tite 243 (blue) on threads and torque to 10 N•m
Disconnect the plug connector from the TOPS valve (89 lbf•in).
and check the resistance of the solenoid itself. Reinstall remaining removed parts.
The resistance should be between 1.27 Ω and TOPS Switch
2.47 Ω.
Disconnect TOPS switch and remove from MPEM
Otherwise, replace the TOPS valve. bracket.
Using and ohmmeter, measure resistance between
Dynamic Test
pins.
Activate the TOPS valve by installing the safety
Position switch as it is located in vehicle. Resistance
lanyard on the DESS post.
should be close to 0 Ω.
If you can hear the movement of the piston (knock-
Rotate switch as it would do in vehicle. Switch
ing), the valve works fine, otherwise follow the pro-
should remain closed up to approximately 120°
cedure shown in the following chart.
(from the vertical axis) in either direction. Other-
wise, replace switch.
TOPS Valve Replacement
NOTE: Since this is a mercury switch, dispose it
Disconnect the wiring harness from the TOPS properly according to the environmental regula-
valve. tions in your area.
Remove the oil separator cover. Refer to OIL SEP- Farther than 120° and when switch is upside
ARATOR REPLACEMENT in the LUBRICATION down, switch should be open and resistance will
SYSTEM section. be infinite.
07-03-28 SMR2002-078 _07_03A.FM
IGNITION COILS Disconnect the plug connector from the ignition

coil and check the voltage supplied by the MPEM.
1
1
2
R1503motr196A
Install safety lanyard on the DESS post.

R1503motr175A Check voltage between terminal 2 of ignition coil
1. Ignition coil
connector on the wiring harness and battery
ground.
NOTE: The MPEM energizes the primary side of The voltage should be 12 V.
each ignition coil individually. It can detect open
and short circuit in the primary winding but it does If 12 V is NOT read, check continuity of appropri-
not check the secondary winding. ate circuit 2-16 (cylinder 1), 2-17 (cylinder 2) or 2-18
(cylinder 3). If it tests good, try a new MPEM.
the B.U.D.S. software, energize the ignition coil If 12 V is read, disconnect the EMS ECU connector
from the Activation section. A from the EMS ECU and check the continuity of
appropriate circuit 41 (cylinder 1), 1 (cylinder 2) or
You should hear the spark occurring. In doubt, use an 29 (cylinder 3).
inductive spark tester or a sealed tester – available
from after-market tool/equipment suppliers – to pre-
1
vent spark occurring in the bilge. Otherwise, perform
the following checks.
An ignition coil with good resistance measure-
ment can still be faulty. Voltage leak can occur at
high voltage level which is not detectable with an
ohmmeter. Replacing the ignition coil may be nec-
essary as a test.
 WARNING
Never make a spark test with spark plug re- 41 29
R1503motr190A
moved. Flammable vapors may be present in
the bilge and ignited which could cause an ex- EMS ECU CONNECTOR
plosion.
If wiring harness is defective, repair the connector
or replace the wiring harness between EMS ECU
Voltage Test connector and the ignition coil.
 WARNING If wiring harness is good, test resistance of prima-

ry and secondary winding of ignition coil.
When disconnecting coil from spark plug, al-
ways disconnect coil from main harness first. Resistance Test
open coil and/or spark plug in the engine CAUTION: Do not remove the ignition coil be-
compartment as spark may cause fuel vapor fore disconnecting the connector, or the wires
to ignite. will be damaged. Do not pry up ignition coil
with a screwdriver to avoid damage.
SMR2002-078 _07_03A.FM 07-03-29
Remove ignition coil from spark plug. ENGINE START/STOP SWITCH

VERIFICATION
1 1
A quick operation test can be done using the vehi-
cle communication kit (VCK) with the B.U.D.S. soft-
ware, using the Monitoring section. Press the
start button and look at the start button LED. It
should turn on, indicating the starting system is
working on the input side of the starting system
(start button, MPEM, EMS ECU and wiring). You
R1503motr197A
2 know now the problem is on the output side of the
starting system (MPEM output signal to starting so-
1. Spark plug terminal lenoid, wiring harness going to the solenoid and
Using a multimeter, check the resistance in both starter motor. Refer to STARTING SYSTEM for test-
primary and secondary windings. ing procedures). Otherwise, check the input side as
follows.
For primary winding check the resistance between
pin 1 and pin 2 of the ignition coil. Disconnect the start/stop switch connector. Using
an ohmmeter, connect test probes to YELLOW/RED
The resistance should be between 0.85 and and PURPLE wires.
1.15 Ω at 20°C (68°F).
Measure resistance, it must be an open circuit
For secondary winding check the resistance be- (switch is normally open). Depress and hold switch,
tween pin 1 and spark plug terminal. the ohmmeter should read lower than 200 ohms.
The resistance should be between 9.5 and 13.5 kΩ Otherwise, replace switch. Reconnect connector.
at 20°C (68°F). If the switch tests good, temporarily disconnect
If the resistance of one of both windings is not the inline DESS auxiliary module (see safety lan-
good, replace the defective ignition coil. yard switch verification below for more informa-
If the windings test good, try a new engine EMS tion). Connect the 6-pin connector to bypass the
ECU. auxiliary module. Try the start/stop switch.
NOTE: Prior to inserting the ignition coil to its lo- If it works, try a new auxiliary module. Otherwise,
cation, apply some silicone lubricant (P/N 293 600 continue testing procedure.
041) around the seal area that touches the spark Test continuity of circuit 2-23. If it is good, try a new
plug hole. After installation, ensure the seal seats MPEM. Otherwise, repair harness/connectors.
properly with engine top surface. Test continuity of circuit B-19. If it is good, try a new
EMS ECU. Otherwise, repair harness/connectors.
 WARNING
Always reconnect ignition coil cables at the SAFETY LANYARD SWITCH
same spark plugs where they come from.
Otherwise, severe backfire may occur with
VERIFICATION
possible damage to exhaust system compo- If 2 short beeps are not heard when installing the
nents. The genuine wiring harness is de- safety lanyard, refer to DIAGNOSTIC PROCEDURES.
signed to prevent a cable mixing by using dif-
The following continuity tests can also be per-
ferent cable lengths.
formed using an ohmmeter.
Disconnect switch wires.
TDC SETTING (Top Dead Center) Safety Lanyard Removed
The EMS is able to determine the exact position Connect test probes to switch BLACK and BLACK/
of camshaft and crankshaft. That means that no YELLOW wires. Measure resistance, there should
TDC setting has to be performed. It is used for be NO continuity (open circuit).
both injection and ignition timings.
07-03-30 SMR2002-078 _07_03A.FM
Connect one test probe to the WHITE/GRAY wire Disconnect the wiring harness from the ignition
and the other test probe to the switch top termi- coil.
nal. Measure resistance, it must be close to Remove the ignition coil.
0 ohm.
First unscrew the spark plug one turn.
Connect one test probe to the BLACK wire and the
other test probe to the switch ring. Measure resis- Clean the spark plug and cylinder head with pres-
tance, it must be close to 0 ohm. surize air then completely unscrew.
DESS Auxiliary Module Spark Plug Installation

This module enhances safety lanyard recognition Prior to installation make sure that contact surfac-
at the EMS ECU. It is located under steering sup- es of the cylinder head and spark plug are free of
port. It is an inline connection of the DESS post grime.
harness.
1. Using a wire feeler gauge, set electrode gap ac-
If a safety lanyard cannot be programmed or it fails cording to the following chart.
to be recognized, first refer to the basic self diagnos-
tic mode in DIAGNOSTIC PROCEDURES section. 2. Apply anti-seize lubricant over the spark plug
threads to prevent possible seizure.
If it still does not work, disconnect the DESS aux-
iliary module and connect the regular 6-pin DESS 3. Hand screw spark plug into cylinder head. Then,
harness. tighten the spark plug clockwise an additional
1/4 turn with a proper socket.
a. If it is now working, check module harness/
connections. Ensure wires from MPEM and
EMS ECU are properly positioned in connector
and match those on auxiliary module side. Refer
to WIRING DIAGRAMS. If harness/connector
are correct, try a new module.
b. Try pushing down and turning the lanyard on its 1 2
post. If it is working now, check module harness/
connections and if they are in good condition, try
a new module.
Reconnect module.
If the above procedures did not work, refer to elec-
trical troubleshooting in TROUBLESHOOTING A00E0BA
and ENGINE MANAGEMENT sections. 1. Proper socket

2. Improper socket
Safety Lanyard on Switch
Connect test probes to switch BLACK and BLACK/ SPARK GAP
ENGINE TORQUE
YELLOW wires. Measure resistance, it must be PLUG mm (in)
close to 0 ohm. Hand tighten
1503 NGK 0.6
+ 1/4 turn with
4-TEC DCPR8-ES (.24)
SPARK PLUGS a socket
Disassembly CRANKING SYSTEM

 WARNING See above for start/stop switch and the DESS post
testing. Refer to STARTING SYSTEM section for
Never remove ignition coil from the spark other tests.
plug without disconnecting it from the wiring
harness. Flammable vapors may be present
in the bilge and ignited by a spark which
could cause an explosion.
SMR2002-078 _07_03A.FM 07-03-31
DIAGNOSTIC PROCEDURES 0
GENERAL
Here is the basic order suggested to diagnose a
suspected engine management or fuel injection
related problem:
– Check the chart in TROUBLESHOOTING sec-
tion to have an overview of problems and sug-
gested solutions.
– Check if there is a message displayed by the
vehicle information center. If so, use the VCK
(Vehicle Communication Kit) and look for fault
codes to diagnose the trouble.
NOTE: Fault codes, the letter P - followed by 4 digits
(P-1234), can be displayed in the information center
for troubleshooting. With safety lanyard on its post,
F18L09C 1
press 5 times the SET button to start the display of
P-codes (onboard diagnostic). Press MODE to scroll 1. Press to scroll if more than one P-code
codes if more than one is present. When “list” is
over, END will appear. When END appears, press
MODE to exit.
F18L09C 1
1. When END appears, press MODE to exit
F18L09D 1 – Check all fuses.

1. Press 5 times to activate display of P-codes (onboard diagnostic) – Check fuel rail pressure.
– Check spark plugs condition.
– Check fuel pump pressure.
– Check all connections of the wiring harness.
– Refer to COMPONENT INSPECTION AND AD-
JUSTMENT section for procedures.
SMR2002-079 _07-04A.FM 07-04-1
Terminology
Some documents or softwares use technical terms
that may be different from the one used in this man-
ual. The following table will help to find the equiva-
lence.
TERMS USED IN
TERMS USED
OTHER DOCUMENTS/
IN THIS MANUAL
SOFTWARES
MAPS
APS
(manifold air pressure
(air pressure sensor)
sensor)
MATS
ATS
(manifold air
(air temperature sensor)
temperature sensor)
CTS WTS
(coolant temperature (water temperature
sensor) sensor)
EGT ETS
(exhaust gas (exhaust temperature
temperature) sensor)
TOPS valve
(tip-over protection Blow-by valve
system)
- DLA
(digital linear actuator)
Idle bypass valve
- Idle actuator
- Idle valve
OSPS OTPS
(oil separator pressure (oil tank pressure
switch) switch)
DESS auxiliary module DESS ECU
Safety lanyard Key

Information center Cluster
07-04-2 SMR2002-079 _07-04A.FM
SELF-DIAGNOSTIC MODE
Refer to the following chart. For other problems, refer to COMPONENT INSPECTION AND ADJUSTMENT
section.
CODED SIGNALS POSSIBLE CAUSE REMEDY
2 short beeps • Confirms safety lanyard signal operation. Engine can be started.
(while installing safety
lanyard on post). • Safety lanyard is recognized by the EMS ECU.
• Good contact between safety lanyard and DESS
post.
1 long beep • Bad DESS system connection. Reinstall safety lanyard cap correctly over post.
(while installing safety
lanyard on watercraft • Wrong safety lanyard. Use a safety lanyard that has been
post). programmed for the watercraft. If it does not
work, check safety lanyard condition with
BUDS. Replace safety lanyard if reported
defective.
• Defective safety lanyard. Use another programmed safety lanyard.
• Dried salt water or dirt in safety lanyard cap. Clean safety lanyard cap to remove salt water.
• Defective DESS post. Refer to ENGINE MANAGEMENT section.
• Improper operation of EMS ECU or defective wir- Refer to ENGINE MANAGEMENT section.
ing harness.
1 short beep followed • EMS ECU has been set to onboard diagnostic Remove and reinstall safety lanyard or press
by 1 long beep. mode. MODE button twice to exit that mode.
2 very short beeps • Safety lanyard has been left on its post without To prevent battery discharge, remove the
every 3 seconds starting engine or after engine was stopped. safety lanyard from its post.
interval for 4 hours.
A 2 seconds beep • High pressure in oil separator tank. Refer to LUBRICATION SYSTEM section.
every minute interval.
• Low fuel level. Refer to INSTRUMENTS AND ACCESSORIES
section.
• Fuel tank level sensor or circuit malfunction. Refer to INSTRUMENTS AND ACCESSORIES
section.
A 2 seconds beep • Watercraft is upside down. Turn watercraft upright. If it does not work,
every 15 minutes check the TOPS switch. Refer to ENGINE
interval. MANAGEMENT section.
• Engine coolant temperature sensor or circuit mal- Refer to ENGINE MANAGEMENT section.
function.
• Exhaust temperature sensor or circuit malfunction. Refer to ENGINE MANAGEMENT section.
• Engine oil pressure sensor or circuit malfunction. Refer to ENGINE MANAGEMENT section.
• Low pressure in oil separator tank (engine oil leak). Refer to ENGINE MANAGEMENT section.
• TOPS sensor or circuit malfunction. Refer to ENGINE MANAGEMENT section.
• TOPS valve solenoid or circuit malfunction. Refer to ENGINE MANAGEMENT section.
• EMS ECU failure. Refer to ENGINE MANAGEMENT section.
• Bilge pump circuit low or high voltage Refer to ENGINE MANAGEMENT section.
(if so equipped).
• Starter solenoid circuit malfunction. Refer to ENGINE MANAGEMENT section.
• Communication link fault detected by MPEM. Refer to ENGINE MANAGEMENT section.
• EMS ECU communication link message missing Refer to ENGINE MANAGEMENT section.
(detected by MPEM).
• Information center communication link message Refer to ENGINE MANAGEMENT section.
missing (detected by MPEM).
Continuously beeps. • High engine temperature coolant. Refer to COOLING SYSTEM.
• High exhaust temperature. Refer to COOLING SYSTEM.
SMR2002-079 _07-04A.FM 07-04-3
VCK
(vehicle communication kit)
Kw2000
The VCK (Vehicle Communication Kit) (P/N 529
035 844) is the primary tool to diagnose engine
management and fuel injection related problems. F18H0WA
NOTE: The MPEM programmer does not work on ONLY ONE “ECU” IS WORKING. THERE IS A PROBLEM
4-TEC models. If an “X” is shown, the safety lanyard is not in-
The 4-TEC requires B.U.D.S. version 1.1 or above. stalled on its post or there is a problem with both
B.U.D.S. diskettes are available under P/N 529 035 “ECUs“. Ensure VCK is working properly and
845 and CD-ROM under P/N 529 035 886. check connections on VCK and watercraft.
B.U.D.S. (Bombardier utility and diagnostic soft-
ware) is designed to allow actuators, sensors and VCK supply
electronic equipments inspection, diagnostic op- The VCK (MPI box) can use the watercraft power
tions and reset such as the closed throttle and idle for its supply.
actuator. The safety lanyard must be connected in order to
For more information pertaining to the use of the use the watercraft as a power source.
software B.U.D.S., use its help which contains de- If watercraft power is used, every time the safety
tailed information on its functions. lanyard is taken off the DESS post, the KW2000
protocol will have to be re-activated.
 WARNING
If the computer you are using is connected to Changes in EMS ECU
the 110 Vac power outlet, there is a potential
Anytime a change is brought in EMS ECU through
risk of electrocution when working in contact
B.U.D.S., there will be an “EMS Tracking” mes-
with water. Be careful not to touch water
sage that will say “Remove key from vehicle“.
while working with the VCK.
When this occurs, remove the safety lanyard from
IMPORTANT: When using the software B.U.D.S., its post and wait until the message disappears (it
with the 4-TEC engines, ensure that the protocol lasts approximately 15 seconds after lanyard re-
“KW2000” is properly selected in “MPI” under moval).
“Choose protocol”.
When B.U.D.S. is connected with MPEM and
4-TEC SYSTEM FAULT CODES
EMS ECU, the status bar shows the protocol
(KW2000) and a number 1 or 2 to the right. To work
General
with the watercraft, number 2 must be displayed. The faults registered in the MPEM/EMS ECU are
Number 2 means that 2 “ECUs” are connected kept when the battery is disconnected.
(MPEM and EMS ECU). IMPORTANT: After a problem has been solved,
ensure to clear the fault(s) in the MPEM/EMS ECU
using the VCK. This will properly reset the appro-
priate counter(s). This will also records that the
Kw2000 problem has been fixed in the MPEM/EMS ECU
memory.
F18H0XA Many fault codes at the same time is likely to be
MPEM AND EMS ECU ARE CONNECTED burnt fuse(s).
Number 1 means that 1 “ECU” is connected (ei- For more information pertaining to the code faults
ther MPEM or EMS ECU). Therefore, there is a (state, count, first, etc.) and report, refer to B.U.D.S.
problem. Check fuses and connections. online help.
07-04-4 SMR2002-079 _07-04A.FM
Supplemental Information for Some

Specific Faults
Communication link fault code 1681: Sometimes
the information center does not synchronize fast
enough for the MPEM. That brings this fault code.
Simply clear the fault and try again.
EMS ECU fault codes P0601, P0602, P0604 and
P605: These codes may occur in the following sit-
uations:
– Electrical noise is picked up by the EMS ECU.
Ensure that all connections are in good condi-
tion, also grounds (battery, EMS ECU, engine
and ignition system), they are clean and well
tightened and that all electronic components
are genuine — particularly in the ignition sys-
tem. Installing resistive caps, non-resistive
spark plugs or knock sensor wiring/routing may
lead to generate this fault code.
– Electrical noise might also lead engine to occa-
sional cutout without generating a fault code
when engine is restarted. When looking at the
fault code, pay attention to the “count” value in
the software B.U.D.S. A value between 1 and 9
confirms an electrical noise problem. A value of
10 and above will generate a fault code.
– When installing a new EMS ECU. It is not proper-
ly programmed from the factory. The EMS ECU
must be returned to be properly “activated”.
– If everything is in good condition, try a new EMS
ECU.
When using the service action suggested in the
Fault section of B.U.D.S., the system circuits are
referred as 4-23 for instance. It means Amp con-
nector no. 4 and the circuit wire no. 23 as found in
the wiring diagram.
When they are referred as A-41, it means connec-
tor “A” on the EMS ECU and the circuit 41.
TPS (Throttle Position Sensor) Faults

Faults which are reported in B.U.D.S. fall into two
groups TPS faults and adaption faults. These are
displayed on the B.U.D.S. system as TPS OUT OF
RANGE and TPS ADAPTION FAILURE.
SMR2002-079 _07-04A.FM 07-04-5
TPS “OUT OF RANGE” Fault

It is caused by the sensor reading going out of its allowable range. This fault can occur during the whole
range of movement of the throttle.
To diagnose this fully, it is recommended to operate the throttle through its full range. It is also recom-
mended to release the throttle quickly as this may also show up a fault that is intermittent.

Check if connector is disconnected from TPS Yes • Fix.
• Fix and reset Closed Throttle and

Check if sensor is loose Yes Idle Actuator.
• Replace and reset Closed Throttle and

Inspect sensor for damage or corrosion Yes
Idle Actuator.
Inspect wiring (voltage test) Failed • Repair.
• If bad wiring, repair.

Inspect wiring and sensor (resistance test) • If bad TPS, replace and
Failed reset Closed Throttle and Idle Actuator.
• Replace and reset Closed Throttle and

Test sensor operation (wear test) Idle Actuator.
TPS “ADAPTATION FAILURE” Fault

It is caused by the idle position moving out of an acceptable range.
Following failures can be effected by a TPS “Adaption Failure“:
– Idle speed is out of range.
– Engine stops, when throttle is released quickly.
– Engine runs inconsistent in low partload or low RPM.
Sensor has been replaced and TPS closed

Yes • Reset Closed Throttle and Idle Actuator.
position not reset
Throttle body has been replaced and TPS

closed position not reset
EMS ECU has been replaced and TPS closed
position not reset
Throttle cable too tight Yes • Fix and reset Closed Throttle and
Idle Actuator.
Sensor is loose Yes • Fix and reset Closed Throttle and

Idle Actuator.
Throttle bracket is loose Yes • Fix and reset Closed Throttle and
Idle Actuator.
Adjustment screw worn or loose Yes • Change throttle body.

• Reset Closed Throttle and Idle Actuator
Idle bypass valve replaced but not reset Yes
using B.U.D.S.
07-04-6 SMR2002-079 _07-04A.FM
Section 08 COOLING SYSTEM
TABLE OF CONTENTS 0
CIRCUIT, COMPONENTS AND CARE................................................................................... 08-02-1
CIRCUIT .............................................................................................................................. 08-02-6
COMPONENTS .................................................................................................................. 08-02-8
CARE .................................................................................................................................. 08-02-12
CIRCUIT .............................................................................................................................. 08-02-13
COOLING SYSTEM LEAK TEST........................................................................................ 08-02-13
INSPECTION ...................................................................................................................... 08-02-15
DRAINING THE SYSTEM .................................................................................................. 08-02-15
COOLANT REPLACEMENT ............................................................................................... 08-02-15
COOLANT PUMP HOUSING............................................................................................. 08-02-17
THERMOSTAT ................................................................................................................... 08-02-18
COOLANT PUMP IMPELLER ............................................................................................ 08-02-18
ROTARY SEAL ................................................................................................................... 08-02-19
CARE .................................................................................................................................. 08-02-21
SMR2002-095_08-01ATOC.FM 08-01-1
Subsection 02 (CIRCUIT, COMPONENTS AND CARE)
CIRCUIT, COMPONENTS AND CARE 0

DI engines
Pipe
Pipe sealant
sealant
Pipe
sealant
Pipe
sealant
Pipe
sealant
Pipe
sealant
Loctite
243
3 Body
Silicone
sealant
2
4
Pipe
7 sealant
0.11 Nm
(1 lbfin)
8
0.6 Nm Loctite

(5 lbfin) 6 243
5 Nm
(44 lbfin) 5
F18E1NS
SMR2002-080_08_02A.FM 08-02-1
4-TEC Engines - Closed loop system
4
6
7
2 5
14
8 15
13
11
10
9
12
F18E0ZS
08-02-2 SMR2002-080_08_02A.FM
4-TEC Engines - Open loop system
F18E1DS
SMR2002-080_08_02A.FM 08-02-3
Water injected in Water flows through water jackets Water flows through
F12E09S
the tuned pipe to cool the magneto area and the crankcase water jackets to cool the
08-02-4
Water injected
controlled by the Temperature air compressor into muffler to
water flow sensor cool exhaust
DI Engines
regulator valve for activates Crankcase components
noise reduction monitoring
and performance beeper when Temperature
improvement temperature Magneto cover Air sensor activate
exceeds compressor monitoring
Water flows out 80°C (176°F) beeper when
of tuned pipe temperature
water jacket exceeds
100°C (212°F)
Quick
connect
hose fitting
for easy
engine
draining
Drain hose
Engine water (lowest point
supply hose of circuit)
from jet
pump
Cooling
System
GTX DI Indicator
routing (CSI)
GTX DI
RX DI
routing
Engine water
Water flows out of exhaust return hose
manifold water jacket and through from tuned Bleed hose Air
Side of hull pipe water (upper point compressor
tuned pipe water jacket before Cooling System
exiting the tuned pipe jacket of circuit) silencer
Indicator RX DI
SMR2002-080_08_02A.FM
(CSI)
4-TEC engines
Coolant temperature sensor (CTS)

activates when temperature exceeds
100°c (212°f)
Expansion
coolant tank
Bleed hose from

cylinder head to
expansion coolant tank
Coolant housing
including thermostat
opens at 87°c/(188°f)
and coolant pump
impeller
Ride plate Coolant flows

(operates as heat to ride plate
exhanger)
Coolant flows
to oil cooler
Oil cooler
Coolant returns Coolant returns
from ride plate from oil cooler
F18E0WS
SMR2002-080_08_02A.FM 08-02-5
DI engines Water circulates through the one piece cylinder

head which features improved combustion cham-
CIRCUIT ber and better spark plug cooling.
CAUTION: All hoses and fittings of the cooling

system have calibrated inside diameters to as-
sure proper cooling of the engine. Always replace
using appropriate Bombardier part number.
The water supply is provided by a pressurized area
in the jet pump between the impeller and venturi.
The water flow is controlled by a reducer located
between the jet pump support and the jet pump
on the inlet side. The reducer is blue on the DI mod-
els.
The water is entering the engine by the water inlet
fitting at the cylinder head. F06D21A
1 Water enters cylinder block water jackets and is

directed to the water jackets of the exhaust man-
ifold and tuned pipe head through passages locat-
ed above and below exhaust ports.
F08E05A
1. Water supply hose
Water from inlet hose also supplies the water reg-

F06D20A 1
ulator on muffler and magneto cover and crankcase
cover. 1. Water passages
Water then is expulsed through the pump support

drain.
08-02-6 SMR2002-080_08_02A.FM
Water exits tuned pipe water jackets through an Bleeding of the cooling system is accomplished by
outlet fitting. the bleed hose located at the uppermost point of
the circuit at the tuned pipe. The bleed hose also
serves as the Cooling System Indicator (CSI).
F06E08A 1
1. Engine water outlet F06E0BA 1
Water circulates in the water outlet hose and is 1. Bleed hose
expelled out of the cooling system through a fit- The water supply of the water flow regulator is pro-
ting located in the jet pump support on the tran- vided by the water supply hose coming from the
som of the watercraft. pump.
Water flows out of tuned pipe water jacket from
upper fitting of tuned pipe and is directed to the
air compressor, then to the air silencer at the tran-
som.
Water continues to flow in the crankcase water
jacket to cool the crankcase area to then be ex-
pulsed to the transom area.
Draining of the cooling system is accomplished by
the drain hose connected to a fitting at the bottom
of the cylinder-block, on tuned pipe side.
F06E09A 1
1. Water flow going to CSI
F06E0IA 1
1. Drain hose
SMR2002-080_08_02A.FM 08-02-7
The lower hose of the valve is the water supply COMPONENTS

and the upper hose is the regulated injection water
for the tuned pipe. Clamp
To cut or secure non-reusable Oetiker clamps of
cooling system hoses, use pliers (P/N 295 000 070).
1
3
F06E0CA
1. Water from engine water supply hose

2. Regulated injection water to the tuned pipe
3. Muffler 2
F01B2KA
Regulated water is injected in the tuned pipe by a
calibrated fitting. 1. Cutting clamp
2. Securing clamp
Elbow Fitting
Water injection used on exhaust system cools the
exhaust gases to obtain maximum performance
from the tuned pipe. The elbow fitting no. 1 has a
calibrated inside diameter to optimize water flow
in tuned pipe.
The water injection also helps in reducing noise
level and cools components of the exhaust sys-
tem.
CAUTION: The elbow fittings are calibrated and
can not be interchanged with one of a different
size as severe engine damage could result.
F06E0AA 1
1. Injection fitting
08-02-8 SMR2002-080_08_02A.FM
The elbow fitting can be identified by using the The water flow regulator valve no. 2 is mounted
number stamped onto the fitting or by measuring directly onto the muffler.
its inside diameter. Refer to the following illustra-
tion and chart.
16
A
F01E1FA 3 1 2
F00E04A
B
TYPICAL
1. Stamped number 1. Water supply hose of regulator valve
A. Outlet diameter = 4.6 mm (.181 in) 2. Regulated water to injection fitting
B. Inlet diameter = 5.5 mm (.219 in) 3. Water injected into the muffler
STAMPED
NOTE: The water injected into the muffler is not
NUMBER FITTING INLET OUTLET regulated by the valve. A calibrated water injection
ON P/N DIAMETER DIAMETER fitting of 4.0 mm (.156 in) inside diameter limits
FITTING water flow into the muffler.
The water flow regulator valve has a calibrated
5.5 mm 4.6 mm
16 293 700 016
(.219 in) (.181 in)
spring and a tapered needle which regulate the
injected water in the tuned pipe.
CAUTION: Do not change anything on the wa-
Water Flow Regulator Valve ter flow regulator valve, otherwise serious en-
A water flow regulator valve is mounted so that gine damage can occur. In many countries it is
they can produce the maximum horsepower out- illegal to tamper with this valve as this will af-
put and yet maintain the necessary diameter of fect the EPA certification.
the injection fitting at the tuned pipe head for un- At low speed, water pressure in the supply hose
obstructed water flow. of the regulator valve is not sufficient to overcome
the spring of the regulator valve; more water is
being delivered to the injection fitting at the tuned
pipe.
SMR2002-080_08_02A.FM 08-02-9
Adjustment
The water flow regulator valve has been calibrated
at the factory and should not be modified.
NOTE: Water flow regulator valves ordered from
the parts channel are also calibrated. The valve cap
on the is sealed and it is not adjustable.
If the maximum engine speed cannot be attained
or if the engine has poor performance, the water
flow regulator valve should be considered in the
2 troubleshooting of the problem.
Disassembly
1 Remove the cover no. 4 of the valve by releasing
the spring no. 3.
 WARNING
Firmly hold cover to valve base. The spring
3 inside the valve is applying a pressure against
F01E2BA
the cover.
LOW SPEED OPERATION
1. Water entering regulator valve
2. Water exiting regulator valve (less restriction)
3. Water injected in the muffler
At higher speed, water pressure increases in the

supply hose of the regulator valve and gradually
overcomes the return spring of the regulator valve. 1
Less water is being delivered to the injection fitting
at the tuned pipe.
F01E1RA
1. Spring
2. Cover
F01E2CA
3
HIGH SPEED OPERATION

1. Water entering regulator valve
2. Water exiting regulator valve (more restriction)
3. Water injected in the muffler
08-02-10 SMR2002-080_08_02A.FM
Remove fitting no. 5 from valve housing. Remove the tapered needle from valve housing.
1
1
F01E1SA F01E20A
1. Fitting 1. Remove tapered needle
Unscrew the tapered needle no. 6. Pull the valve slightly. Using pliers, release the clamp
NOTE: Hold the valve to prevent it from turning. which retains the bellows no. 8.
Remove valve no. 7 and bellows no. 8.
F01E1TA
F01E21A
1. Tapered needle
Loosen clamp to separate valve from bellows.
F01E24A 1
1. Clamp
SMR2002-080_08_02A.FM 08-02-11
Inspection When towing your watercraft in water, pinch the

Inspect parts for damage. Verify especially bellows water supply hose from the jet pump housing to the
for cracks. engine with a large Hose Pincher (P/N 529 032 500).
Assembly
Assembly is essentially the reverse of disassembly
procedures.
CARE
For flushing purposes, the cooling system is equipped
with hose adapter.
A garden hose is used to flush the whole system by
backwash. For flushing procedure, refer to FLUSH-
ING AND LUBRICATION.
F01B23A
For winterization of cooling system, refer to STOR-
AGE.
This will prevent the cooling system from filling
When servicing the hull, always rotate watercraft which may lead to water being injected into and
clockwise (seen from the rear). Rotating water- filling the exhaust system. Without the engine run-
craft on the opposite side could allow residual wa- ning there isn’t any exhaust pressure to carry the
ter in tuned pipe to enter the engine and cause water out the exhaust outlet.
damage.
CAUTION: Failure to do this may result in dam-
age to the engine. If you must tow a stranded wa-
max. 90° tercraft in water and do not have a hose pincher
be sure to stay well below the maximum towing
speed of 24 km/h (15 MPH).
Snugly install the hose pincher on the water sup-
ply hose as shown in the following illustrations.
F06L0GA
Towing the Watercraft in Water F18E01A 1

Special precautions should be taken when towing 1. Hose pincher on water supply hose on this side of the T-fitting
a Sea-Doo watercraft in water.
CAUTION: When finished towing the watercraft,
Maximum recommended towing speed is 24 km/h the hose pincher must be removed before oper-
(15 MPH). ating it.
08-02-12 SMR2002-080_08_02A.FM
1503 engines CAUTION: Never modify cooling system arrange-

ment, otherwise serious engine damage could
CIRCUIT occur.
Closed Loop System
Pressure Cap
A closed loop cooling system is utilized on the
1503 4-TEC engines, which offers an efficient en- Check if cap pressurize the system. if not, install
gine cooling while keeping dirt and salt water out a new 90 kPa (13 PSI) cap (do not exceed this pres-
of the cooling system. This system keeps the tem- sure).
perature constant and prevents internal engine
corrosion. COOLING SYSTEM LEAK TEST
A separate coolant expansion tank ensures that
enough engine coolant is in the circuit during any  WARNING
operating condition. To prevent burning yourself, do not remove
The coolant flow comes from the coolant pump the expansion tank cap or loosen the ride-
impeller into the engine block. It goes around the plate drain plug if the engine is hot.
cylinders and straight up to the cylinder head. A
Install test radiator cap (P/N 529 021 400) and hose
smaller quantity of engine coolant enters the en-
pincher (P/N 295 000 076) on overflow hose. Pres-
gine block on the exhaust side for a better cooling.
surize all system through coolant expansion tank
In the cylinder head the water channels flow
to 90 kPa (13 PSI).
around the exhaust and then the intake valves and
leave the engine through a large hose. From there
the coolant goes back to the water pump housing
and depending on the engine temperature, it
flows through the thermostat directly back to the 2
water pump impeller, or it takes its way through
the ride plate which operates as a heat exchanger.
A smaller quantity of engine coolant is also direct-
ed towards the oil cooler, which is located under
the air intake manifold, to increase cooling effi-
ciency.
Coolant temperature sensor and bleed nipple are
located on the cylinder head.
1 F18E1IA 1
1. Hose pincher
2. Pressure pump (P/N 529 021 800)
2
Check all hoses, ride plate, engine and oil cooler for
coolant leaks. Spray a soap/water solution and look
for air bubbles.
Remove hose pincher and test pressure cap.
Open Loop system

The water supply is provided by a pressurized area
in the jet pump between the impeller and venturi.
F18E0XA The water flow is controlled by a reducer located
1. Bleed nipple between the jet pump support and the jet pump
2. Coolant temperature sensor (CTS) on the inlet side. The reducer is black on the 4-TEC
models.
SMR2002-080_08_02A.FM 08-02-13
Water is directed to the exhaust manifold fitting Water enters exhaust pipe and flows in the water
located at front of manifold. jacket of pipe.
3 1
F18E1FA 2
1. Exhaust manifold
2. Water inlet
3. Water outlet
Water enters the manifold end and is directed to

water jackets of exhaust manifold.
Water exits exhaust manifold through 2 hoses at 2
rear manifold.
3 2 1
F18E1GA
1. Exhaust pipe
2. Outlet holes of exhaust pipe
3. Muffler
Bleeding of the exhaust system is accomplished

by the bleed hose located at the upper most point
of the circuit of the exhaust pipe.
Water exits exhaust pipe through holes at the end
of the water packet and mixes with exhaust gas
in the muffler.
F18E1EA
Water is expulsed from mufflers then through the
1. Water coming from exhaust manifold exhaust outlet in transom area.
2. Exhaust pipe
3. Bleed hose
08-02-14 SMR2002-080_08_02A.FM
Clamp DRAINING THE SYSTEM

To cut or secure non-reusable Oetiker clamps of
cooling system hoses, use pliers (P/N 295 000 070).  WARNING
Never drain or refill cooling system when en-
gine is hot.
Remove expansion tank cap.

To drain cooling system, unscrew cooling system
drain plug at the rear of ride plate.
2
F01B2KA
1. Cutting clamp
2. Securing clamp
INSPECTION F18E1JA 1
Check general condition of hoses and clamp tight- 1. Cooling drain plug
ness.
Use an appropriate container to collect coolant.
Check the weep hole if there is oil or coolant. Dispose coolant as per local regulations.
Do not reinstall drain plug at this time.
COOLANT REPLACEMENT
Recommended Coolant
Use a blend of 50% antifreeze with 50% water.
Premixed antifreeze/water is available (P/N 293 600
038).
To prevent antifreeze deterioration, always use the
same brand. Never mix different brands unless cool-
ing system is completely flushed and refilled.
Do not reinstall pressure cap.
F18E1CA 1 CAUTION: To prevent rust formation or freez-
1. Weep hole ing condition in cold areas, always replenish the
system with 50% antifreeze and 50% water.
NOTE: Flowing coolant indicates a damaged rota- Pure antifreeze will freeze at a higher tempera-
ry seal. Oil out of the weep hole indicates a non ture than the optimal water/antifreeze mix. Al-
working oil seal. ways use ethylene glycol antifreeze containing
corrosion inhibitors specifically recommended
for aluminum engines.
System Capacity
Refer to TECHNICAL DATA.
SMR2002-080_08_02A.FM 08-02-15
Coolant Replacement Procedure Continue to pour and fill expansion tank between
marks.
 WARNING
To prevent burning yourself do not remove
the expansion tank cap or loosen the ride
plate drain plug if the engine is hot.
Drain the system completely as described above.

Watercraft should be level, engine cold and drain
plug removed for refilling.
Place a container under drain plug to collect anti- 1
freeze.
Ask someone to pour antifreeze in expansion tank
while watching antifreeze and air bubble flowing out
through drain hole. When no air bubbles escape, re-
install drain plug. Torque to 8.3 N•m (73 lbf•in).
F18E0NA
1. Level between marks when engine is cold

1
Do not install pressure cap at this time.
Properly cool exhaust system by installing a gar-
den hose. Refer to flushing in MAINTENANCE
Section.
Start engine and let run for 2 minutes. Stop engine
and wait 15 minutes to cool down. Refill tank as
necessary.
Repeat this run-stop cycle 2-3 times until thermo-
F18E1LA
stat opens and stop engine.
1. Pour antifreeze/water mix in expansion tank
Last, refill expansion tank and install cap.
When engine has completely cooled down, re-
check coolant level in radiator and coolant tank and
top up if necessary.
Test the density of the coolant using an antifreeze
hydrometer.
1 NOTE: Follow hydrometer manufacturer instruc-
tions for proper use.
The reading should be some degrees below the
coldest temperature you expect in the area where
the watercraft is to be used. Add water or anti-
freeze accordingly. Refill to the proper level.
F18E1KA
CAUTION: Pure antifreeze will freeze at a high-
er temperature than the optimal water/anti-
1. Watch air bubbles flowing here freeze mix.
08-02-16 SMR2002-080_08_02A.FM
COOLANT PUMP HOUSING Check if thermostat is in good condition. Refer to

THERMOSTAT elsewhere in this section.
Installation
cedure. Install screws as per the following illustra-
tion.
2 2 1
1
1 1
F18E0YA
1. Coolant pump housing
Removal 1
Drain cooling system and engine oil, refer to LU-
BRICATION SYSTEM.
F18E10A 1 1
Remove from housing:
1. Screw M6 x 25
– ride plate inlet and outlet hoses 2. Screw M6 x 105
– cylinder head outlet hose no. 1 CAUTION: To prevent leaking, take care that
– oil cooler inlet hose no. 2 the gaskets are exactly in groove when you re-
install the coolant pump housing.
– oil cooler outlet hose no. 3
Apply Loctite 243 on screw threads and torque to
– screws no. 4 and no. 5 retaining coolant pump 10 N•m (88 lbf•in).
housing no. 6
Tightening sequence for screws on coolant pump
– coolant pump housing no. 6. housing is as per following illustration.
Inspection 7 8 1
Check if gasket no. 7 is brittle, hard or damaged
and replace as necessary.
1 6
5
F18E10B 2 3
F18E11A
1. Weep hole pump housing gasket
SMR2002-080_08_02A.FM 08-02-17
THERMOSTAT Dynamic Test

The thermostat is a single action type. To check the operation of the thermostat, put it in
water and heat water. Look inside the cylinder
Removal head return hose connection to see the move-
ment of the thermostat. Thermostat should open
Remove the coolant pump housing from the PTO when water temperature reaches 87°C (188°F).
cover. Refer to COOLANT PUMP HOUSING RE-
MOVAL elsewhere in this section. If there is no operation, replace coolant pump
housing and thermostat.
NOTE: The thermostat is located inside the cool-
ant pump housing. Installation
Leak Test For installation, reverse the removal procedure,
paying attention to the following details.
Plug the connections of the oil cooler return hose,
coolant tank hose, ride plate return hose and cyl- Refer to COOLANT PUMP HOUSING REPLACE-
inder head return hose with a rag. MENT in this section.
COOLANT PUMP IMPELLER

Removal
Remove:
– coolant pump housing no. 6
– unscrew the impeller no. 8 clockwise.
4 1
F18E12A 1 3
1. Oil cooler return connection
2. Coolant tank hose connection
3. Ride plate return hose connection
4. Cylinder head return hose connection
F18E13A
Fill the coolant pump housing with water.
1. Impeller
If a bigger quantity of coolant leaks out at the ride
plate outlet connection, replace the coolant pump CAUTION: Coolant/Oil pump shaft no. 9 and
housing. Refer to COOLANT PUMP HOUSING in impeller no. 8 have left-hand threads. Remove
this section. by turning clockwise and install by turning
If there is no leak, check the operation of the ther- counterclockwise.
mostat.
Inspection
Check impeller for cracks or other damage. Replace
impeller if damaged.
08-02-18 SMR2002-080_08_02A.FM
Installation 2
cedure. Pay attention to the following details.
CAUTION: Be careful not to damage impeller
wings during installation.
Torque impeller to 3 N•m (26 lbf•in).
ROTARY SEAL 1
Inspection
Check weep hole for oil or coolant leak.
F18E14A
1. Retaining screws
2. Oil pump cover
– remove oil pump cover no. 12

– remove outer oil pump rotor no. 13
1
F18E1CA 1
1. Weep hole
Coolant leaking out of the hole indicates a defective

rotary seal. Leaking oil indicates a faulty oil seal.
However, if seal is disassembled both parts have
to be replaced together.
F18E15A
Removal 1. Outer oil pump rotor

Remove:
– coolant pump housing no. 6
CAUTION: Always unscrew the impeller clock-
wise otherwise you can damage the compo-
nents.
– unscrew the impeller no. 8 clockwise
– remove PTO cover no. 10. Refer to PTO HOUS-
ING/MAGNETO Section
– remove screws no. 11 retaining oil pump cover
SMR2002-080_08_02A.FM 08-02-19
– extract the coolant/oil pump shaft no. 9 from Installation

outside PTO housing cover with a pusher
cedure. Pay attention to the following details.
1
2 NOTE: Never use oil in the press fit area of the oil
seal and rotary seal.
Push water pump shaft oil seal in place by using
thumb.
Install the new rotary seal using the rotary seal in-
staller P/N 529 035 823.
CAUTION: Never use a hammer for the rotary
seal or water/oil pump shaft installation. Only
use a press to avoid damaging the ceramic
component.
F18E16A
2 1
1. Pusher
– remove Rotary Seal no. 14 with a screwdriver
F18E19A
1. Rotary seal
2. Rotary seal installer
F18E17A
Install the coolant/oil pump shaft using the rotary
CAUTION: Be careful not to damage the surface of seal installer P/N 529 035 823 on the opposite side
the rotary seal bore in magneto housing cover. to the rotary seal and the oil seal protector P/N 529
035 822 with a press.
– always replace also the oil seal no. 15 behind
the rotary seal. 2 1
F18E1AA
1. Oil seal protector

F18E18A
1. Oil seal
08-02-20 SMR2002-080_08_02A.FM
This will prevent the exhaust cooling system from

1 filling which may lead to water being injected into
and filling the exhaust system and the engine.
Without the engine running there isn’t any ex-
haust pressure to carry the water out the exhaust
outlet.
CAUTION: Failure to do this may result in dam-
age to the engine. If you must tow a stranded wa-
tercraft in water and do not have a hose pincher
be sure to stay well below the maximum towing
2 speed of 24 km/h (15 MPH).
F18E1BA
Snugly install the hose pincher on the water sup-
ply hose as shown in the following illustrations.
1. Coolant/oil pump shaft with oil seal protector
2. Rotary seal installer
CARE
For flushing purposes, the exhaust cooling system is
equipped with a hose adapter.
To connect to the fitting spigot. A garden hose is
used to flush the whole system by backwash. For
flushing procedure, refer to FLUSHING AND LU-
BRICATION.
For winterization of cooling system, refer to STOR-
AGE.
When servicing the hull, rotate watercraft either
way (seen from the rear) maximum to 90°.
Towing the Watercraft in Water

Special precautions should be taken when towing
a Sea-Doo watercraft in water.
Maximum recommended towing speed is 24 km/h
(15 MPH).
When towing your watercraft in water, pinch the
water supply hose from the jet pump housing to the
engine with a large Hose Pincher (P/N 529 032 500).
1
F18E0RA
1. Hose pincher
CAUTION: When finished towing the watercraft,

the hose pincher must be removed before oper-
ating it.
F01B23A
SMR2002-080_08_02A.FM 08-02-21
TECHNICAL DATA
TYPE:
Closed and open loop cooling system.
COOLANT FLOW:
Pressure build-up at coolant pump.
TEMPERATURE CONTROL:
Thermostat.
SYSTEM BLEEDING:
Self-bleed type through expansion tank
(hose at uppermost point of circuit).
SYSTEM DRAINING:
Self-drain type on the exhaust cooling system
(hose at lowest point of circuit).
SYSTEM FLUSHING:
Required only for exhaust cooling system
(open loop system).
MONITORING BEEPER:
Turns on at 100°C (212°F).
COOLANT LIFE CYCLE
2 years
08-02-22 SMR2002-080_08_02A.FM
TABLE OF CONTENTS 0
FUEL CIRCUIT........................................................................................................................ 09-02-1
GENERAL ........................................................................................................................... 09-02-3
REMOVAL........................................................................................................................... 09-02-3
INSPECTION ...................................................................................................................... 09-02-5
ASSEMBLY......................................................................................................................... 09-02-6
FUEL SYSTEM PRESSURIZATION ................................................................................... 09-02-6
AIR INTAKE ............................................................................................................................ 09-03-1

REMOVAL........................................................................................................................... 09-03-3
ASSEMBLY ........................................................................................................................ 09-03-4
SMR2002-095_09-01ATOC.FM 09-01-1
Subsection 02 (FUEL CIRCUIT)
FUEL CIRCUIT 0
947 DI Engines
6
7
16
4 Nm
(35 lbfin)
4
22 Nm 2.5 Nm
(16 lbfft) (22.12 lbfin)
8
5
13
4 Nm
4 (35 lbfin)
14
F12F0ZT
SMR2002-081_09_02A.FM 09-02-1
4-TEC Engines
22 Nm
(16 lbfft)
8
2.5 Nm
(22.12 lbfin)
4
4 Nm 5
(35 lbfin)
13
4 Nm
(35 lbfin)
4
14
F18F08S
09-02-2 SMR2002-081_09_02A.FM
GENERAL
 WARNING
The fuel system of a fuel injection system
hold much more pressure than on a carburet-
ed watercraft. Prior to disconnecting a hose
or to removing a component from the fuel
system, follow the recommendations de-
scribed in ENGINE MANAGEMENT under F01B04A 1
Fuel System.
1. Securing clamp
 WARNING
Whenever repairing the fuel system, always
verify for water infiltration in reservoir. Re-
place any damaged, leaking or deteriorated
fuel lines.
When working with fuel, pay attention to the fol-

lowing warning.
 WARNING
Fuel is flammable and explosive under cer-
tain conditions. Always work in a well venti- 1
F01B05A
lated area. Always wipe off any fuel spillage
from the watercraft. 1. Securing clamp in limited access
When replacing fuel lines on SEA-DOO water-

To secure or cut Oetiker clamps on fuel lines, use
craft, be sure to use “B1” hoses as available from
pliers (P/N 295 000 070).
Bombardier parts department. Use hoses ass’y
available as parts replacement only. This will en-
sure continued proper and safe operation.
 WARNING
Use of improper fuel lines could compromise
fuel system integrity.
REMOVAL
1 Fuel Filter
F01B03A
DI Models
1. Cutting clamp A replaceable inline filter is located near the fuel
tank. Another filter is located at the electric fuel
pump inlet. The pump has to be removed from the
fuel tank to have access to its filter. Refer to EN-
GINE MANAGEMENT (DI) section.
SMR2002-081_09_02A.FM 09-02-3
Disconnect MPEM connectors.

 WARNING Detach MPEM assembly and support from bilge.
The inline filter needs to be replaced only with
4 Oetiker clamps (2 on each side). Remove TOPS switch from electrical harness or
MPEM bracket.
CAUTION: A pressure test needs to be complete Remove air box. (Refer to AIR INTAKE SYSTEM
after replacement. sub-section.
Electric Fuel Pump From storage compartment disconnect fuel pump
connections.
Refer to appropriate ENGINE MANAGEMENT
Remove fuel pump from fuel tank. Refer to EN-
section.
GINE MANAGEMENT section.
Fuel Tank Detach reverse system support.
947 DI Engines
Remove electric fuel pump. Refer to the above sec-
tion.
Detach all fuel tank straps.
Pull out fuel tank.
4-TEC Engines
NOTE: It is necessary to remove the engine. Refer
to REMOVAL AND INSTALLATION sub-section.
Siphon fuel tank. 1
Use pliers to pull out darts and remove front ac-
cess panel.
F18F0BA
1. Screw
Remove battery. Refer to CHARGING SYSTEM

sub-section.
Disconnect fuel tank connections.
Cut locking ties as required to release wiring har-
ness.
Detach straps with hook tool (P/N 529 035 559).
Remove fuel tank from the vehicle.
 WARNING
Check that fiberglass is not exposed.
F18F0AA
1. Dart
09-02-4 SMR2002-081_09_02A.FM
INSPECTION Pressure Relief Valve

This valve will eliminate fuel spillage when the wa-
Fuel Filter Bowl tercraft is upside down. If pressure is built up in fuel
Check filter bowl for water contamination. system the valve should open at 3.5 kPa (0.5 PSI)
for DI.
Gasket
Inspect gasket condition. Make sure gasket no. 3  WARNING
is well positioned into the filter bowl no. 2. If pressure relief valve is stuck, the pressure
in fuel system will build up and it may cause
fuel leakage in engine compartment.
1
NOTE: It is a one-way valve with an arrow to indi-
cate the air flow.
Check Valve
Black side of the one-way check valve no. 7 is the
valve outlet. It allows air to get in reservoir.
Fuel Tank
Visually inspect the inside and outside of the fuel
tank necks for crack(s). If crack(s) are existing, re-
place fuel tank no. 14.
F01F02A
Check with your finger to feel the inside and out-
1. Gasket in bowl side surfaces of fuel tank. Flex fuel tank necks to
Inspect inline filter condition. Carefully use low ensure there are no hidden cracks.
pressure compressed air to clean. Replace if per- 4 2
manently clogged or damaged.
DI Models
NOTE: The fuel filter needs to be replaced after
250 hours. 1
All Models
The filter at fuel pump inlet is not replaceable indi-
vidually. The complete fuel pump unit has to be
3 A 5
replaced. F07F06A
1. Tank upper surface

Fuel Filler Hose 2. Inspect outside, above upper surface
3. Normal molding seam
Verify fuel filler hose no. 5 for damage. Always en- 4. Inspect inside, above upper surface
5. Base of the neck
sure that clamps no. 4 are well positioned and A. Approx. 4 mm (5/32 in)
tightened. Torque clamps to 4 N•m (35 lbf•in).
NOTE: A fuel tank is comprised of 3 components:
the tank, the fuel pick up neck and the filler neck.
The necks are injection molded and the tank is
then blow molded over the necks. During the
molding process, a small molding seam may ap-
pear on the inner side of the necks at approximate-
ly 4 mm (5/32 in) from the base of the neck. It is a
normal situation to have a molding seam and it
should not be confused with a crack.
Inspect rubber carpet under tank for damage.
SMR2002-081_09_02A.FM 09-02-5
ASSEMBLY FUEL SYSTEM PRESSURIZATION

bly procedures.  WARNING
Whenever doing any type of repair on water-
947 DI Engines craft or if any components of the fuel system
Install fuel pump on fuel tank and torque nuts to are disconnected, a pressure test must be
2.5 N•m (1.8 lbf•in). done before starting engine. Ensure to verify
fuel line ends for damage. Always cut dam-
2 aged end before reinstallation.
9
8
10 Pressure Test (supply and vent circuits)
Proceed as follows:
– Fill up fuel tank.
3
7 – Disconnect air inlet hose of fuel tank from body.
– Install a hose pincher (P/N 295 000 076) on fuel
11 tank vent hose.
RE
S
OU
T
12 1
1 2
F18F09A 5
TORQUE AS PER SEQUENCE
4-TEC Engines
Ensure rubber carpet is in place.
Insert tank, air box and straps. F01F0KA
Place straps in clips (bottom) and in guides of air-

TYPICAL
box. 1. Disconnect air inlet hose
Insert strap ends in hoops. Use tape to hold in 2. Install a hose pincher to vent hose
place. – Connect pump gauge tester (P/N 529 021 800)
Properly secure harnesses. to air inlet hose.
Reinstall fuel pump. Refer to ENGINE MANAGE- NOTE: This pump is included in the ENGINE LEAK
MENT section. TESTER KIT (P/N 295 500 352).
09-02-6 SMR2002-081_09_02A.FM
– Pressurize fuel system to 34 kPa (5 PSI).

– If no leaks are found, turn fuel valve to ON po-
sition and pressurize once more.
– If pressure is not maintained locate leak and
repair/replace component leaking. To ease leak
search spray a solution of soapy water on com-
ponents, bubbles will indicate leak location.
NOTE: The system must maintain a pressure of
34 kPa (5 PSI) during 10 minutes. Never pressurize
over 34 kPa (5 PSI).
Reconnect air inlet hose of fuel tank to body.
 WARNING
If any leak is found, do not start the engine
and wipe off any fuel leakage. Do not use
electric powered tools on watercraft unless
system has passed pressure test.
NOTE: Before removing the hose pincher, block

with your finger the outlet fitting to feel if air is
coming out when removing hose pincher. This will
indicate that pressure relief valve and the outlet
fitting are not blocked.
Remove hose pincher from fuel tank vent hose.
High Pressure Test (fuel pump circuit)

Refer to the appropriate ENGINE MANAGEMENT
section.
 WARNING
Prior to installing the safety lanyard, refer to
the appropriate ENGINE MANAGEMENT sec-
tion for safety precautions to take.
SMR2002-081_09_02A.FM 09-02-7
Subsection 03 (AIR INTAKE)
AIR INTAKE 0
947 DI Engines
Loctite 243
2
1112
Loctite 243
14 4
13
Super
Lube Loctite
243
3
F12F0KT
SMR2002-082_09_03A.FM 09-03-1
4-TEC Engines
1
14
4 Nm
(35 lbfin)
13
5
7
6
4
2
8 2
3
12
9
10
11
10
11
F18F0FS
09-03-2 SMR2002-082_09_03A.FM
REMOVAL Pull air ducts out.
947 DI Engines
Air Intake Silencer
Pull hair pin out to allow removal of clip no. 2.
1
F08F09A
1. Air duct
4-TEC Engines
F00F0FA
Disconnect connectors no. 1, no. 2 and no. 3.

1. Air intake silencer
2. Clip Detach straps no. 4 using hook tool (P/N 529 035
3. Hair pin
559).
Unlock the clip no. 2 on top of air intake silencer.
1 2 3
Remove bolts retaining both air ducts to engine (both
sides).
F18F0GA 4
1. Magneto connector
F08F08A 1 1 2.
3.
Voltage regulator connector
Fuse connector
4. Straps
1. Remove bolts
Loosen spring clamp no. 2 and remove formed
hose no. 3 from engine.
Loosen clamp no. 5 and remove intake hose no. 6
from engine.
SMR2002-082_09_03A.FM 09-03-3
ASSEMBLY Ensure the elbow adaptor is well inserted and that

it has not pushed the gasket inside the air box.
Assembly is essentially the reverse of removal
NOTE: Make sure the air intake silencer is retained
procedures. However pay particular attention to
by the lower bracket no. 4.
the following.
Place protector pads on duct supports. Use slot in
CAUTION: Do not modify air intake system,
rubber to insert pad on bracket eyelet. Side tongue
otherwise calibration will be affected.
of protector pad should be toward outside of vehi-
947 DI Engines cle and bent downward toward the exhaust flange.
Air Intake Silencer Put air ducts in intake adapters and secure them
on duct supports with hexagonal screws no. 13,
Ensure that support plate edges no. 14 are prop- wide washers, narrow washers and elastic stop
erly crimped to air intake silencer. Use pliers as nuts. A slight lift will be required to make the bolts
necessary. line up with brackets.
Make sure that gaskets no. 11 are installed into
4-TEC Engines
carburetor holes of air intake silencer or throttle
bodies. Air Intake Silencer
Check O-rings no. 12 on carburetor intake adap- Put air intake silencer in place over fuel tank.
tors or throttle bodies and change them if neces-
Fasten air intake silencer with straps no. 4, using
sary.
hook tool (P/N 529 035 559).
NOTE: Apply Super Lube grease (P/N 293 550
Attach intake hose no. 6 to engine and tighten
014) to mating surface of air intake silencer no. 1.
clamp no. 5 to 4 N•m (35 lbf•in).
Install air intake silencer on carburetor intake adap-
Attach formed hose no. 3 to engine and fasten
tor or throttle bodies and latch in place.
with spring clamp no. 2.
Clip air intake silencer back in place.
Attach connectors no. 1, no. 2 and no. 3.
Properly reinstall hair pin to secure clip no. 2.
09-03-4 SMR2002-082_09_03A.FM
Section 10 LUBRICATION SYSTEM (DI)
TABLE OF CONTENTS 0
OIL INJECTION SYSTEM ...................................................................................................... 10-02-1
GENERAL ........................................................................................................................... 10-02-2
OIL SYSTEM PRESSURIZATION ...................................................................................... 10-02-2
OIL INJECTION PUMP .......................................................................................................... 10-03-1

OIL PUMP IDENTIFICATION ............................................................................................. 10-03-2
REMOVAL........................................................................................................................... 10-03-2
DISASSEMBLY .................................................................................................................. 10-03-2
CLEANING ......................................................................................................................... 10-03-2
ASSEMBLY ........................................................................................................................ 10-03-2
ADJUSTMENT ................................................................................................................... 10-03-3
CHECKING OPERATION.................................................................................................... 10-03-4
SMR2002-095_10-01ATOC.FM 10-01-1
Subsection 02 (OIL INJECTION SYSTEM)
OIL INJECTION SYSTEM 0
Under Air
Compressor
27 Nm
(20 lbfft)
3.5 Nm 1
(31 lbfin)
3
2
3.5 Nm 1
(31 lbfin)
Dielectric
grease
4
F12G07S
SMR2002-083_10_02A.FM 10-02-1
Subsection 02 (OIL INJECTION SYSTEM)
GENERAL Disconnect oil tank vent line on PTO side throttle

body.
Whenever repairing the oil injection system, al-
Connect pump gauge tester (P/N 529 021 800) to
ways verify for water infiltration in reservoir.
disconnected tube at throttle body.
Perform also a pressure test of the oil injection
NOTE: Use the same pump included in the EN-
system.
GINE LEAK TESTER KIT (P/N 295 500 352).
Clamp and Hose 1
Verify oil filler neck hose no. 2 for damage. Always
ensure that clamps no. 1 are well positioned and
tightened. Torque clamps to 3.5 N•m (31 lbf•in).
Check Valve
Black side of the one-way check valve no. 3 is the
valve outlet. It allows air to get in reservoir.
Oil Filter
Oil filter no. 4 should be replaced annually. F01G0IA
TYPICAL
OIL SYSTEM PRESSURIZATION 1. Connect pump to check valve
 WARNING – Pressurize oil system to 21 kPa (3 PSI).

Whenever oil system components are dis- – If pressure is not maintained, locate leak and
connected or replaced, a pressure test must repair/replace component leaking. To ease leak
be done before starting engine. Ensure to ver- search spray a solution of soapy water on compo-
ify oil line ends for damage. Always cut dam- nents, bubbles will indicate leak location.
aged end before reinstallation. Verify check valve inside filler neck if pressure
does not hold. Also ensure air can enter through
check valve in the opposite direction.
Pressure Test
NOTE: The system must maintain a pressure of
Proceed as follows: 21 kPa (3 PSI) for at least 10 minutes. Never pres-
– Fill up oil reservoir. surize over 21 kPa (3 PSI).
– Install a hose pincher to oil injection pump sup- CAUTION: If any leak is found, do not start the
ply hose. engine and wipe off any oil leakage.
Install a hose pincher to return line of air compres- – Disconnect pump gauge tester and remove
sor. hose pinchers. Reconnect line at throttle body.
10-02-2 SMR2002-083_10_02A.FM
Subsection 03 (OIL INJECTION PUMP)
OIL INJECTION PUMP 0
To air compressor
(supply line)
Loctite 1 To crankcase
243
6 Nm
(53 lbfin) 6
4.5 Nm
(40 lbfin)
Molykote 111
7 4.5 Nm
(40 lbfin)
Throttle body
F12G01S
SMR2002-084_10_03A.FM 10-03-1
OIL PUMP IDENTIFICATION

Pump Lever
Different engines need different pumps. See identifi-
cation on lever.
CAUTION: Always mount proper pump on en-
gine.
OIL PUMP
ENGINE
IDENTIFICATION
947 09
NOTE: The following procedures can be done with-

out removing the engine from hull.
F12G02A
REMOVAL
Oil Injection Pump
The cable end has a slight press fit in the lever.
Using a small screwdriver, pry cable end out.
Disconnect oil injection pump cable no. 7.
Remove 2 Allen screws no. 6 with flat washers
retaining oil injection pump to magneto housing
cover.
Pull pump.
Disconnect oil hoses from fittings of oil injection
pump.
DISASSEMBLY
F12G03A
NOTE: Some oil pump parts are not available in
single parts. A gasket set is available for the pump.
If the pump is found defective, it should be replaced
by a new one.
CLEANING
Discard all seals and O-rings. Clean metal compo-
nents in a solvent.
ASSEMBLY
Oil Injection Pump and Shaft
Make sure shaft no. 8 is installed in crankshaft
end.
Install pump. Secure with flat washers and screws
F12G04A 2 1
no. 6. Torque to 6 N•m (53 lbf•in).
1. Cable end completely inserted
Install oil injection pump cable. 2. Cable end NOT seated on the steps
10-03-2 SMR2002-084_10_03A.FM
CAUTION: Ensure cable end is completely en-

tered in its housing. Ensure it is NOT seated on
the steps. 1
ADJUSTMENT
CAUTION: As oil injection pump adjustment is
dependent on throttle cable position, make
sure to perform throttle cable adjustment first
except if otherwise specified.
Preliminary Synchronization
NOTE: To check synchronization of pump as a rou-
tine maintenance, see FINAL SYNCHRONIZATION.
Turn oil pump cable adjustment nut to align refer-
ence marks on pump.
NOTE: A mirror may be used to facilitate this ver-
ification.
Loosen jam nut and turn cable adjustment nut to
obtain pump mark alignment. Refer to following
photos.
The adjustment is located under the throttle body
bracket.
F16G03B
1 2
1. Mark on pump must be facing longest mark on lever
Start and bring engine to normal operating temper-

ature.
must be cooled using the flush kit. If air bubbles
are present in the oil injection system, bleed
system before operating engine.
There is no idle speed adjustment to perform.
Stop engine.
Final Synchronization
F16F01A
Eliminate throttle cable free-play by depressing
throttle lever until a slight resistance is felt. In this
1. Oil pump cable adjustment
2. Throttle cable position, marks on pump body and lever must
align.
Adjust the cable to the rich position. Use the long-
est mark. If necessary, turn cable adjustment nut to obtain
pump mark alignment. Refer to above illustrations.
Tighten jam nut and recheck alignment marks.
CAUTION: Proper oil injection pump adjustment
is very important. Any delay in the opening of
pump can result in serious engine damage.
SMR2002-084_10_03A.FM 10-03-3
Bleeding 1
CAUTION: Oil injection system must be bled and
adjustment checked before operating engine.
Ensure oil injection reservoir is sufficiently filled.
Install a dry rag below oil injection pump.
Loosen bleed screw to allow oil to flow.
1
F07G06A 2
1. Lines must be full of oil
2. Oil pump
If not, proceed as follows.

– Use the VCK (Vehicle Communication Kit) P/N
529 035 676. Look in the Monitoring section of
the software B.U.D.S.
– Use the “Oil lines bleeding” function that al-
lows to “lock” the engine RPM in idle speed
while the throttle is fully depressed to ease the
bleeding operation.
F16G02A
– Since oil cannot be seen through the small oil
1. Bleed screw lines, press and hold the vehicle throttle to wide
Keep bleeding until all air has escaped from line. open position for 45 seconds.
Make sure no air bubbles remain in oil supply line. CAUTION: If watercraft is out of water, engine
Tighten bleed screw. must be cooled using the flush kit.
Wipe any oil spillage.
CHECKING OPERATION
Check small oil lines of pump. They must be full
of oil. On Watercraft
NOTE: Oil line supply must be full of oil. See
bleeding procedure above.
Start engine and run at idle while holding the pump
lever in fully open position. Oil must advance into
small oil lines.
NOTE: The engine should have a rich mixture,
idling irregularly and emitting smoke at exhaust
outlet.
If not, remove pump assembly and check the shaft
for defects, replace as necessary. Test pump as
describes below:
NOTE: Through normal use, oil level must not
drop in small tubes. If oil drops, verify check valve
operation. Replace as necessary.
10-03-4 SMR2002-084_10_03A.FM
Bench Test
Connect a hose filled with injection oil to main line
fitting. Insert other hose end in an injection oil con-
tainer. Using a counterclockwise (reverse position)
rotating drill rotate pump shaft. Oil must drip from
fittings in parts of rotary valve cover while holding
lever in a fully open position.
2
3
F01G02A
TYPICAL
1. Supply oil line to an oil container
2. Hold lever in fully open position
3. Counterclockwise (reverse) rotating drill
4. Oil must drip here
For an accurate test, each port should be checked

separately to ensure equal delivery on both ports.
To obtain a precise result of the oil pump delivery
rate, rotate it counterclockwise at 1500 RPM for a
total time of 5 minutes.
NOTE: To ensure accuracy of test, oil lines should
be completely filled before starting test.
Compare the results with the chart below. If oil
pump is out of specification, replace it.
OIL PUMP FLOW RATE AT

ENGINE
1500 RPM (5 minutes)
947 DI 7.5 - 9.1 mL (each port)
SMR2002-084_10_03A.FM 10-03-5
Section 11 ELECTRICAL SYSTEM
TABLE OF CONTENTS 0
CHARGING SYSTEM............................................................................................................. 11-02-1
GENERAL ........................................................................................................................... 11-02-1
TESTING PROCEDURE ..................................................................................................... 11-02-1
BATTERY ............................................................................................................................ 11-02-3
STARTING SYSTEM .............................................................................................................. 11-03-1

GENERAL ........................................................................................................................... 11-03-2
STARTING SYSTEM TROUBLESHOOTING ..................................................................... 11-03-3
STARTER REMOVAL.......................................................................................................... 11-03-4
STARTER DISASSEMBLY.................................................................................................. 11-03-4
CLEANING ......................................................................................................................... 11-03-7
PARTS INSPECTION .......................................................................................................... 11-03-8
STARTER ASSEMBLY........................................................................................................ 11-03-9
STARTER INSTALLATION ................................................................................................. 11-03-9
STARTER SPECIFICATION ................................................................................................ 11-03-11
INSTRUMENTS AND ACCESSORIES .................................................................................. 11-04-1

GENERAL ........................................................................................................................... 11-04-1
ADDITION OF ACCESSORIES .......................................................................................... 11-04-6
INSPECTION ...................................................................................................................... 11-04-6
SMR2002-095_11-01ATOC.FM 11-01-1
Subsection 02 (CHARGING SYSTEM)
CHARGING SYSTEM 0
GENERAL DI
A 25 A fuse is mounted on the MPEM and a 30 A
Magneto fuse is located in the rear electrical box.
The purpose of the charging system is to keep the 4-TEC Engines
battery at a full state of charge.
The charging system is protected by 1 fuse (30 A)
The magneto is the primary source of electrical in starter relay.
energy. It transforms magnetic field into electric
current (AC).
TESTING PROCEDURE
DI Engines
NOTE: First, ensure that battery is in good condi-
The magneto has a 3 phase, delta wound stator tion prior to performing the following tests.
4-TEC Engines
Rectifier/Regulator
The magneto has a 3 phase, delta wound stator STATIC TEST: CONTINUITY
on 18 poles. Capacity is 380 watts. Due to internal circuitry, there is no static test avail-
able.
Rectifier/Regulator DYNAMIC TEST
All Current Test
The rectifier receives AC current from the magne- Proceed as follows:
to and transforms it into direct current (DC).
– Start engine.
The regulator, included in the same unit, limits
voltage at a maximum level (14.5 to 14.8 volts) to – Lay an inductive ammeter on positive cable of
prevent any damage to components. battery.
The unit is using a 3 phase in series rectifier/regulator – Bring engine to approximately 6000 RPM.
which transforms (AC) from the magneto into (DC) to Current reading should be approximately 5 amperes,
allow battery charging. depending on battery state. If not, check magneto
output prior to concluding that rectifier is faulty.
Battery Voltage Test
The battery is the DC source for the electric start-
er, the Multi-Purpose Electronic Module and all ac- All Models
cessories. Proceed as follows:
– Start engine.
Fuse
– Connect a multimeter to battery posts. Set mul-
If the battery is regularly discharged, check fuse timeter to Vdc scale.
condition.
– Bring engine to approximately 5500 RPM.
The rectifier/regulator could be the culprit of a blown
fuse. To check, simply disconnect the rectifier/ If multimeter reads over 15 volts, regulator is defec-
regulator from the circuit. tive. Replace it.
The charging system is protected by 2 fuses. NOTE: If it is continually necessary to add distilled
water to the battery, this indicates an over voltage
If the fuse still burns, check for a defective wire. situation, requiring replacement of the rectifier/
CAUTION: Do not use a higher rated fuse as this regulator. If, on the other hand, the battery will not
could cause severe damage. stay charged, the problem can be any of the charg-
ing circuit components. If these all check good,
you would be accurate in assuming the problem
to be in the rectifier/regulator.
SMR2002-085_11_02A.FM 11-02-1
Stator 4 3 1
STATIC TEST: CONTINUITY
1. Disconnect the magneto wiring harness connec-
tor.
2. Install the 6-pin magneto harness adapter (P/N
295 000 136).
NOTE: On 4-TEC engines disconnect the stator
wiring harness connector and probe the three con-
nectors.
3. Check resistance between two of the YELLOW
wires. The resistance should be between 0.1 to
1.0 ohm.
3 1 F01H60A 2
1. Multimeter
2. Magneto harness adapter
3. Positive (+) probe to YELLOW wire
4. Negative (-) probe to ground
5. Repeat test with the other two YELLOW wires of

the 6-pin magneto harness adapter.
NOTE: There should be no continuity (infinity) be-
tween the stator insulated coils and ground. If
there is a reading, the stator coils and/or the wiring
from the coils is grounded and needs to be re-
placed or repaired.
DYNAMIC TEST
F01H5ZA 3 2 1. Disconnect the magneto wiring harness connec-
tor.
1. Multimeter
2. Magneto harness adapter 2. Install the 6-pin magneto harness adapter (P/N
3. YELLOW wires 295 000 136). Leave wiring harness side discon-
4. Place either meter lead into the remaining YEL- nected.
LOW wire and note the resistance (same as NOTE: On 4-TEC engines disconnect the stator
step no. 3). If the readings are out of specifica- wiring harness connector and probe the three con-
tion, the stator will need to be replaced. nectors.
STATIC TEST: INSULATION 3. Connect test probes of the multimeter to two
1. Disconnect the magneto wiring harness connec- of the YELLOW wires of the 6-pin magneto har-
tor. ness adapter.
2. Install the 6-pin magneto harness adapter (P/N 4. Set multimeter to Vac scale.
295 000 136). 5. Start and rev engine to 3500 RPM. The obtained
NOTE: On 4-TEC engines disconnect the stator value should be between 45 and 70 Vac on DI
wiring harness connector and probe the three con- engines, and 25 Vac on 4-TEC engines.
nectors. 6. If the stator is out of specification, replace it.
3. Insert multimeter positive (+) probe to one of
the YELLOW wire of the 6-pin magneto harness
adapter.
4. Ground the multimeter negative (-) probe to the
engine or the stator iron core and note the read-
ing.
11-02-2 SMR2002-085_11_02A.FM
BATTERY CAUTION: Should any electrolyte spillage oc-

cur, immediately wash off with a solution of
Troubleshooting baking soda and water.
SYMPTOM: DISCHARGED OR WEAK BATTERY Cleaning

CAUSE REMEDY Clean the battery casing, caps, cables and battery
posts using a solution of baking soda and water.
1. Battery posts and/or Clean and coat with CAUTION: Do not allow cleaning solution to en-
cable terminal dielectric grease.
oxidized. ter battery.
Remove corrosion from battery cable terminals
2. Loose or bad Check wiring and
connections. connector cleanliness,
and battery posts using a firm wire brush. Rinse
damaged or short circuit. with clear water and dry well.
3. Faulty battery Replace. Inspection

(sulfated, doesn’t
keep a full charge, Visually inspect battery casing for cracks or other
damaged casing, possible damage. If casing is damaged, replace
loose post). battery and thoroughly clean battery tray and close
4. 15 amp fuse(s) burnt First check fuse.
area with water and baking soda.
or faulty rectifier. If it is in good condition, Inspect battery posts for security of mounting.
check rectifier/regulator. Inspect for cracked or damaged battery caps, re-
5. Faulty battery charging Replace. place defective caps.
coil (or stator).
4-TEC Models
NOTE: Hand tighten caps then tighten an addi-
Removal tional 1/4 turn using a 20 mm (3/4 in) socket. Using
other tool could damage the plastic battery caps.
 WARNING
Battery BLACK negative cable must always  WARNING
be disconnected first and connected last. Battery electrolyte is caustic. To prevent spill-
Never charge or boost battery while installed age, battery cell cap should be sufficiently tight
in watercraft. to properly seal.
All Models All Models

Proceed as follows:
1. Disconnect the BLACK negative cable first.  WARNING
2. Disconnect the RED positive cable last. Battery caps do not have vent holes. Make sure
that vent line is not obstructed.
3. Remove the vent line from the battery.
4. Remove the holding strap(s).
Electrolyte Level
5. Withdraw battery from watercraft being careful
not lean it so that electrolyte flows out of vent Check electrolyte level in each cell, add distilled wa-
elbow. ter up to upper level line.
CAUTION: Add only distilled water in an activat-
 WARNING ed battery.
Electrolyte is poisonous and dangerous. Avoid
contact with eyes, skin and clothing. Wear a
suitable pair of non-absorbent gloves when re-
moving the battery by hand.
SMR2002-085_11_02A.FM 11-02-3
Battery Testing
ELECTROLYTE
There are 2 types of battery tests: electrolyte read- TEMPERATURE OPERATION TO
ing and load test. An electrolyte reading is made PERFORM
on a battery without discharging current. It is the °C °F
simplest and commonly used. A loaded test gives
more accuracy of the battery condition. 38 100 .012 Add
32 90 .008 to the
Electrolyte Reading 27 80 .004 reading
Check charge condition using either a hydrometer
or multimeter. 21 70 CORRECT READING
With a multimeter, voltage readings appear in- 16 60 .004
stantly to show the state of charge. Always re- Subtract
10 50 .008
spect polarity. A fully charge battery will have a from the
4 40 .012
reading of 12.6 Vdc. reading
-1 30 .016
A hydrometer measures the charge of a battery in
terms of specific gravity of the electrolyte. A fully EXAMPLE NO. 1 EXAMPLE NO. 2
charge battery will have a specific gravity between TEMPERATURE ABOVE 21°C (70°F): TEMPERATURE ABOVE 21°C (70°F):
Hydrometer reading: 1.250 Hydrometer reading: 1.235
1.265 to 1.280. Electrolyte temperature: - 1°C (30°F) Electrolyte temperature: 38°C (100°F)
Most hydrometers give a true reading at 21°C (70°F). Subtract .016 Sp. Gr. Add .012 Sp. Gr.
Corrected Sp. Gr. is 1.234 Corrected Sp. Gr. is 1.247
SPECIFIC GRAVITY READING

1 USING A HYDROMETER
ELECTROLYTE
STATE OF TEMPERATURE
CHARGE
27°C (80°F) 4°C (40°F)
100% 1.26/1.27 1.27/1.28
75% 1.21/1.22 1.22/1.23
A17E0JA
50% 1.16/1.17 1.17/1.18
1. Specific gravity 1.265
25% 1.12/1.13 1.13/1.14
In order to obtain correct readings, adjust the initial
0% 1.10 or less 1.11 or less
reading by adding .004 points to the hydrometer
readings for each 5.5°C (10°F) above 21°C (70°F)
and by subtracting .004 point for every 5.5°C Load Test
(10°F) below 21°C (70°F). This is the best test of battery condition under a
This chart will be useful to find the correct reading. starting load. Use a load testing device that has an
adjustable load.
Apply a load of 3 times the ampere-hour rating of
the battery. At 14 seconds into the test, check bat-
tery voltage; if battery is in good condition, it will
have at least 10.5 Vdc.
11-02-4 SMR2002-085_11_02A.FM
Battery Storage Activation of a New Battery

CAUTION: Battery storage is critical for battery
life. Regularly charging the battery during stor-  WARNING
age will prevent cell sulfation. Keeping the bat- Never charge or boost battery while installed in
tery in vehicle for storage may lead to contacts watercraft.
degradation/corrosion and case damage if freez-
ing occurs. A discharged battery will freeze and A new battery is factory fresh dry charged.
break in area where freezing point is experi- CAUTION: Do not loosen battery caps unless
enced. Electrolyte leakage will damage sur- activation is desired.
rounding parts. Always remove battery from ve-
NOTE: In case of accidental premature removal
hicle for storage and regularly charge to keep
of caps, battery should be given a full charge.
an optimal condition.
Perform the following operations anytime a new
Disconnect and remove battery from watercraft
battery is to be installed.
as explained in REMOVAL.
1. Remove caps and fill battery to UPPER LEVEL
Check electrolyte level in each cell, add distilled
line with electrolyte (specific gravity: 1.265 at
water up to upper level line.
21°C (70°F)).
CAUTION: Do not overfill.
NOTE: This battery may fill slower than others
The battery must always be stored in fully charged due to the anti-spill check ball design.
condition. If required, charge until specific gravity
2. Allow the battery to stand for 30 minutes MIN-
of 1.265 is obtained.
IMUM so that electrolyte soak through battery
CAUTION: Battery electrolyte temperature must cells.
not exceed 50°C (122°F). The casing should not
feel hot.
Clean battery terminals and cable connections using
a wire brush. Apply a light coat of dielectric grease
on terminals.
Clean battery casing and caps using a solution of
baking soda and water.
CAUTION: Do not allow cleaning solution to en- 1
ter battery.
A17E0GA
Rinse battery with clear water and dry well using
a clean cloth. 1. 30 minutes
Store battery in a cool dry place. Such conditions 3. Readjust the electrolyte level to the UPPER LEVEL
reduce self-discharging and keep fluid evaporation line.
to a minimum. Keep battery away from dew, high
moisture and direct sunlight.
During the storage period, recheck electrolyte level
and specific gravity readings at least every month. 1
If necessary, keep the battery at its upper level line
and near full charge as possible (trickle charge).
A17E0RB
1. Battery electrolyte
2. Upper level line
SMR2002-085_11_02A.FM 11-02-5
4. Connect a 2 A battery charger for 3 to 5 hours. 6. Test battery state of charge. Use a hydrometer.
3
1
2 - + 1
A17E0IA
Step 1 : Connect + lead to battery + post

Step 2 : Connect - lead to battery - post A17E0JA
Step 3 : Plug battery charger

1. Specific gravity 1.265
 WARNING 7. If electrolyte level has dropped after charging,

Gases given off by a battery being charged fill with distilled water to UPPER LEVEL line. Af-
are highly explosive. Always charge in a well ter water is added, continue charging for 1 to 2
ventilated area. Keep battery away from cig- hours to mix water with electrolyte.
arettes or open flames. Always turn battery 8. Reinstall caps and clean any electrolyte spillage
charger off prior to disconnecting cables. Oth- using a solution of baking soda and water.
erwise a spark will occur and battery might ex-
plode. 4-TEC Models
NOTE: Hand tighten caps then tighten a additional
CAUTION: If charging rate raises higher than 1/4 turn using a 20 mm (3/4 in) socket. Using other
2.4 A reduce it immediately. If cell temperature tool could damage the plastic battery caps.
rises higher than 50°C (122°F) or if the casing
feels hot, discontinue charging temporarily or  WARNING
reduce the charging rate. Battery electrolyte is caustic. To prevent spill-
5. Disconnect battery charger. age, battery cell cap should be sufficiently tight
to properly seal.
1 All Models
Charging a Used Battery
2 - + 3
 WARNING
Never charge battery while installed in water-
craft.
A17E0IB
For best results, battery should be charged when
Step 1 : Unplug battery charger the electrolyte and the plates are at room temper-
Step 2 : Disconnect - lead ature. A battery that is cold may not accept current
Step 3 : Disconnect + lead for several hours after charging begun.
Do not charge a frozen battery. If the battery charge
is very low, the battery may freeze. If it is suspected
to be frozen, keep it in a heated area for about 2 hours
before charging.
11-02-6 SMR2002-085_11_02A.FM
NOTE: Some chargers have a polarity protection

 WARNING feature which prevents charging unless the charg-
Always charge battery in a well ventilated area. er leads are connected to the correct battery ter-
minals. A completely discharged battery may not
The time required to charge a battery will vary de- have enough voltage to activate this circuitry, even
pending on some factors such as: though the leads are connected properly. This will
– Battery temperature: The charging time is in- make it appear that the battery will not accept a
creased as the temperature goes down. The charge. Follow the charger manufacturer’s instruc-
current accepted by a cold battery will remain tion on how to bypass or override this circuitry
low. As the battery warms up, it will accept a so that the charger will turn on and charge a low-
higher rate of charge. voltage battery.
– State of charge: Because the electrolyte is near- – Since the battery chargers vary in the amount
ly pure water in a completely discharged battery, of voltage and current they provide, the time
it cannot accept current as well as electrolyte. required for the battery to accept measurable
This is the reason the battery will not accept charger current might be up to approximately
current when the charging cycle first begins. As 10 hours or more.
the battery remains on the charger, the current – If the charging current is not up to a measurable
from the charger causes the electrolytic acid amount at the end of about 10 hours, the bat-
content to rise which makes the electrolyte a tery should be replaced.
better conductor and then, the battery will ac-
cept a higher charging rate. – If the charging current is measurable before the
end or at the end of about 10 hours, the battery
– Type of charger: Battery chargers vary in the is good and charging should be completed in
amount of voltage and current that they can the normal manner as specified in ACTIVATION
supply. Therefore, the time required for the bat- OF A NEW BATTERY.
tery to begin accepting measurable current will
also vary. – It is recommended that any battery recharged
by this procedure be load tested prior to return-
Charging a Very Flat or Completely Discharged ing it to service.
Battery
The battery charger should have an adjustable Battery Installation
charging rate. Variable adjustment is preferred,
but a unit which can be adjusted in small incre-  WARNING
ments is acceptable. Always connect battery cables exactly in the
The battery charger must be equipped with an am- specified order, RED positive cable first BLACK
meter capable of accurately measuring current of negative cable last.
less than 1 ampere.
Proceed as follows:
Unless this procedure is properly followed, a good
battery may be needlessly replaced. 1. Install battery in its emplacement.
– Measure the voltage at the battery posts with 2. Secure vent line to the battery and support. En-
an accurate voltmeter. If it is below 10 volts, the sure vent line is not kinked or obstructed.
battery will accept current at very low rate, in
term of milliamperes, because electrolyte is  WARNING
nearly pure water as explained above. It could Vent line must be free and open. Avoid skin con-
be some time before the charging rate increas- tact with electrolyte.
es. Such low current flow may not be detect-
able on some charger ammeters and the bat- 3. First connect RED positive cable.
tery will seem not to accept any charge. 4. Connect BLACK negative cable last.
– Exceptionally for this particular case, set the 5. Apply dielectric grease on battery posts.
charger to a high rate.
6. Verify cable routing and attachment.
Reinstall seat support.
SMR2002-085_11_02A.FM 11-02-7
Subsection 03 (STARTING SYSTEM)
STARTING SYSTEM 0
DI Engines
Dielectric
grease
Loctite 2
243
1
10 Nm Ground
(89 lbfin) cable
Synthetic
grease
Synthetic
grease
8
12
10
11
9
7
F07H0TT
SMR2002-086_11_03A.FM 11-03-1
4 -TEC Engines Battery

To check battery condition, refer to CHARGING
Grease Klueber Isoflex
Topas NB 52 SYSTEM.
4 3 2 MPEM/ECU
If 2 short beeps are not heard when installing the
5
1 safety lanyard, refer to ENGINE MANAGEMENT
section.
Engine Start/Stop Switch and Safety

Lanyard Switch
Refer to ENGINE MANAGEMENT section.
Solenoid
NOTE: Solenoid is located in the electrical box for
the DI engines and besides the MPEM for 4-TEC
engines.
Inspect connections and clean as necessary.
Static Test: Continuity
With a multimeter, check primary winding resis-
F18H0MA
tance. It should be approximately 5 Ω (ohms) for
the DI engines and 7.2 Ω (ohms) for 4-TEC en-
GENERAL gines. Measure the resistance value through pins
1 and 2 for 4-TEC engines.
Causes of troubles are not necessarily related to
starter but may be due to a burnt fuse, faulty bat-
tery, start/stop switch, safety lanyard switch,
MPEM, or ECU, DESS auxiliary module on 4-TEC
engines, solenoid, electrical cables or connec-
tions.
Check these components before removing start-
er. Consult also the starting system troubleshoot-
ing table on next page for a general view of possi-
ble problems.
 WARNING
Short circuiting electric starter is always a dan-
ger, therefore disconnect the battery ground 1
cable before carrying out any kind of mainte-
nance on starting system. Do not place tools
on battery.
Fuse F18H0SA
Make sure the starting system fuse on MPEM is 1. Pins 1 and 2

in good condition.
There should be no continuity between the posi-
The solenoid may be the cause of a burnt fuse. If tive posts of the solenoid.
the solenoid checks good, one of the accessory
may be defective.
11-03-2 SMR2002-086_11_03A.FM
Dynamic Test Electrical Cables or Connections

Depress start/stop button and measure the volt- Check all connections, cables and wires. Tighten
age on the solenoid positive posts with a multim- any loose cables. Replace any chafed wires.
eter.
If there is no voltage and battery is in good condi-
tion, replace the solenoid.
STARTING SYSTEM TROUBLESHOOTING

NOTE: Other causes of the problem may not be related to the starting system. Refer to TROUBLESHOOT-
ING section.
SYMPTOM CAUSE REMEDY
STARTER DOES NOT TURN. Burnt fuse on MPEM. Check wiring condition and replace fuse.
Poor contact of battery terminal(s). Clean and tighten terminal(s).
Poor battery ground cable connection. Clean and tighten.
Weak battery. Recharge or replace battery.
Poor contact of start/stop switch, Check connectors and clean contacts.
safety lanyard switch or solenoid. Check and replace defective parts.
Open circuit: start/stop switch or
Check and replace.
solenoid.
Safety lanyard or MPEM or ECU. Refer to ENGINE MANAGEMENT.
DESS auxiliary module. Refer to engine management.
STARTER ENGAGES; Poor battery cable connections. Clean battery cable connections.
BUT DOES NOT CRANK Poor contact of brush. Straighten commutator and brush.
THE ENGINE.
Burnt commutator. Turn commutator on a lathe.
Worn commutator segments. Undercut mica.
Shorted armature. Repair or replace armature.
Weak brush spring tension. Replace brush holder or spring.
Weak magnet. Replace yoke assembly.
Worn bushings. Replace clutch.
Weak battery. Recharge or replace battery.
STARTER TURNS, BUT Worn clutch pinion gear. Replace clutch.
OVERRUNNING CLUTCH Defective clutch. Replace clutch.
PINION DOES NOT MESH
WITH RING GEAR. Poor movement of clutch on splines. Clean and correct.
Worn clutch bushing. Replace clutch.
Worn ring gear. Replace ring gear.
STARTER MOTOR KEEPS Shorted solenoid winding. Replace solenoid.
RUNNING.
Melted solenoid contacts. Replace solenoid.
Sticking or defective starter clutch. Lubricate or replace.
SMR2002-086_11_03A.FM 11-03-3
STARTER REMOVAL 4-TEC Engines

Remove retaining screws no. 1 from starter.
Disconnect BLACK cable ground connection from
battery. Pull starter no. 3 out. Lift starter enough to reach
starter cable then disconnect from starter (nut
 WARNING no. 2).
Always disconnect ground cable first and re-
connect last.
Disconnect RED cable connection from battery.

4 2
DI Engines
1
Disconnect starter cables and loosen Allen screws
no. 1 retaining starter bracket to engine.
3 2
F18H0UA
1. Exhaust manifold
2. Starter
3. Retaining screws
4. Nut
STARTER DISASSEMBLY
F06H35B 1 3 DI Engines
Locate index marks on yoke no. 6 and end covers
1. Positive starter cable
2. Negative starter cable no. 7 and no. 8.
3. Allen screw
1
Remove bracket and starter.
NOTE: To remove the starter drive assembly, mag-
neto flywheel has to be removed. Refer to MAG-
NETO SYSTEM and BOTTOM END.
To check and replace the starter end bearing, refer
to BOTTOM END section.
F06H1FA
1. Index marks
11-03-4 SMR2002-086_11_03A.FM
Loosen through bolts no. 9.

1
1
F06H1IA
1. Washers
F06H1GA
Remove armature no. 12.
1. Through bolts
Remove end cover no. 7 and gasket on armature

shaft side.
Remove thrust washers no. 10 from armature shaft.
F06H1JA 1
TYPICAL
1. Pull armature shaft
Release brush wires of yoke from brush holder

no. 11.
Remove brush holder no. 11.
F06H1HA 1
TYPICAL
1. Thrust washers
Remove the other end cover no. 11 and gasket.

Remove the three washers no. 10 from armature
shaft.
F06H1KA
1. Remove brush holder
SMR2002-086_11_03A.FM 11-03-5
To remove brushes from yoke no. 6, loosen nut 4-TEC Engines

and remove washers. Remove bendix retaining circlip no. 4 and starter
bendix no. 5.
F06H1LA
1. Loosen nut and remove washers
Remove brushes.
To remove bearing and seal in end cover, release
tabs of retainer.
F18H0NA 1 2
1. Retaining circlip
2. Starter bendix
Locate index marks on yoke and end covers.
F06H1MA 1
1. Retainer
F18H0OA 1
1. Index marks
11-03-6 SMR2002-086_11_03A.FM
Loosen through bolts.
F06H1JA 1
1 TYPICAL
1. Pull armature shaft
Remove brushes from brush holder by loosening

retaining screws.
1 2 3
F18H0PA
1. Through bolts
Remove end cover.

Remove thrust washer from armature shaft.
F18H0QA
1. Brushes
2. Retaining screw
3. Brush holder
Remove springs.
F06H1HA 1
TYPICAL CLEANING
1. Thrust washers
All Models
Remove the other end cover with brushes and brush
holder assembly. CAUTION: Yoke ass’y and drive unit assembly
must not be immersed in cleaning solvent.
Remove armature.
Discard all O-rings.
Clean brushes and holders with a clean cloth
soaked in solvent. Brushes must be dried thorough-
ly with a clean cloth.
SMR2002-086_11_03A.FM 11-03-7
Blow brush holders clean using compressed air. Check commutator outer diameter. If less than
27 mm (1.063 in), replace.
 WARNING
Always wear safety glasses when using com-
pressed air.
Remove dirt, oil or grease from commutator using

a clean cloth soaked in suitable solvent. Dry well
using a clean, dry cloth.
Clean engine ring gear teeth and drive unit (clutch).
NOTE: Bushings or bearings must not be cleaned
with grease dissolving agents.
Immerse all metal components in cleaning solution. A03E06A
Dry using a clean, dry cloth.
4-TEC Engines
PARTS INSPECTION
Check commutator condition with an indicator. If
Armature out of specification, replace the starter.
NOTE: An ohmmeter may be used for the follow-
ing testing procedures, except for the one con-
cerning shorted windings in armature.
1
Check commutator for roughness, burnt or scored
surface. If necessary, turn commutator on a lathe,
enough to resurface only.
Check commutator for mica depth. If depth is less
than 0.20 mm (.008 in), undercut mica. Be sure
that no burrs are left and no copper dust remains
between segments after undercutting operation
is completed.
DI Engines F18H0RA
1. Commutator undercut 0.20 mm (.008 in)
Brush Holder
1 All Engines
Check brush holder for insulation using an ohm-
meter. Place one test probe on insulated brush
F01H0RA
holder and the other test probe on brush holder
1. Commutator undercut 0.20 mm (.008 in) plate. If continuity is found, brush holder has to be
repaired or replaced.
Check commutator out of round condition with V-
shaped blocks and an indicator. If commutator out
of round is more than 0.40 mm (.016 in), commu-
tator should be turned on a lathe.
11-03-8 SMR2002-086_11_03A.FM
Brush
Measure brush length. If less than 8.5 mm (.335 in),
replace them.
NOTE: New brush length is 12 mm (.472 in).
1 2
F06H1HA 1
1. Thrust washers
DI Engines
A03E05A
Install the three washers no. 10 onto armature shaft.
TYPICAL All Engines
1. New
2. Wear limit, 8.5 mm (.335 in) When installing end covers no. 7 and no. 8 to yoke,
align index marks.
Overrunning Clutch Apply Loctite 271 (red) on through bolts no. 9 and
torque to 6 N•m (53 lbf•in).
DI Engines
Pinion of overrunning clutch should turn smoothly STARTER INSTALLATION
in clockwise direction, and should not slip in a
counterclockwise direction. If defective, replace. Installation is essentially the reverse of removal
procedure. However, pay particular attention to
Check pinion teeth for wear and damage. If defec-
the following.
tive, replace.
Make sure that starter and engine mating surfaces
NOTE: Always check engine ring gear teeth for
are free of debris. Serious trouble may arise if
wear and damage. If defective replace ring gear.
starter is not properly aligned.
Refer to MAGNETO.
DI Engines
STARTER ASSEMBLY Screw
All Engines Apply Loctite 243 (blue) to Allen screws no. 4 of
Reverse the order of disassembly to reassemble starter bracket and torque to 10 N•m (89 lbf•in).
starter. However, attention should be paid to the
following operations.
Install new O-rings on 4-TEC engines and gaskets
on DI engines.
Insert thrust washers no. 19 onto armature shaft.
SMR2002-086_11_03A.FM 11-03-9
Nut Nut
Connect the RED positive cable to the starter and CAUTION: The cable nut features 1/4-20UNC
torque nut no. 2 to 7 N•m (62 lbf•in). Apply dielec- SAE threads. If for some reason you replace it,
tric grease on terminal and nut. DO NOT use a metric one.
3 2 Connect the RED positive cable to the starter and
torque nut to 7 N•m (62 lbf•in). Apply dielectric
grease on terminal and nut.
Ensure to slide protector over nut to hide metallic
parts.
F06H35B 1 3
1. Torque nut to 7 N•m (62 lbf•in), apply dielectric grease and install
protection cover 2 3 1
2. Negative BLACK cable
3. Apply Loctite 243 to threads and torque screw to 10 N•m
(89 lbf•in)
 WARNING F18H0UB
Always connect RED positive cable first then 1. Grease on O-rings.

BLACK negative cable last. Whenever con- 2. Torque nut to 7 N•m (62 lbf•in) and apply dielectric grease and
necting the RED positive cable to the starter install protection cover
3. Apply Loctite 243 to threads and torque screws to 10 N•m
motor make sure the battery cables are dis- (89 lbf•in)
connected to prevent electric shock.
 WARNING
4-TEC Engines Always connect RED positive cable first then
Apply grease Isoflex Topas NB52 (P/N 293 550 021) BLACK negative cable last. Whenever con-
on O-rings of starter. necting the RED positive cable to the starter
motor make sure the battery cables are dis-
Install Starter. connected to prevent electric shock.
NOTE: If starter does not mesh properly, try to pull
it out and slightly rotate the starter gear; then rein-
stall starter. One could also temporarily remove both
O-rings, properly mesh gears then remove starter
to reinstall O-rings, being careful not to rotate gear
to keep its position, to finally reinstall starter.
Apply Loctite 243 (blue) on retaining screws no. 1
and torque to 10 N•m (89 lb•in).
11-03-10 SMR2002-086_11_03A.FM
STARTER SPECIFICATION
DI Engines
Nominal output 0.8 kW
Voltage 12 V
Rated time 30 seconds
Rotation Counterclockwise (viewed from pinion side)
Weight 1.7 kg (3.7 lb)
No load 10.9 V 45 A max. 8600 RPM
Performance specification at 20°C (68°F) Load 9V 120 A max. 5350 RPM
Stall 2.25 V 390 A max. 0 RPM
Battery 12 V, 19 Ah
4-TEC Engines
Nominal output 0.9 kW
Voltage 12 V
Rated time 30 seconds
Rotation Counterclockwise (viewed from pinion side)
Weight 2.5 kg (5.39 lb)
No load 11.4 V 23 A max. 8600 RPM
Performance specification at 20°C (68°F) Load 8.5 V 140 A max. 5200 RPM
Stall 3.75 V 330 A max. 0 RPM
Battery 12 V, 30 Ah
SMR2002-086_11_03A.FM 11-03-11
Subsection 04 (INSTRUMENTS AND ACCESSORIES)
INSTRUMENTS AND ACCESSORIES 0

GENERAL
It is possible to activate the instruments when the
engine is not running.
Make sure the safety lanyard is removed, then de-
press the start/stop button.
The timer of the MPEM will maintain the gauge(s)
activated during a period of approximately 33 sec-
onds.
Information Center Gauge/Buttons

This is a multifunction gauge that supplies several
real time useful information to the driver.
Components Description
F18L09A 1
1 2 1. Function buttons
Display Area
The display area comprises the following.
F18H08A 3
1. Speedometer
2. Tachometer
3. Display area
F18H08C 1 3 2
1. Fuel level indicator
2. Numerical section
3. Units and messages section
Fuel Level Display

Bar gauge continuously indicates the amount of
fuel in the fuel tank while riding. A low-fuel condi-
tion is also indicated when in the information cen-
ter when only one bar is displayed. See MESSAGE
DISPLAY below.
F18H08B 1 Numerical Section
1. Text and numerical area This section shows the digits of the function dis-
played such as the clock, trip hour meter etc. Time
is displayed in 12 hour format (from 1 to 12) with-
out am and pm indication.
SMR2002-087_11_04A.FM 11-04-1
Units and Messages Section

This section shows the units related to the num-
bers displayed. Units such as KMH (MPH), HOUR
etc. are displayed.
This section also display navigational and system
fault informations.
See the gauge functions and message lists below
for more details.
Gauge Functions
Clock: Indicates the actual time in hours and min-
utes (hh:mm).
Compass: Displays the cardinal points to indicate
the orientation of the watercraft.
1 2
 WARNING
F18L09B
1. To change display mode

Use the compass as a guide only. Not to be 2. To set or reset a function
used for navigation purposes.
Resetting a Function
Average Speed: The information center approxi- To reset a function (such as the trip hour meter, dis-
mately calculates and displays the average speed tance, etc.) press and hold the SET button for 2 sec-
(AV KM/H or AV MPH) of the watercraft since the onds while in the appropriate mode.
last engine start.
Display Selection
Distance (KM or MILES). The information center
The default display is the clock/compass unless
approximately calculates the distance based on the
another mode has been selected. See DISPLAY
operation time and the watercraft speed and dis-
PRIORITIES below.
plays the result in kilometers (KM) or miles (MILES).
Repeatedly pressing the MODE button scrolls the
Hourmeter: Displays the time in hours of the water-
following displays: average speed, distance, hour-
craft usage (HOUR).
meter, water temperature, exterior temperature
Water Temperature: Displays the water tempera- and trip hour meter.
ture (L TEMP) in degrees Celsius (°C) or Fahrenheit
(°F).
Exterior Temperature: Displays the exterior air
temperature (E TEMP) in degrees Celsius (°C) or
Fahrenheit (°F).
Trip Hour Meter: (TRIPMTR) Allows to measure an
interval of time in hours and minutes (hh:mm).
Function Buttons
Different displays and functions can be activated
using 2 buttons — MODE and SET — following
specific sequences as described below.
F18L09C 1
1. Press to change display mode
When you are satisfied with your choice, stop press-

ing the button and it will become active.
11-04-2 SMR2002-087_11_04A.FM
Display Priorities
As a self test at start-up, the needles of the speed-
ometer and tachometer will sweep to their maxi-
mum position, all LCD segments and the LED will
turn on for 3 seconds each time the information cen-
ter is activated. This allows the driver to validate
they are all working properly.
The clock/compass is the default display mode.
The default display is the one that appears when
the information center is first activated or dis-
played back after an alternate display was chosen.
The trip hour meter is the only mode that may be
chosen to replace the default display. When dis-
playing the trip hour meter, it becomes active
when you do not touch any button for 10 seconds. F18L09C 1
When active, it becomes the default display until
1. Repeatedly press
it is changed again.
When another display mode is chosen, the default
display will be displayed back after 10 seconds.
In the event of a warning message, the message
will blink and override the units display unless
MODE button is pressed. The display will then dis-
play the clock/compass after 10 seconds.
If more than one warning message occurs, the
blinking messages will scroll every 4 seconds.
Other Functions
The following describes how to select other avail-
able functions.
Language Option
While in the clock/compass mode:
F18L09D 1
1. Press to end
English/Metric System
Allows to display the units in the metric system or
in the SAE english system.
NOTE: This function is not available when infor-
mation center displays the clock/compass, hour-
meter or trip hour meter.
F18L09D 1
1. Press and hold for 2 seconds
SMR2002-087_11_04A.FM 11-04-3
F18L09A 1 F18L09C 1
1. Press TOGETHER and hold for 2 seconds 1. Repeatedly press to adjust HOURS
Clock Adjustment
While in the clock/compass mode:
F18L09D 1
1. Repeatedly press to adjust MINUTES
F18L09A 1
1. Press TOGETHER and hold for 2 seconds
F18L09A 1
1. Press TOGETHER to end
11-04-4 SMR2002-087_11_04A.FM
NOTE: If MODE and SET buttons are not pressed • high battery voltage (12 V HI).
at the end, the default display will come back after • low fuel level (FUEL-LO)
10 seconds and the time entered will remain.
• maintenance reminder (MAINT)
Trip Hour Meter
• check engine (CHK ENG)
While in the trip hour meter mode:
• sensor failure
(vehicle electronic equipment) (SENSOR)
• invalid safety lanyard (KEY)
• safety lanyard, learning key active (L KEY)
• end of faults (END).
A beeper will sound depending on the fault occur-
ring to catch the driver attention when necessary.
Except for low liquid levels, which can be corrected
by refilling.
NOTE: If a fault occurs, this system generates num-
bered fault codes (P-XXXX) that can be displayed
through the information center using a special pro-
cedure. In case of a failure, refer to DIAGNOSTIC
PROCEDURES in ENGINE MANAGEMENT.
F18L09D 1 Warning Light
1. Press to start or stop trip hour meter The red warning LED (Light-Emitting Diode) blinks
along with the beeper to catch your attention.
Maintenance Information
When the watercraft is due for a maintenance in-
spection, the message MAINT will blink. Afterwards,
it will blink at every start-up for 10 seconds.
GTX 4-TEC Models

Information Center Not Working
When there is no display at the information center,
perform the following:
– Check fuses.
– Check supply wire (1-23) and ground wire (1-8)
from MPEM.
F18L09D 1 – Check communication link wires (WHITE/RED
1. Press and hold for 2 seconds to reset and WHITE/BLACK):
Trip hour meter is reset every time engine is – To quickly check if the communication link is
turned off. working, temporarily disconnect a sensor on the
engine to create a fault code. The information
Message Display should display a fault code when in onboard di-
The information center features a display area that agnostic mode.
blinks a message whenever one of the following cir- – Check if wires are swapped, unconnected or
cumstances occurs. The abbreviations between pa- short circuit.
renthesis here are the code displayed:
– One faulty wire will cause a longer delay to
• low oil pressure (OIL) perform the self-test when safety lanyard is
• low battery voltage (12 V LOW). installed.
SMR2002-087_11_04A.FM 11-04-5
– If everything tests good, try a new information To check if the water temperature sensor is oper-
center. ational, activate the Info Center and select the lake
temperature mode.
ADDITION OF ACCESSORIES With a garden hose, spray the speed sensor with
water. The temperature reading on the Info Center
Every time an accessory is added such as an elec-
should adjust to the water temperature.
tric bilge pump or a VTS for instance, it must be
registered using BUDS to activate it in the MPEM. If not, replace the speed sensor.
If an option is installed but not checked in BUDS,
the information center will not display that option.
Compass
If an option is checked in BUDS but not installed The compass is located in the storage cover.
in vehicle, a fault code will be generated. Remove the back panel of the storage cover to ac-
Use the OPTIONS area in the Setting tab in cess the compass.
BUDS.
INSPECTION
All Models
Air Temperature Sensor
The temperature sensor is located in the storage
cover.
Remove the back panel of the storage cover to
access the temperature sensor.
F07H02A 1
1. Compass
Remove the compass from the support.

Activate the Info Center.
Change the direction of the compass and keep it
horizontal (± 10°). There should be a change of
direction on the Info Center.
NOTE: To check the accuracy of the compass, you
can use a portable compass and point it in the
F07H01A 1 same direction. Compare the given directions,
they should be the same.
1. Temperature sensor
To check if the temperature sensor is operational, Speed Sensor

activate the Info Center and select the exterior The speedometer gives a reading through a speed
temperature mode. sensor. Speed sensor is installed on riding plate. It
Use a heat gun to warm up the sensor. The tem- works with the water flow which turns a magnetic
perature should raise rapidly on the gauge. paddle wheel that triggers an electronic pick-up
that in turn sends a speed signal to the MPEM.
If not, replace the temperature sensor.
The paddle wheel is protected by the pick-up hous-
Water Temperature Sensor ing.
The water temperature sensor is integrated with
the speed sensor located on the ride plate.
11-04-6 SMR2002-087_11_04A.FM
Remove the BLACK wire from the receptacle hous-

ing.
Reconnect the connector housing.
Connect potentiometer test probes to the PINK
and BLACK wires.
Adjust potentiometer to the resistance values as
per following chart to test the accuracy of the gauge.
1 NOTE: The gauge must be activated to obtain a
reading.
GTX 4-TEC
F01H3VA
2
RESISTANCE WET HEIGHT FROM
1. Pick-up housing (Ω) BOTTOM (mm)
2. Paddle wheel
4.8 ± 2.2 247 ± 5.0
To check if the speed sensor is operational, dis-
17.8 ± 2.2 207 ± 5.0
connect the speed sensor connector housing
from inside bilge. 27.8 ± 2.2 183 ± 5.0
Using an appropriate terminal remover (Snap-on 37.8 ± 2.2 158 ± 5.0
TT600-4), remove the PURPLE/YELLOW and 47.8 ± 2.2 133 ± 5.0
BLACK/ORANGE wires from the tab housing of 57.8 ± 2.4 105 ± 5.0
the speed sensor.
67.8 ± 2.8 76 ± 5.0
Reconnect the PURPLE/YELLOW and BLACK/
ORANGE wires in the receptacle housing. 77.8 ± 3.6 55 ± 5.0
Connect the positive probe of a multimeter to 89.8 ± 3.6 35.3 ± 5.0

speed sensor PURPLE/YELLOW wire and the
negative probe to speed sensor BLACK/ORANGE GTX DI
wire.
RESISTANCE WET HEIGHT FROM
Install safety lanyard to acticvate MPEM. (Ω) BOTTOM (mm)
Slowly rotate the paddle wheel. Every 1/8 turn, the 4.8 ± 2.2 228 ± 5.0
observed voltage should fluctuate between 5.5
17.8 ± 2.2 188 ± 5.0
and 8.5 Vdc.
27.8 ± 2.2 164 ± 5.0
Information Center Verification 37.8 ± 2.2 139 ± 5.0
The BLACK wire is the ground. 47.8 ± 2.2 114 ± 5.0
The RED/PURPLE wire is the 12 Vdc from the bat- 57.8 ± 2.4 88 ± 5.0
tery. It is protected by a fuse on the MPEM; the 67.8 ± 2.8 57 ± 5.0
fuse “MPEM” and the fuse “ACC” on DI models.
77.8 ± 3.6 38 ± 5.0
The accuracy of some features of the Information
89.8 ± 3.6 16 ± 5.0
Center can be checked with a potentiometer.
Fuel Level Water Temperature (L temp) (if so equipped)
Disconnect the 4-circuit connector housing of the Disconnect the 2-circuit connector housing of the
Info Center. Info Center which contains a BLACK/ORANGE
Using an appropriate terminal remover, remove and TAN/ORANGE wires.
the PINK wire from the tab housing. Connect potentiometer test probes to the BLACK/
Reconnect the connector housing. ORANGE and TAN/ORANGE wires.
Disconnect the 2-circuit connector housing which Adjust potentiometer to the resistance values as
contains a PURPLE and BLACK wires. per following chart to test the accuracy of the gauge.
SMR2002-087_11_04A.FM 11-04-7
NOTE: The gauge must be activated to obtain a GTX DI

reading.
RESISTANCE DISPLAY
GTX 4-TEC (Ω) TEMPERATURE (°F)
22919.8 45 ± 4
RESISTANCE DISPLAY
(Ω) TEMPERATURE (°C) 17491.7 55 ± 4
25407.3 5±2 13487.5 65 ± 4
19911.1 10 ± 2 10501.5 75 ± 4
15718.0 15 ± 2 8252.0 85 ± 4
12495.0 20 ± 2 6518.7 95 ± 4
10000.0 25 ± 2
8054.9 30 ± 2 Fuel Baffle Pick Up Sender
6528.3 35 ± 2 The fuel pick up system is part of the fuel pump
module mounted inside the fuel reservoir.
GTX DI
The fuel level gauge sender is also mounted on this
RESISTANCE DISPLAY module.
(Ω) TEMPERATURE (°F)
22799.0 45 ± 4
17262.0 55 ± 4
13470.0 65 ± 4
10496.3 75 ± 4
8264.4 85 ± 4
6528.3 95 ± 4
Exterior Temperature (if so equipped)

Disconnect the 2-circuit connector housing of the
Info Center which contains a TAN/WHITE and
BLACK/WHITE wires.
Connect potentiometer test probes to the TAN/
WHITE and BLACK/WHITE wires. F07F09A
Adjust potentiometer to the resistance values as TYPICAL — FUEL LEVEL GAUGE SENDER MOUNTED ON FUEL
per following chart to test the accuracy of the PUMP MODULE
gauge.
Refer to ENGINE MANAGEMENT.
NOTE: The gauge must be activated to obtain a
reading.
GTX 4-TEC
RESISTANCE DISPLAY
(Ω) TEMPERATURE (°C)
4712 5±2
3792 10 ± 2
3069 15 ± 2
2500 20 ± 2
2057 25 ± 2
1707 30 ± 2
1412 35 ± 2
11-04-8 SMR2002-087_11_04A.FM
DI Model Only NOTE: Wait about 15 - 20 seconds before taking

any reading to give the oil enough time to flow out
Oil Sensor or inside sensor reservoir.
The sensor sends the signal to the low-oil level Soak sensor in oil so that its reservoir fills up. Max-
light in the fuel gauge or the LED in the Info Center. imum resistance should be approximately 2 Ω
(closed circuit).
TEST CONDITION READING (Ω)

Sensor OUT of oil ∞ (open circuit)
Sensor soaked IN oil 2 Ω max. (closed circuit)
F00H0LA 1
1. Oil sensor
The bottom of the sensor has a small reservoir

with two small holes underneath to let the oil en- 2
ter inside and one at the top to let the air enter F03H0BA
allowing the oil to flow out.

1. Measure resistance here
When there is enough oil inside the oil tank (and 2. Sensor reservoir
therefore in the sensor reservoir), the sensor de-
tects the liquid and the light DOES NOT turn on. To Reinstall Sensor:
When the oil level goes at critical LOW level inside – Remove rubber seal from sensor.
the oil tank (and therefore in sensor reservoir), the – Install seal in oil tank hole.
sensor detects the absence of liquid and the light
TURNS ON. – Push sensor in seal.
To check the oil sensor, unplug its connector and – Plug connector.
pull sensor out of oil tank. NOTE: This sensor turns the LED to ON if the con-
Using a multimeter, check the continuity between nector has been forgotten unconnected even when
the BLUE and BLUE/BLACK terminals. there is enough oil in tank.
When sensor is out of oil tank and its reservoir is
empty, resistance must be infinite (open circuit).
SMR2002-087_11_04A.FM 11-04-9
Section 12 PROPULSION SYSTEM
TABLE OF CONTENTS 0
JET PUMP .............................................................................................................................. 12-02-1
GENERAL ........................................................................................................................... 12-02-2
JET PUMP INSPECTION ON WATERCRAFT.................................................................... 12-02-2
REMOVAL........................................................................................................................... 12-02-4
DISASSEMBLY................................................................................................................... 12-02-6
CLEANING ......................................................................................................................... 12-02-9
ASSEMBLY......................................................................................................................... 12-02-11
PUMP PRESSURIZATION ................................................................................................. 12-02-19
INSTALLATION .................................................................................................................. 12-02-20
GENERAL ........................................................................................................................... 12-02-23
JET PUMP INSPECTION ON WATERCRAFT.................................................................... 12-02-23
REMOVAL........................................................................................................................... 12-02-24
DISASSEMBLY................................................................................................................... 12-02-27
CLEANING ......................................................................................................................... 12-02-30
ASSEMBLY......................................................................................................................... 12-02-31
PUMP PRESSURIZATION ................................................................................................. 12-02-36
INSTALLATION .................................................................................................................. 12-02-36
DRIVE SYSTEM ..................................................................................................................... 12-03-1

GENERAL ........................................................................................................................... 12-03-3
REMOVAL........................................................................................................................... 12-03-3
INSPECTION ...................................................................................................................... 12-03-7
INSTALLATION .................................................................................................................. 12-03-9
LUBRICATION.................................................................................................................... 12-03-14
REVERSE SYSTEM................................................................................................................ 12-04-1

DISASSEMBLY................................................................................................................... 12-04-2
INSPECTION ...................................................................................................................... 12-04-3
ASSEMBLY......................................................................................................................... 12-04-3
ADJUSTMENT ................................................................................................................... 12-04-4
SMR2002-095_12-01ATOC.FM 12-01-1
Subsection 02 (JET PUMP)
JET PUMP 0
GTX DI Models
Loctite 518
3 1
2
31
38 Loctite
454 Loctite 518
6 Nm
(53 lbfin) 40 29
41 30
25
44
30 3 Nm
32
33 (27 lbfin) Primer N and
28 Pipe sealant 567
24 Nm
Primer N 36 Primer N 21 (18 lbfft)
and 35 and Pipe
37 45 sealant 23
Loctite 243
13 592 22
Synthetic
grease 26
34
Loctite
243 24
7.5 Nm 42
(66 lbfin)
Loctite 43
243 39 20
21 Nm
16 (16 lbfft)
14
15
2.5 Nm
(22 lbfin)
6
19
7 13
13
5
2.5 Nm
20 Nm 18 (22 lbfin)
(15 lbfft)
17 4
20 Nm
(15 lbfft) 8
F18J0CS
SMR2002-088_12_02A.FM 12-02-1
GENERAL JET PUMP INSPECTION ON

WATERCRAFT
4
To work on watercraft, securely install it on a stand.
3 Thus, if access is needed to water inlet area, it will
be easy to slide underneath watercraft.
A lift kit can be used to install watercraft on a stand.
2
5
1
F00J0SA
TYPICAL
1
1. Nozzle
2. Venturi
3. Housing
4. Wear ring
5. Impeller 2
F01J42A
6. Stator
TYPICAL
Impeller Identification 1. Lift kit
2. Work stand
To identify the impeller refer to the following illus-
tration and chart. Impeller Condition
Condition of impeller no. 1, boot no. 2 and ring
no. 3 can be quickly checked from underneath of
the watercraft. Remove grate and look through
water inlet opening.
F02J0VA
1. Stamped part number

F01J0DA
WATERCRAFT IMPELLER
MATERIAL PITCH TYPICAL
MODEL P/N
1. Inspect impeller and boot
Progressive
Stainless
GTX DI 271 000 920 pitch
steel
15° - 21°
12-02-2 SMR2002-088_12_02A.FM
Impeller/Wear Ring Clearance

This clearance is critical for jet pump performance.
Clearance can be checked from water inlet open-
ing or from venturi side. However, the last method
requires more work.
To check clearance from water inlet side, remove
inlet grate.
To check clearance from venturi side, remove
venturi/nozzle assembly as described in Oil In-
spection in this subsection.
Using a feeler gauge with 30 cm (12 in) blades,
measure clearance between impeller blade tip and
wear ring. Measure each blade at its center. Clear- F01J0FA 1
ance should not exceed 1.0 mm (.040 in). If clear-
TYPICAL — MEASURING FROM VENTURI SIDE
ance is greater, disassemble jet pump and inspect
1. Feeler gauge
impeller and wear ring. Renew worn parts.
Oil Inspection
1
Remove:
– reverse gate cable
– steering cable
– screws no. 10 retaining venturi to the housing.
Pull venturi.
Remove plug from cover.
F01J0EA
TYPICAL — MEASURING FROM WATER INLET SIDE

1. Feeler gauge
F01J5IA 1
TYPICAL
1. Remove plug
Check oil level, it should be at bottom of hole threads.

If oil level is low, check impeller shaft housing for
leaks. A pressure test must be performed. See
PUMP PRESSURIZATION in this subsection.
To check oil condition, insert a wire through oil lev-
el hole then withdraw. A whitish oil indicates wa-
ter contamination.
SMR2002-088_12_02A.FM 12-02-3
This may involve defective impeller shaft seal and/or CAUTION: This is a synthetic oil. Do not mix with
O-ring of housing cover. Jet pump unit should be mineral based oil. Do not mix oil brands.
overhauled to replace seal. Apply Loctite pipe sealant (P/N 293 800 018) on
If everything is correct, apply Loctite pipe sealant plug threads and reinstall it on cover.
(P/N 293 800 018) on plug threads and reinstall it NOTE: The plug threads are perpendicular to the
on cover. Properly reinstall removed parts. impeller shaft.
NOTE: The plug threads are perpendicular to the Properly reinstall removed parts.
impeller shaft.
Oil Replacement REMOVAL

Remove venturi as described in OIL INSPECTION. Reverse Gate
Remove 3 screws retaining cover. To remove reverse gate no. 4, put shift lever in
reverse position.
Unscrew pivot bolt no. 5.
1
F02J0TB 1
TYPICAL
1. Screws
Using a fiber hammer, gently tap cover to release

it from housing cover.
F16J04A 2
Thoroughly clean reservoir and inside of cover
1. Pivot bolt no. 5
with a solvent. Check O-ring condition. Replace as 2. Screw no. 8
necessary.
Remove both reverse gate screws no. 8.
Apply a thin layer of Loctite 518 on mating surface
of cover and reinstall it with its O-ring.
Apply Loctite 243 on threads and torque screws
Remove plug from cover.
Pour oil through hole until oil reaches the bottom
of hole threads. Use SEA-DOO JET PUMP SYN-
THETIC OIL (P/N 293 600 011) only. Oil will drain
slowly into center area of housing, wait a few min-
utes and readjust oil level.
12-02-4 SMR2002-088_12_02A.FM
Pivot Support – pivot arm bolts no. 18. Take note of bushing size
for reinstallation.
Remove reverse gate.
Withdraw pivot arm no. 19.
Unscrew pivot support bolts no. 13.
1 2
F16J06A 2 3 1
1. Pivot bolts (each side)
F18J0JA 4 3 2. Spring
3. Pivot arm
1. Pivot bolt
2. Pivot support
3. Reverse gate Nozzle
4. Pivot support bolt no. 13
Withdraw pivot support.
Disconnect steering cable from jet pump nozzle.
Connecting Rod Remove OPAS “U” lever screw, washer and bush-
ings from nozzle.
Remove:
– reverse gate
– pivot bolt no. 14.
Withdraw connecting rod.
Pivot Triangle
Remove:
– reverse gate
– connecting rod
– pivot triangle bolts no. 15.
Withdraw pivot triangle no. 16.
Pivot Arm F18J0DA 1

Position shift lever in forward. 1. “U” lever screw
Remove: Remove 2 retaining screws no. 21, 2 sleeves no. 22,

– reverse gate 2 washers no. 23.
– connecting rod Remove nozzle.
– spring no. 17
– reverse cable
SMR2002-088_12_02A.FM 12-02-5
Venturi
1
Remove:
– reverse gate
– nozzle.
Unfasten reverse cable from pivot arm.
Unplug OPAS hose from plastic elbow.
Remove 4 retaining screws no. 39 and withdraw
venturi no. 24.
It’s possible to remove the venturi without remov-
ing the reverse gate and the nozzle, see the fol-
lowing instructions.
Disconnect:
– steering cable
F02J0TA 1
1
TYPICAL
1. Remove screws
Jet Pump Housing

Remove:
– nozzle
– venturi.
Loosen 4 hexagonal nuts no. 24 and remove flat
washers and lock washers from jet pump housing.
Remove jet pump with a wiggle movement.
CAUTION: When removing pump unit, a shim
F18J0KA
could have been installed between hull and
pump housing. Be sure to reinstall it otherwise
1. Steering cable engine and jet pump alignment will be altered.
– OPAS hose NOTE: After jet pump removal, if drive shaft re-
– reverse cable. mains in the PTO flywheel, simply pull it out. If
drive shaft is seized in the PTO flywheel, refer to
Remove 4 retaining screws no. 39 and withdraw DRIVE SYSTEM.
venturi no. 24.
DISASSEMBLY
NOTE: Whenever removing a part, visually check
for damage such as: corrosion, crack, split, break,
porosity, cavitation, deformation, distortion, heat-
ing discoloration, wear pattern, missing plating,
missing or broken needles in needle bearing, wa-
ter damage diagnosed by black-colored spots on
metal parts, etc. Renew any damaged part. As a
quick check, manually feel clearance and end play,
where applicable, to detect excessive wear.
12-02-6 SMR2002-088_12_02A.FM
Cover
With pump assembly in horizontal position, remove
3 retaining screws no. 26.
Place container under cover no. 27 to catch oil.
Using a fiber hammer, gently tap cover to release
it from jet pump housing.
Impeller 1
Insert impeller shaft holder (P/N 295 000 082) on
impeller shaft flat end.
Using 2 screws previously removed from venturi,
secure shaft holder to housing.
F00J0HA
1. Shaft holder
Impeller is loosened using impeller remover tool

(P/N 295 000 001).
F01J0TA
F00J07A 1
1. Shaft holder
Insert special tool in impeller splines.
Heat impeller shaft end with a propane torch to 1

approximately 150°C (300°F) to break the Loctite
bond before to remove impeller. Do not heat im-
peller directly.
Install shaft holder in a vice.
F00J08A
1. Impeller remover tool
SMR2002-088_12_02A.FM 12-02-7
Rotate impeller remover tool counterclockwise After cutting ring, insert a screwdriver blade be-
and unscrew completely impeller. tween jet pump housing and ring outside diameter.
CAUTION: Never use any impact wrench to loos- Push ring so that it can collapse internally.
en impeller. Pull ring out.
To remove impeller, apply a rotating movement
and pull at same time. Slide impeller out of hous- Impeller Shaft
ing. Remove tool from impeller. Remove shaft holder tool.
Wear Ring Remove impeller shaft no. 28 with thrust washer
and thrust bearing.
Remove the screws retaining wear ring in the jet
pump housing. Seal and Needle Bearing
Place jet pump housing in a vise with soft jaws. It Remove seal no. 29 and bearings no. 30 at the
is best to clamp housing using a lower ear. same time using bearing/seal remover tool (P/N 295
Cut wear ring at two places. 000 144).
CAUTION: When cutting ring, be careful not to
damage jet pump housing.
NOTE: Wear ring can be cut using a jigsaw, a small
grinder or a low clearance hacksaw such as Snap-
on HS3 or equivalent.
F01J11A
Insert bearing remover then press tool using a ar-

bor press until seal and bearings are out. However,
care should be taken not to damage bearing jour-
nals.
F01J0VA
TYPICAL 1
F00J0MA
1. Bearing/seal remover tool
NOTE: It is always recommended to renew both

F01J0WA
bearings, even if only one bearing needs to be re-
TYPICAL placed.
1. Snap-on HS3
12-02-8 SMR2002-088_12_02A.FM
CLEANING PARTS INSPECTION

Thoroughly clean jet pump housing by applying Loc- Impeller
tite Stripper (P/N 293 110 004). Allow it some time
to dissolve the old dried Loctite (10 to 15 minutes). Visually inspect impeller splines. Check for wear or
deformation. Renew parts if damaged.
 WARNING NOTE: Check also PTO flywheel and drive shaft
Technician should wear gloves when using this condition. Refer to BOTTOM END and DRIVE SYS-
cleaning product. TEM.
Examine impeller in wear ring for distortion.
CAUTION: DO NOT use Loctite Stripper on wear
ring since it will cause irreparable damage to it. Check if blade tips are blunted round, chipped or
broken. Such impeller is unbalanced and will vi-
Wipe Loctite Stripper with a clean cloth. brate and damage wear ring, impeller shaft, shaft
Make sure surface is cleaned and dried of Loctite seal or bearings. Renew if damaged.
Stripper.
1
Sealant on the jet pump housing can be removed
with a wire brush (disc) mounted on a drill or a
scraper.
Properly clean all threads.
Remove all O-rings and clean parts in a solvent.
Carefully check water passages and oil passages.
Blow low pressure compressed air through them
and make sure they are clear.
F02J0VB
1
1. Replaced if blunted round or damaged
Check impeller for cavitation damage, deep scratch-

es or any other damage.
F01J13A
2
TYPICAL
1. Water passages
2. Oil passages
Brush and clean impeller shaft threads, impeller

and drive shaft splines with Pulley flange cleaner
(P/N 413 711 809) or equivalent. Free threads and
splines from any residue.
CAUTION: Be careful not to damage impeller F02J0UA
shaft diameter. 1. Check for cavitation, deep scratches or other damage
SMR2002-088_12_02A.FM 12-02-9
Wear Ring To check both bearings, proceed the same way

with other shaft end. Position gauge tip on diam-
Check wear ring no. 31 for deep scratches, irreg-
eter, close to flats on shaft.
ular surface or any apparent damage.
If impeller/wear ring clearance is too large and im-
peller is in good shape, renew wear ring. 1
Needle Bearing and Impeller Shaft

WEAR
Inspect needle bearings no. 30 and their contact
surface. Check for scoring, pitting, chipping or oth-
er evidence of wear.
With your finger nail, feel contact surface of seal.
If any irregular surface is found, renew impeller
shaft no. 28.
Install bearings, then install impeller shaft and ro-
tate it. Make sure it turns smoothly. F01J19A 2
RADIAL PLAY TYPICAL — MEASURING IMPELLER SHAFT RADIAL PLAY
1. Dial gauge
Radial play is critical for jet pump unit life span. 2. Measure close to flats at shaft end
Radial play of impeller shaft is checked with shaft Excessive play can come either from worn bear-
in housing, without impeller. ings or impeller shaft or damaged jet pump hous-
Retain housing in a soft jaw vise making sure not ing bearing surfaces.
to damage housing lug. Measuring shaft diameter will determine the de-
Set a dial gauge and position its tip onto shaft end, fective parts.
close to end of threads. Using a micrometer, measure diameter on bearing
Move shaft end up and down. Difference between contact surfaces. Minimum shaft diameter should
highest and lowest dial gauge reading is radial be 22.24 mm (.876 in).
play.
1
Maximum permissible radial play is 0.05 mm (.002 in).
F01J1AA
1. Inspect for wear at the bearing pilot

2. Radial bearing raceway
F01J18A 2 NOTE: If shaft is to be replaced, it is recommend-

ed to replace both bearings at the same time. In
TYPICAL — MEASURING IMPELLER SHAFT RADIAL PLAY addition, it is suggested to replace thrust bearing
1. Dial gauge and thrust washer.
2. Measure close to threads at shaft end
12-02-10 SMR2002-088_12_02A.FM
Thrust Washer and Thrust Bearing Seal

Visually inspect thrust washer no. 32, thrust bear- Carefully inspect seal lips. Make sure that lips are
ing no. 33 and their contact surface. Check for not worn, distorted, cracked or show signs of any
scoring, pitting, flaking, discoloration or other evi- other damage. Replace after 150 hours even if it
dence of wear. For best inspection, use a 7X mag- seems good.
nifying glass to check wear pattern.
OPAS Filter
1 2
OPAS filter is part of plastic elbow no. 45. Check
3 for cleanness. Replace or clean it as necessary.
ASSEMBLY
Plastic Elbow
Install plastic elbow no. 45 at 20° angle to the right.
It may exceed inside housing by 1.0 mm (.039 in).
It may be positioned up to 2.0 mm (.078 in) from
housing edge.
F01J52A
TYPICAL
1. Worn roller (trunnion worn on end roller)
2. Good roller (cylindrical shape)
3. Look for scoring on retainer
NOTE: When replacing either washer or bearing,

it is recommended to renew both.
Anti-Rattle Pusher
B
Check for melted plastic around metal pad. If so,
replace it.
F18J0EA C
A. 20°
B. 2.0 mm (.078 in)
C. 1.0 mm (.039 in)
F08J05A
Check for excessive wear of pad.
SMR2002-088_12_02A.FM 12-02-11
Wear Ring
This model is equipped with large pump. It is im-
portant that the screws retaining wear ring to hous-
ing are installed on this model.
F01J5DA
1. Seal lip
2. Press wear ring
F08J06A
If a press is not readily available, a piece of wood
such as a 2 x 4 in x 12 in long, can be used.
Manually engage ring in housing making sure it is
equally inserted all around. Place wood piece over
ring. Using a hammer, strike on wood to push ring.
Strike one side then rotate wood piece about 90°
and strike again. Frequently rotate wood piece so
that ring slides in evenly until it seats into bottom
of housing.
F08J07A
To install ring in housing, use a square steel plate of 3

approximately 180 x 180 mm x 6 mm thick (7 x 7 in
x 1/4 in) and a press.
equally inserted all around. Press ring until it seats 2
into bottom of housing. 1
F01J5EA
1. Piece of wood
2. Seal lip facing upward
3. Wear ring
Install retaining screws.
12-02-12 SMR2002-088_12_02A.FM
Seal and Needle Bearing

Bearings no. 30 and seal no. 29 will be properly
installed in housing using bearing/seal installer
tool (P/N 295 000 107).
1
F01J4KA 2
BEARING/SEAL INSTALLER TOOL
F01J1HA
1. Seal side
2. Bearing side
1. Stamped end this side
For the bearing on venturi side use inner bearing
CAUTION: Never hammer the bearing into its
installer tool (P/N 529 035 609).
housing.
1
F08B01A
CAUTION: Failure to use this tool will cause ma-

jor damage to the pump.
Impeller Side 2
Stamped end of bearings (showing identification
markings) must be located toward outside of hous-
ing.
Properly insert bearing on tool. Using an arbor press F00J0ZA
only, push tool until tool flange contacts housing.
1. Press on tool until it stops
2. Bearing
CAUTION: These tools have been designed to

properly position bearings and seal, thus pro-
viding space for lubrication purposes. The tool
flanges allow this. If a different pusher type is
being used, components must be properly po-
sitioned as follows.
SMR2002-088_12_02A.FM 12-02-13
Bearing on impeller side must be 1.5 to 2.5 mm CAUTION: Prevent sealant from contacting any
(.060 - .100 in) inside reservoir measured from seal needles of bearing.
seat. Refer to following illustration. Push on tool end with a press until tool flange con-
tacts housing.
F01J5YA
1. Seal seat
2. Stamped end of bearing
A. 1.5 - 2.5 mm (.060 - .100 in) F00J0CA 1
Apply Loctite 518 (P/N 293 800 038) to seal hous- 1. Press on tool until it stops
ing, all around outer diameter and on seal seat. Apply synthetic grease (P/N 293 550 010) between
Properly insert seal on tool. seal lips.
NOTE: Apply synthetic grease on tool to ease seal
insertion. 1
Install seal with the spring toward the outside.
F01J1MA
F01J1KA 1 1. Loctite 518 all around and behind

2. Spring of seal lip this side
1. Spring of seal this side
12-02-14 SMR2002-088_12_02A.FM
Venturi Side Bearing on venturi side must be 2 to 3 mm (.078 -

Stamped end of bearings (showing identification .118 in) inside reservoir measured from thrust wash-
markings) must be located toward outside of hous- er seat. Refer to following illustration.
ing.
Properly insert bearing on tool. Using an arbor press
only, push tool until tool flange contacts housing.
F01J5YB
1. Thrust washer seat

1 2. Stamped end of bearing
A. 2 - 3 mm (.078 - .118 in)
F01J1HA
Thrust Washer
1. Stamped end this side
Position jet pump housing with the stator vanes on
top.
CAUTION: Never hammer the bearing into its
Insert thrust washer no. 32 in the stator seat.
housing.
F00J0DA 1
1. Thrust washer properly installed in stator seat
F16J09A
1. Press on tool until it stops
CAUTION: These tools have been designed to

properly position bearing, thus providing space
for lubrication purposes. The tool flanges allow
this. If a different pusher type is being used,
components must be properly positioned as fol-
lows.
SMR2002-088_12_02A.FM 12-02-15
Thrust Bearing
Apply SEA-DOO JET PUMP SYNTHETIC OIL (P/N
293 600 011) on both sides of thrust bearing.
Position thrust bearing no. 33 on thrust washer
no. 32.
F00J0FA 1 2
1. Impeller shaft
2. Impeller shaft guide
NOTE: If jet pump housing rest against a table,

raise it slightly to allow complete shaft insertion
with the shaft guide.
F00J0EA 1
Remove shaft guide.
1. Thrust bearing on top of thrust washer
Impeller Shaft Impeller

To prevent seal lip damage when inserting impeller Apply Loctite primer N (P/N 293 600 012) on threads
shaft, use impeller shaft guide (P/N 295 000 002). of impeller shaft no. 28. Allow to dry for 2 minutes.
NOTE: Loctite primer is used to reduce Loctite
243 curing time and to activate stainless steel and
aluminum surfaces for better bonding action. If ap-
plied, complete curing time is 6 hours, if primer is
not used, allow 24 hours for curing time.
Apply Loctite 243 (blue) to shaft threads.
F01J1OA
Insert tool onto shaft end then carefully install

shaft in jet pump housing.
F00J0GA 1
1. Apply Loctite 243 (blue) on threads
12-02-16 SMR2002-088_12_02A.FM
Using 2 screws previously removed from venturi, Torque impeller to 115 N•m (85 lbf•ft) then remove
secure impeller shaft holder tool (P/N 295 000 082) tools.
to housing. CAUTION: Never use any impact wrench to tight-
Install shaft holder tool in a vise. en impeller.
Apply synthetic grease (P/N 293 550 010) on im-
peller splines.
Insert a new boot no. 2 and ring no. 3 to impeller.
F00J0HA
1. Impeller shaft holder secured in a vise
To ease impeller installation, apply BOMBARDIER

LUBE lubricant on wear ring. F00J10A 1
Insert impeller into wear ring. Manually rotate im- 1. Boot and ring
peller and push so that it slides on impeller shaft
threads. Carefully engage threads making sure Anti-Rattle System
they are well aligned. Install spring no. 34 on slider no. 35.
Install impeller remover/installer tool into impeller
splines and tighten.
F00J0VA 2 1
F00J08A
1. Spring
1. Impeller remover/installer tool 2. Slider
CAUTION: Make sure thrust washer and bear-

ing are not wedged in shaft groove. To check,
manually pull and push jet pump housing, some
axial play must be felt.
SMR2002-088_12_02A.FM 12-02-17
Insert slider and spring into cover. Hold tab and torque screws.
NOTE: Align the longer slider tab with hole. Remove pencil or tool to release locking mecha-
nism.
Check if the mechanism worked properly. Push
tab with the pencil or tool; if there is a small play
the installation is correct. If not, redo the proce-
dure.
Verify if the impeller is rotating freely.
Add oil.
Oil Fill
NOTE: It is highly recommended to perform a
leakage test prior adding the oil. See PUMP PRES-
SURIZATION in this subsection.
F00J0WA
Place housing horizontally as in its operating posi-
tion so that filler plug is located on top. Remove
Apply synthetic grease in the center hole of the filler plug from cover. Pour SEA-DOO JET PUMP
cover. SYNTHETIC OIL (P/N 293 600 011) in reservoir un-
Install pusher no. 36 into cover. Place the flat side til oil comes level with bottom of hole. Let oil drain
in front of slider tab. into housing and after a few minutes add more oil
until it is level with bottom of filler hole.
CAUTION: This is a synthetic oil. Do not mix
with mineral based oil. Do not mix oil brands.
NOTE: When filling reservoir, oil must be poured
into cover quite slowly to allow complete housing
fill.
Apply Loctite pipe sealant (P/N 293 800 018) on
plug threads and reinstall it on cover.
NOTE: The plug threads are perpendicular to the
impeller shaft.
F00J0XA
Install O-ring no. 37 to cover. Apply Loctite 518 on

O-ring.
Install cover to jet pump housing making sure to
properly position filler plug on top side. Do not
torque yet, keep a small gap. F00J0JA 1
Insert a pencil or any other plastic tool in the hole TYPICAL
and push on the slider tab. 1. Pour oil slowly until it is level with bottom of filler hole
CAUTION: Do not use a metal tool to push the
tab. It is possible to damage the inner threads.
12-02-18 SMR2002-088_12_02A.FM
Venturi O-Rings
If needed, install new O-rings no. 38 around bailer Install O-rings no. 38 around bailer passages or
passages. make sure they are in place if they were not re-
moved.
PUMP PRESSURIZATION
Whenever doing any type of repair on jet pump, a
pressure test should be done to check for leakage.
Proceed as follows:
– Remove drain plug from cover.
– Apply Loctite Pipe sealant on threads of fitting
tool (P/N 295 000 086) then secure on cover.
– Connect pump gauge tester (P/N 529 021 800)
to fitting.
– Pressurize pump to a maximum of 70 kPa (10 PSI).
F00J0KA 1
1. O-rings
Apply Primer N on mating surface. Allow to dry for

2 minutes.
Apply Loctite 518 (Gasket Eliminator) on mating
surface.
Position venturi no. 24 with bailer passages on
top.
Apply Loctite 243 (blue) on threads of screws no. 39.
Install screws no. 39, lock washers and flat wash-
ers then torque to 21 N•m (16 lbf•ft).
1 F00J0LA
– Pump must maintain this pressure for at least

10 minutes.
CAUTION: Repair any leak, failure to correct a
leak will lead to premature wear of pump com-
ponents.
NOTE: If there is a pressure drop spray soapy wa-
ter around cover. If there are no bubbles, impeller
shaft, impeller shaft seal, or jet pump housing is
leaking through porosity and has to be replaced.
Jet pump unit has to be disassembled. If jet pump
has been overhauled, the impeller shaft seal
no. 22 may be leaking; Add a small quantity of
1 SEA-DOO JET PUMP SYNTHETIC OIL to wet the
F02J0TA
oil seal. Let soak and recheck.
1. Torque screws to 21 N•m (16 lbf•ft)
SMR2002-088_12_02A.FM 12-02-19
– Disconnect pump gauge tester and remove fit- Nozzle

ting.
Insert bushing no. 42 in nozzle no. 20.
– Check oil level. Refill as necessary.
Insert bushing no. 43 in nozzle no. 20 with its off-
– Apply Loctite Pipe sealant (P/N 293 800 018) to set pointing rearward.
threads of filler plug then secure it in cover.
1
NOTE: The plug threads are perpendicular to the
impeller shaft.
INSTALLATION
Jet Pump Housing
Make sure that blue rubber covered reducer no. 44
is installed as shown.
1
F18J0GA
1. Bushing offset
Position their flanges from inside of nozzle.

Insert sleeves no. 22 in bushings no. 42 and no. 43.
Install nozzle on venturi no. 24; position its steer-
ing arm on RH side. Apply Loctite 243 (blue) on
F18J0FA
screw threads (or use new self-locking screws).
Install screws no. 21 and washer no. 23 then
1. Blue rubber covered reducer
torque to 24 N•m (18 lbf•ft).
Generously apply synthetic grease on drive shaft
splines.  WARNING
Make sure rubber damper is on drive shaft end. Screws must be torqued as specified.
Install jet pump. If necessary, wiggle jet pump to
engage drive shaft splines in impeller. OPAS
CAUTION: Some watercraft require a shim be- Reconnect OPAS hose. Torque clamp screw to 1.7
tween hull and pump; if shim has been re- N•m (15 lbf•in).
moved at pump removal, be sure to reinstall it,
otherwise engine alignment will be altered. Fasten OPAS “U” lever to nozzle. Apply Loctite 243
(blue) on screw threads (or use new self-locking
Apply Loctite 243 (blue) on stud threads of jet screws). Torque screw to 20 N•m (15 lbf•ft).
pump housing.
Install flat washers no. 40, lock washers no. 41 Pivot Triangle
and nuts no. 25. Tighten nuts of jet pump housing Install head bolts toward inside.
in a criss-cross sequence and torque to 31 N•m
(23 lbf•ft). NOTE: Make sure the pivot triangle turn freely.
NOTE: Slightly lubricate wear ring with BOMBARDIER
LUBE lubricant to minimize friction during initial
start.
12-02-20 SMR2002-088_12_02A.FM
Reverse Gate
Install reverse gate with spacer and washer. Torque
NOTE: When installing the reverse gate, pay atten-
tion to position its lever behind the reverse gate
support stopper.
F07J07A
1. Stopper
Steering Cable
Refer to section, STEERING SYSTEM.
Reverse Cable
Refer to REVERSE SYSTEM.
SMR2002-088_12_02A.FM 12-02-21
GTX 4-TEC Models
Loctite 454
3
2 1
31
Loctite
518
6 Nm
(53 lbfin) 38
44
40
41
34 25 31 Nm
35 (23 lbfft)
36
30 Alsaco
46 grease
32 33 Pipe sealant
592 24 Nm
(18 lbfft)
Primer N 28 45
and 21
37 23
Loctite 243 24
13 22
26
7.5 Nm
(66 lbfin) 20
42
Loctite 43
243 39
16 21 Nm
(16 lbfft)
14
15
2.5 Nm
(22 lbfin)
6 7
19
13
13
5
2.5 Nm
18 (22 lbfin)
17 4
20 Nm
(15 lbfft) 8
F18J0HS
12-02-22 SMR2002-088_12_02A.FM
GENERAL WATERCRAFT IMPELLER

MATERIAL PITCH
MODEL P/N
4
Progressive
Stainless
GTX 4-TEC 271 001 171 pitch
3 steel
13° - 23°
2 JET PUMP INSPECTION ON

5
1 WATERCRAFT
To work on watercraft, securely install it on a stand.
Thus, if access is needed to water inlet area, it will
6 be easy to slide underneath watercraft.
A lift kit can be used to install watercraft on a stand.
F00J0SA
TYPICAL
1. Nozzle
2. Venturi
3. Housing
4. Wear ring
5. Impeller
6. Stator
Cleanness Requirements
Hands, tools, bench, rags must be clean before 1
pump disassembly.
CAUTION: Pump grease tube must be opened
at very last moment to avoid contamination. F01J42A 2
TYPICAL
Impeller Identification 1. Lift kit
2. Work stand
To identify the impellers refer to the following il-
lustration and chart.
Impeller Condition
Condition of impeller no. 1, boot no. 2 and ring
no. 3 can be quickly checked from underneath of
the watercraft. Remove grate and look through
water inlet opening.
F02J0VA
1. Stamped part number
F01J0DA
TYPICAL
1. Inspect impeller and boot
SMR2002-088_12_02A.FM 12-02-23
Impeller/Wear Ring Clearance

This clearance is critical for jet pump performance.
Clearance can be checked from water inlet open-
ing or from venturi side. However, the last method
requires more work.
To check clearance from water inlet side, remove
inlet grate.
To check clearance from venturi side, remove
venturi/nozzle assembly.
Using a feeler gauge with 30 cm (12 in) blades,
measure clearance between impeller blade tip and
wear ring. Measure each blade at its center. For
GTX 4-TEC clearance should not exceed 0.35 mm F01J0FA 1
(.014 in). If clearance is greater, disassemble jet
TYPICAL — MEASURING FROM VENTURI SIDE
pump and inspect impeller and wear ring. Renew
1. Feeler gauge
worn parts.
1
REMOVAL
Pump Assembly
Remove OPAS “U” lever screw, washer and bush-
ings from nozzle.
F01J0EA
TYPICAL — MEASURING FROM WATER INLET SIDE

1. Feeler gauge
F18J0DA 1
1. “U” lever screw
Disconnect steering and reverse cables.

Disconnect OPAS hose from top of pump.
Remove 4 pump retaining nuts.
Pull out pump.
12-02-24 SMR2002-088_12_02A.FM
Reverse Gate Withdraw pivot support.

To remove reverse gate no. 4, put shift lever in
reverse position.
Connecting Rod
Unscrew pivot bolt no. 5. Remove:
– reverse gate
1
– pivot bolt no. 14.
Withdraw connecting rod.
Pivot Triangle
Remove:
– reverse gate
– connecting rod
– pivot triangle bolts no. 15.
Withdraw pivot triangle no. 16.
Pivot Arm
Position shift lever in forward.
Remove:
F16J04A 2 – reverse gate
1. Pivot bolt no. 5 – connecting rod
2. Screw no. 8
– spring no. 17
Remove both reverse gate screws no. 8. – reverse cable
Pivot Support – pivot arm bolts no. 18. Take note of bushing
size for reinstallation.
Withdraw pivot arm no. 19.
Unscrew pivot support bolts no. 13.
1 2
F18J1AA 2 3 1
1. Pivot bolts (each side)
2. Spring
3. Pivot arm
F18J0JA 4 3
1. Pivot bolt
2. Pivot support
3. Reverse gate
4. Pivot support bolt no. 13
SMR2002-088_12_02A.FM 12-02-25
Nozzle 1
Disconnect steering cable from jet pump nozzle.
Remove OPAS “U” lever screw, washer and bush-
ings from nozzle.
F18J0KA
1. Steering cable
– OPAS hose
– reverse cable.
F18J0DA 1 Remove 4 retaining screws no. 39 and withdraw
venturi no. 24.
1. “U” lever screw
Remove 2 retaining screws no. 21, 2 sleeves no. 22, 1

2 washers no. 23.
Remove nozzle.
Venturi
Remove:
– reverse gate
– nozzle
– pivot arm.
Unplug OPAS hose from plastic elbow.
Remove 4 retaining screws no. 39 and withdraw
venturi no. 24.
It’s possible to remove the venturi without remov- 1
F02J0TA
ing the reverse gate and the nozzle, see the fol-
lowing instructions. TYPICAL
1. Remove screws
Disconnect:
– steering cable
12-02-26 SMR2002-088_12_02A.FM
Jet Pump Housing Using a fiber hammer, gently tap cover to release
it from jet pump housing. Use flat screwdriver to
Remove pump as an assembly or remove the fol-
remove cap.
lowing:
– nozzle
– venturi.
Loosen 4 hexagonal nuts no. 24 and remove flat
washers and lock washers from jet pump housing.
Remove jet pump with a wiggle movement.
CAUTION: When removing pump unit, a shim
could have been installed between hull and
pump housing. Be sure to reinstall it otherwise
engine and jet pump alignment will be altered.
NOTE: After jet pump removal, if drive shaft re-
mains in the PTO flywheel, simply pull it out. If
drive shaft is seized in the PTO flywheel, refer to
DRIVE SYSTEM.
DISASSEMBLY F18J0MA
NOTE: Whenever removing a part, visually check Check for presence of water in cone and bearing.
for damage such as: corrosion, crack, split, break, If so, replace oil seal no. 35 and sleeve no. 30.
porosity, cavitation, deformation, distortion, heat- Remove both O-rings no. 37 and circlip.
ing discoloration, wear pattern, missing plating,
missing or broken balls in ball bearing, water dam-
age diagnosed by black-colored spots on metal
parts, etc. Renew any damaged part. As a quick
check, manually feel clearance and end play,
where applicable, to detect excessive wear.
Cover
With pump housing in vertical position, remove 3
retaining screws no. 26.
F18J0NA
F18J0LA
F18J0OA
SMR2002-088_12_02A.FM 12-02-27
Impeller NOTE: It may be needed to heat the impeller to

break Loctite bond.
Remove ring no. 3, impeller boot no. 2. Replace
them if damaged.
Mount impeller remover/installer (P/N 529 035 820)
in a vise.
529 035 820
F18J0RA
CAUTION: Never use any impact wrench to loos-

en impeller.
F18J0PA To remove impeller, apply a rotating movement and
pull at same time. Slide impeller out of housing.
Install pump over this tool.
Pull pump housing out.
F18J0QA F18J0SA
Using a 12 mm Allen key, unscrew the impeller.
12-02-28 SMR2002-088_12_02A.FM
Remove shield no. 34.
F18J0VA 529 035 819

F18J0TA
From the outlet side of pump, use the seal/bearing
Use the impeller shaft pusher (P/N 529 035 818) pusher (P/N 529 035 819) to press out the oil seal
to press out impeller shaft no. 28 of pump hous- no. 35.
ing. Bearing no. 33, shaft sleeve no. 30, O-ring
no. 46 and spacer no. 32 will come out with the
impeller shaft.
529 035 819
529 035 818
F18J0WA
Remove large O-ring no. 36 from pump housing.
F18J0UA Wear Ring

CAUTION: Bearing inner race being in 2 parts, Remove the screws retaining wear ring in the jet
bearing may fall apart during removal. pump housing.
Use the seal/bearing pusher (P/N 529 035 819) to Place jet pump housing in a vise with soft jaws. It
press out bearing no. 33 from impeller shaft. is best to clamp housing using a lower ear.
Cut wear ring at two places.
CAUTION: When cutting ring, be careful not to
damage jet pump housing.
NOTE: Wear ring can be cut using a jigsaw, a small
grinder or a low clearance hacksaw such as Snap-
on HS3 or equivalent.
After cutting ring, insert a screwdriver blade be-
tween jet pump housing and ring outside diameter.
Push ring so that it can collapse internally.
Pull ring out.
SMR2002-088_12_02A.FM 12-02-29
CLEANING PARTS INSPECTION

Thoroughly clean jet pump housing by applying Impeller
Loctite Stripper (P/N 293 110 004). Allow it some
time to dissolve the old dried Loctite (10 to 15 min- Visually inspect impeller splines. Check for wear or
utes). deformation. Renew parts if damaged.
NOTE: Check also PTO flywheel and drive shaft con-
 WARNING dition. Refer to BOTTOM END and DRIVE SYSTEM.
Technician should wear gloves when using Examine impeller in wear ring for distortion.
this cleaning product.
Check if blade tips are blunted round, chipped or
CAUTION: DO NOT use Loctite Stripper on wear broken. Such impeller is unbalanced and will vi-
ring since it will cause irreparable damage to it. brate and damage wear ring, impeller shaft, shaft
seal or bearings. Renew if damaged.
Wipe Loctite Stripper with a clean cloth.
Make sure surface is cleaned and dried of Loctite 1
Stripper.
Sealant on the jet pump housing can be removed
with a wire brush (disc) mounted on a drill or a
scraper.
Properly clean all threads.
Remove all O-rings and clean parts in a solvent.
Carefully check water passages. Blow low pres-
sure compressed air through them and make sure
they are clear.
1
F18J1BA
1. Replaced if blunted round or damaged
Check impeller for cavitation damage, deep scratch-

es or any other damage.
1
F18J0XA
1. Water passages
Brush and clean impeller shaft threads, impeller

and drive shaft splines with Pulley flange cleaner
(P/N 413 711 809) or equivalent. Free threads and
splines from any residue.
F18J1CA
1. Check for cavitation, deep scratches or other damage
12-02-30 SMR2002-088_12_02A.FM
Wear Ring Excessive play can come either from worn bearing
or damaged jet pump housing bearing surface.
Check wear ring no. 31 for deep scratches, irreg-
ular surface or any apparent damage.
Seal
If impeller/wear ring clearance is too large and im-
peller is in good shape, renew wear ring. Carefully inspect seal lips. Make sure that lips are
not worn, distorted, cracked or show signs of any
Ball Bearing and Impeller Shaft other damage. Replace after 100 hours.
WEAR Bearing
IMPORTANT: Make sure to reassemble ball cage, Replace bearing whenever the marks of corrosion
bearing inner and outer races to their original po- and presence of water is found.
sition.
Inspect ball bearing no. 33. Check for corrosion, OPAS Filter
scoring, pitting, chipping or other evidence of wear. OPAS filter is part of plastic elbow no. 45. Check
With your finger nail, feel contact surface of sleeve. for cleanness. Replace or clean it as necessary.
If any irregular surface is found, renew sleeve
no. 30 and seal. ASSEMBLY
Install bearing, then install impeller shaft and ro- Hands, tools, bench, rags must be clean before
tate it. Make sure it turns smoothly. pump disassembly.
RADIAL PLAY CAUTION: Pump grease tube must be opened
Radial play is critical for jet pump unit life span. at very last moment to avoid contamination.
Radial play of impeller shaft is checked with shaft
in housing, with impeller. Plastic Elbow
Retain housing in a soft jaw vise making sure not Install plastic elbow no. 45 at 20° angle to the right.
to damage housing lug. It may exceed inside housing by 1.0 mm (.039 in).
Set a dial gauge and position its tip onto metal end, It may be positioned up to 2.0 mm (.078 in) from
close to end of threads. housing edge.
Move shaft end up and down. Difference between A
highest and lowest dial gauge reading is radial play.
Maximum permissible radial play is 0.75 mm (.029 in).
F18J0EA C
A. 20°
B. 2.0 mm (.078 in)
C. 1.0 mm (.039 in)
F18J1DA 1 2
MEASURING IMPELLER SHAFT RADIAL PLAY
1. Dial gauge
2. Measure close to threads at shaft end
SMR2002-088_12_02A.FM 12-02-31
Wear Ring
This model is equipped with large pump. It is im-
portant that the screws retaining wear ring to
housing are installed on this model.
F01J5DA
1. Seal lip
2. Press wear ring
F08J06A
If a press is not readily available, a piece of wood
such as a 2 x 4 in x 12 in long, can be used.
equally inserted all around. Place wood piece over
ring. Using a hammer, strike on wood to push ring.
Strike one side then rotate wood piece about 90° and
strike again. Frequently rotate wood piece so that ring
slides in evenly until it seats into bottom of housing.
F08J07A
3
To install 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 2
equally inserted all around. Press ring until it seats 1
into bottom of housing.
F01J5EA
1. Piece of wood
2. Seal lip facing upward
3. Wear ring
NOTE: Do not forget, install two retaining screws

on tops of the large pump models.
12-02-32 SMR2002-088_12_02A.FM
Bearing Coat shaft surface with jet pump bearing grease

(P/N 293 550 032) then, install sleeve no. 30 on
Using the seal/bearing pusher (P/N 529 035 819)
impeller shaft no. 28.
press the bearing no. 33 by its inner race on the
impeller shaft no. 28.
Be careful when removing the plastic retainer
from the bearing no. 33 to avoid the inner races
from falling apart. Make sure to reassemble bear-
ing parts to their original position.
The bearing no. 33 can be installed either side.
529 035 819

F18J10A
From the outlet side of pump, press impeller shaft

assembly into housing using shaft pusher (P/N
529 035 818).
F18J0YA
529 035 818
Install spacer no. 32 on shaft no. 28.
Install O-ring no. 46 in sleeve no. 30.
F18J11A
Install circlip and O-rings no. 37.
F18J0ZA
1. O-ring
SMR2002-088_12_02A.FM 12-02-33
Apply 10 cc of jet pump bearing grease (P/N 293 On the outlet side, install 2 O-rings no. 37 in their
550 032) on bearing. respective groove.
Before installing any other parts. pump can be
pressurized to insure proper seal installation. See
PUMP PRESSURIZATION below.
On the impeller side, install shield no. 34.
Apply Loctite 243 on impeller shaft and impeller
threads.
F18J12A
Press oil seal no. 35 using seal/bearing pusher

(P/N 529 035 819) until tool bottoms. Make sure
seal lips are facing up.
1 F18J15A
F18J13A F18J16A
1. Lips facing up
Apply BOMBARDIER Lube on the wear ring sur-
face. Start screwing the impeller on its shaft. If
529 035 819
impeller is too tight, use impeller tool to turn im-
peller to machine wear ring before installing on ve-
hicle. Make sure to turn it smooth enough so that
engine starter should turn it.
Mount impeller remover/installer (P/N 529 035 820)
in a vise.
Install partially screwed impeller on it.
Use a 12 mm Allen key to torque impeller shaft to
Torque impeller to 125 N•m (92 lbf•ft) then remove
tool.
F18J14A
12-02-34 SMR2002-088_12_02A.FM
CAUTION: Never use any impact wrench to tight-

en impeller shaft.
Apply 50 cc of jet pump bearing grease (P/N 293
550 032) in the impeller shaft area.
F00J0KA 1
1. O-rings
F18J17A
Position venturi no. 24 with bailer passages on top.
Apply another 50 cc of jet pump bearing grease Apply Loctite 243 (blue) on threads of screws no. 39.
(P/N 293 550 032) in the impeller cover. Install screws no. 39, lock washers and flat wash-
ers then torque to 21 N•m (16 lbf•ft).
F18J18A
Install impeller cover with new self-locking screws.

Torque to 7 N•m (62 lbf•in).
Venturi
F02J0TA 1
If needed, install new O-rings no. 38 around bailer
passages. 1. Torque screws to 21 N•m (16 lbf•ft)
O-Rings
Install O-rings no. 38 around bailer passages or make
sure they are in place if they were not removed.
SMR2002-088_12_02A.FM 12-02-35
PUMP PRESSURIZATION INSTALLATION

Whenever doing any type of repair on jet pump, a Jet Pump Housing
pressure test should be done to check for leakage.
Make sure that black rubber covered reducer
Proceed as follows: no. 44 is installed as shown.
– Remove impeller cover no. 13. Install pressure CAUTION: Misinstallation can cause overheating
cap (P/N 529 035 843) on pump housing. and damage to exhaust system.
– Connect pump gauge tester (P/N 529 021 800)
1
to fitting.
– Pressurize pump to a maximum of 70 kPa (10 PSI).
529 035 843
F18J0IA
1. Black rubber covered reducer
Generously apply synthetic grease on drive shaft

splines.
F18J19A
Make sure rubber damper is on drive shaft PTO
end.
– Pump must maintain this pressure for at least 5 Install jet pump. If necessary, wiggle jet pump to
minutes. engage drive shaft splines in impeller.
CAUTION: Repair any leak, failure to correct a CAUTION: Some watercraft require a shim be-
leak will lead to premature wear of pump com- tween hull and pump; if shim has been re-
ponents. moved at pump removal, be sure to reinstall it,
NOTE: If there is a pressure drop spray soapy wa- otherwise engine alignment will be altered.
ter around cover. If there are no bubbles, impeller Apply Loctite 243 (blue) on stud threads of jet
shaft, impeller shaft seal, or jet pump housing is pump housing.
leaking through porosity and has to be replaced.
Jet pump unit has to be disassembled. There may Install flat washers no. 40, lock washers no. 41
be 2 or 3 bubbles coming out from sleeve no. 30/ and nuts no. 25. Tighten nuts of jet pump housing
seal area. This small leak is acceptable. Leaks from in a criss-cross sequence and torque to 31 N•m
other areas must be repaired. (23 lbf•ft).
– Disconnect pump gauge tester and remove pres- NOTE: Slightly lubricate wear ring with BOMBARDIER
sure cap. LUBE lubricant to minimize friction during initial
start.
– Reinstall impeller cover no. 13 with 3 new self-
locking screws.
12-02-36 SMR2002-088_12_02A.FM
Nozzle Pivot Triangle

Insert bushing no. 42 in nozzle no. 20. Install head bolts toward inside.
Insert bushing no. 43 in nozzle no. 20 with its off- NOTE: Make sure the pivot triangle turn freely.
set pointing rearward.
Reverse Gate
1
Install reverse gate with spacer and washer. Torque
NOTE: When installing the reverse gate, pay at-
tention to position its lever behind the reverse
gate support stopper.
F18J0GA
1. Bushing offset
Position their flanges from inside of nozzle.

Insert sleeves no. 22 in bushings no. 42 and no. 43.
Install nozzle on venturi no. 24; position its steer-
ing arm on RH side. Apply Loctite 243 (blue) on F07J07A
screw threads (or use new self-locking screws). 1. Stopper

Install screws no. 21 and washer no. 23 then
torque to 24 N•m (18 lbf•ft). Steering Cable
 WARNING Refer to section, STEERING SYSTEM.
Screws must be torqued as specified. Reverse Cable
Refer to REVERSE SYSTEM.
OPAS
Reconnect OPAS hose. Torque clamp screw to 1.7
N•m (15 lbf•in).
Fasten OPAS “U” lever to nozzle. Apply Loctite 243
(blue) on screw threads (or use new self-locking
screws). Torque screw to 20 N•m (15 lbf•ft).
SMR2002-088_12_02A.FM 12-02-37
Subsection 03 (DRIVE SYSTEM)
DRIVE SYSTEM 0
GTX DI Models
2
3
4
5 1
6
7
8
2 Nm
9 (18 lbfin)
10
13
2 Nm
11 (18 lbfin)
Synthetic
grease 12
Synthetic
grease
13
F18I0LS
SMR2002-089_12_03A.FM 12-03-1
GTX 4-TEC MOdels
5
6
7
8
9
10
11
Loctite
antiseize 15
lubricant
12
16
Synthetic
grease
F18I01S
12-03-2 SMR2002-089_12_03A.FM
GENERAL
Jet pump must be removed to replace any com-
ponents of the drive system. Refer to JET PUMP
for removal procedure.
REMOVAL
GTX DI Models
PTO Flywheel Guard
Remove seat.
Remove vent tube support.
Remove plastic wing nuts retaining PTO flywheel
guard no. 1 to engine support.
Detach PTO flywheel guard from engine and with- F01J2AA
1
draw from bilge.
TYPICAL
Large Clamp 1. Closing hooks
GTX DI Models – Squeeze pliers to draw hooks together and dis-

engage windows from locking hooks.
Unfasten large clamp of PTO flywheel boot no. 3
as follows:
– Use pliers (P/N 295 000 069).
F01J0GA
– Insert pointed tips of pliers in closing hooks.
F01J29A 1
TYPICAL
1. Locking hooks
Small Clamp
Unfasten small clamp of PTO flywheel boot as fol-
lows:
SMR2002-089_12_03A.FM 12-03-3
– Use pliers (P/N 295 000 054). 4-TEC Models

oil will flow out. To prevent it, start engine, run at
4000 RPM for 10 seconds and stop engine at this
RPM. This will move oil out of PTO housing into
oil tank.
Remove seat.
Detach coolant expansion reservoir from vent
F01B1TA
tube support then move away.
2 1
– To open clamp, place flat side of plier on clamp
embossment, squeeze and twist plier.
F18L1GB
1. Detach expansion reservoir

2. Remove vent tube support
F02J0PA
Detach vent tube.

Circlip and Floating Ring Remove vent tube support.
Hold floating ring no. 6 and compress boot no. 10; Floating Ring and PTO Seal
then, pull out circlip no. 5 from drive shaft groove.
CAUTION: Strictly follow this procedure other-
1 2 wise damage to component might occur. Lift
splash guard to expose PTO seal assembly. In-
stall PTO seal support tool (P/N 529 035 842) on
bottom of PTO seal assembly as shown.
F06I06A
TYPICAL
1. Push floating ring
2. Remove circlip
F18B01A
1. PTO seal support tool
12-03-4 SMR2002-089_12_03A.FM
F18B03A
Disconnect EGT sensor to make room.

Install drive shaft/floating ring tool (P/N 529 035
1
841) as shown.
F18I04A
1. Insert in groove of PTO seal assembly
Remove jet pump. Refer to JET PUMP section.

Install drive shaft holder (P/N 529 035 871) on
pump support as shown. F18B04A
NOTE: This is necessary so the drive shaft cannot DRIVE SHAFT/FLOATING RING TOOL
move rearwards when using the drive shaft/floating
ring tool.
F18B02A
1. Drive shaft holder
SMR2002-089_12_03A.FM 12-03-5
2 1 1
F18I05A
1. Largest opening here F18I08A

2. Floating ring
1. Largest opening here
Turn screw clockwise so that the tool pushes the 2. Lubricate both O-rings
floating ring rearwards to expose the c-clip. Do not Turn screw clockwise so that the tool pushes the PTO
remove clip at this time. seal forward and the drive shaft to the rear to expose
NOTE: This step is done to ensure floating ring is both O-rings. Lubricate O-rings with BOMBARDIER
free and not stuck on the drive shaft. LUBE (P/N 293 600 016).
Remove drive shaft/floating ring tool and drive NOTE: This is necessary to ease drive shaft re-
shaft holder. moval later.
Reinstall drive shaft/floating ring tool as shown. Remove drive shaft/floating ring tool and PTO seal
support.
Reinstall drive shaft holder tool.
12-03-6 SMR2002-089_12_03A.FM
Remove drive shaft holder tool then drive shaft/

floating ring tool.
NOTE: Use this sequence to minimize the
amount of movement the drive will slide back into
PTO seal assembly.
All Models
Drive Shaft
Simply pull out drive shaft.
4-TEC Models
F18B03A If spillage occurs, clean immediately with the pul-
ley flange cleaner (P/N 413 711 809) to prevent oil
Reinstall drive shaft/floating ring tool as shown. stains.
Push floating ring rearwards to expose C-clip and NOTE: It may require a slight jerk to the rear to
remove it. remove the O-rings from the PTO seal assembly.
2 1
All Models
Boot
Loosen gear clamp no. 11 holding boot, then care-
fully pull boot and carbon ring no. 8 from hull in-
sert.
Carbon Ring
Loosen gear clamp no. 9 then pull carbon ring from
boot no. 10.
INSPECTION
Drive Shaft
Inspect condition of drive shaft and PTO flywheel
splines.
Inspect condition of groove.
With your finger nail, feel machined surface of
drive shaft. If any irregular surface is found, renew
drive shaft.
F18I0BA
1. Largest opening here

2. Remove C-clip
SMR2002-089_12_03A.FM 12-03-7
Damper
GTX DI Models
Visually inspect shape of dampers no. 13 for de-
formation or other damage.
4-TEC Models
Discard damper to install a new one.
F01I0FA 1 2 3
TYPICAL Floating Ring and O-Ring
1. Surface condition Inspect condition of O-rings no. 7 and floating ring
2. Groove condition
3. Splines condition contact surface.
4-TEC Models 1
Discard both O-rings to install new ones.
All Models
Excessive deflection could cause vibration and
damage to drive shaft splines, impeller, flywheel
or floating ring (seal carrier depending upon the
model).
Place drive shaft on V-blocks and set-up a dial gauge 2
in center of shaft. Slowly rotate shaft; difference
between highest and lowest dial gauge reading is
deflection. Refer to the following illustration.
F01I0GA
Maximum permissible deflection is 0.5 mm (.020 in).
1. O-rings
2. Floating ring contact surface
Boot
Inspect the condition of boot. If there is any dam-
age or evidence of wear, replace it.
GTX DI Models
1
To verify the preload of the boot no. 10, proceed
as follows:
NOTE: To verify the boot preload and free length,
jet pump and drive shaft must be installed.
F01J15A 2 Measure boot length when normally installed on
drive shaft. Ensure circlip no. 5 is properly in-
MEASURING DRIVE SHAFT DEFLECTION
stalled into groove.
1. Dial gauge
2. V-blocks
12-03-8 SMR2002-089_12_03A.FM
F00J03A 1 A
F00J04B
1. Boot
A. Measure here 1. Spacer
Push floating ring to compress boot; then, remove NOTE: Drive shaft must be removed to install spacer.
circlip out of drive shaft groove.
4-TEC Models
1 2
Inspect PTO seal assembly. Refer to PTO HOUSING/
MAGNETO section.
All Models
INSTALLATION
procedure. However, pay particular attention to
the following.
Drive Shaft and Dampers
F06I06A GTX DI Models

1. Push floating ring Install dampers no. 13 on drive shaft no. 12.
2. Remove circlip
NOTE: Make sure dampers were not left in PTO
Slide floating ring far enough forward in order to flywheel or impeller.
release it from carbon ring.
Install drive shaft and jet pump at the same time.
Measure boot free length.
Insert drive shaft through carbon ring no. 8 and
Subtract the installed length measurement from floating ring no. 6.
the free length measurement. A difference of 4 mm
NOTE: Make sure to install floating ring before in-
to 12 mm (5/32 in to 15/32 in) should be obtained.
serting the drive shaft in the PTO flywheel.
If the length is less than 4 mm (5/32 in), install a
While holding jet pump, guide and engage drive
spacer (P/N 293 250 017) between boot and thru
shaft splines in PTO flywheel. Rotate shaft to
hull fitting.
properly index splines. Make sure boot is well po-
sitioned over shaft end.
SMR2002-089_12_03A.FM 12-03-9
Circlip
Push the floating ring to compress the boot. Insert
the circlip no. 5 in the drive shaft groove.
1 2
F01J2BA 1
F06I06A
TYPICAL
1. Closing hooks
1. Push floating ring
2. Insert circlip in the groove – Squeeze pliers. When both large and small win-
Slide the floating ring onto the circlip. dows are directly over the 2 locking hooks,
press those windows down to engage hooks in
Large Clamp windows.
Secure large clamp no. 2 as follows: NOTE: At installation, clamp tail should be in op-
– Use pliers (P/N 295 000 069) as for removal. posite direction of engine rotation.
– Manually engage holding hook in large window. 1
This is a pre-clamping position only.
F01J23B 2
1. Engine rotation (counterclockwise)
2. Tail in opposite direction
F01J23A 2
PRE-CLAMPING POSITION Small Clamp
1. Holding hook To secure small clamp no. 4, place notch side of
2. Large window
plier on clamp embossment and squeeze plier.
– Insert pointed tips of pliers first in closing hooks.
12-03-10 SMR2002-089_12_03A.FM
F02J0PB
F18I0FA 1
1. Squeeze plier
WRONG INSTALLATION
1. Inner sleeve not flush with outer circumference
4-TEC Models
Slightly apply BOMBARDIER LUBE (P/N 293 600
Ensure to install a new damper no. 15 and new O- 016) on O-rings of drive shaft.
rings on drive shaft no. 12.
Apply a thin coat of synthetic grease (P/N 293 550
NOTE: Ensure to install floating ring before insert- 010) on the O-rings of floating ring and on splines
ing the drive shaft on PTO seal assembly. going in impeller. Do not get grease on it’s sealing
Before installing drive shaft, inspect PTO seal as- surface.
sembly. The inner sleeve must be flush with outer
circumference of the assembly. Otherwise, gently
push or tap on inner sleeve until flush.
1 2
F18I0KA
1. Synthetic grease
2. No lubrication
CAUTION: Note that drive shaft features a tell

tale groove. If exposed after installation, the in-
stallation is wrong and PTO seal assembly will
F18I0EA 1 be pressed into crankshaft splines which could
CORRECT INSTALLATION rub a hole in seal thus creating an oil leak.
1. Inner sleeve flush with outer circumference
SMR2002-089_12_03A.FM 12-03-11
When properly aligned, maintain PTO seal assembly

in the proper position and tap shaft end until it bot-
toms against engine. At this time, the tell tale MUST
NOT be visible. This validate the correct position.
F18I0GA 1
1. Tell tale groove F18I0HA 1 2 3
1. PTO seal support
Install PTO seal assembly. 2. Drive shaft end
3. Insert floating ring on shaft end
Install PTO seal support tool on PTO seal assembly.
Slide drive shaft far enough to install floating ring. 3 1
F18I02A
Continue pushing drive shaft towards engine care- F18I0IA 2

fully guiding it in the PTO seal then in crankshaft GOOD INSTALLATION
splines. 1. PTO seal assembly
2. Shaft pushed in, hiding tell tale groove
Then, push drive shaft until it bottoms against the 3. Inner sleeve flush with outer circumference
engine.
While someone is pushing drive shaft, slide float-
ing ring rearward and guide drive shaft in PTO seal
assembly. It may be necessary to move PTO seal
assembly up and down to position it in the same
axis as the drive shaft.
12-03-12 SMR2002-089_12_03A.FM
3 1 2 1
F18I06A
1. Largest opening
2. Install C-clip
F18I0JA 2
Remove drive shaft/floating ring tool, drive shaft
WRONG INSTALLATION holder then PTO seal support.
1. PTO seal assembly
2. Tell tale groove visible NOTE: Pushing boot no. 10 rearwards will ease
3. Inner sleeve NOT flush with outer circumference removal of PTO seal support tool.
Install drive shaft holder tool. Now ensure everything is properly positioned: Tell
tale is not exposed, inner sleeve is flush with outer
circumference of PTO seal assembly and C-clip is
not exposed.
If tell tale mark is exposed, push PTO seal assem-
bly rearwards to fully extend it.
If inner sleeve is not flush, gently tap it until it is
flush.
Reposition splash guard.
Reconnect EGT sensor.
Install jet pump. Refer to JET PUMP section.
Check engine oil level. Refill as necessary.
F18B03A
Run watercraft then ensure there is no oil leak in
PTO seal area.
Install Drive shaft/floating ring tool as shown. En-
sure PTO seal support is still in place.
Push floating ring rearwards and install C-clip.
SMR2002-089_12_03A.FM 12-03-13
LUBRICATION
PTO Flywheel
GTX DI Models
Using a grease gun, carefully lubricate PTO fly-
wheel with synthetic grease (P/N 293 550 010),
until boot is just beginning to expand. At this point,
immediately stop greasing.
F01I0BB
12-03-14 SMR2002-089_12_03A.FM
Subsection 04 (REVERSE SYSTEM)
REVERSE SYSTEM 0
2.5 Nm
(22 lbfin)
5 2.5 Nm Synthetic
(22 lbfin) grease
Loctite
243 7 2.5 Nm
(22 lbfin)
Loctite 243
9 10
Silicone Silicone
sealant sealant 3
2
7 3.3 Nm
Loctite 243 (29 lbfin)
Silicone Loctite 243
sealant
6
9
2.5 Nm
(22 lbfin)
Loctite 243
8
10
4 Nm
(35 lbfin) 4
12
11 10 Nm
(89 lbfin)
2 2.6 Nm
(23 lbfin)
F18J1GS
SMR2002-090_12_04A.FM 12-04-1
DISASSEMBLY 3 4
Reverse Gate
To remove reverse gate, refer to JET PUMP sec-
tion.
Reverse Cable
Unscrew bolt no. 1, washers and the elastic stop
nut retaining reverse cable no. 2 on pivot arm.
1 2
F18J1IA 2 1
1. Engine cooling air intake hose
2. Air intake locking device
3. Interior lever
4. Reverse cable support
On the interior lever no. 3, unscrew the elastic stop

nut and the washer retaining the reverse cable.
Remove the bracket no. 6.
NOTE: Before removing reverse cable from hull,
note cable routing for reinstallation.
F18J1HA 3 4 5
1. Reverse cable
2. Pivot arm
3. Bolt
4. Washer
5. Elastic stop nut 1
Unscrew the cable lock no. 11 then remove the
half rings no. 12. 2
Remove the seat and the glove box. Refer to HULL/
BODY. 3
Push the engine cooling air intake hose toward the
front of the vehicle to get more access to the in-
terior lever and the reverse cable support.
To release the engine cooling air intake hose press
down the air intake locking devices and move the
hose.
4
There are two air intake locking devices; one above
and one underneath the hose. F18J1JA
DO NOT REMOVE the engine cooling air intake 1. Interior lever

hose completely. 2. Elastic stop nut and Washer
3. Reverse cable
4. Bracket
12-04-2 SMR2002-090_12_04A.FM
Interior Lever INSPECTION

Detach the reverse cable from interior lever no. 3. Visually inspect parts for wear or cracks on friction
Unscrew the shift lever retaining bolt no. 4, wash- parts. Replace all defective parts.
er and nut, then remove interior lever.
ASSEMBLY
Shift Lever
Unscrew the shift lever retaining bolt no. 4, wash- bly procedures. However pay particular attention
er and nut. to the following.
Disengage the shift lever slots from interior lever Insert interior lever cursor into reverse cable sup-
tabs, then remove the shift lever no. 5. port slider and make that the cursor slides freely
in the slider.
1 2
F18J1KA 4 3 1 2
1. Shift lever retaining bolt
2. Shift lever slot
3. Interior lever tab
4. Shift lever
F18J1LA
Reverse Cable Support 1. Interior lever cursor

2. Reverse cable support slider
Remove:
– shift lever Interior Lever
– interior lever Apply synthetic grease on the interior lever pivot
and in the reverse cable support hole.
– bracket no. 6
Install the interior lever in a rotating movement.
– bolts no. 7.
Engage properly the interior lever tabs in the shift
Withdraw reverse cable support no. 8. lever slots.
Make sure the shift lever action is smooth and pre-
Handle Housing cise. Forward and reverse positions should be
Remove: easy to select with a detent position between
– shift lever each.
– interior lever
– reverse cable support
– bolts no. 9.
Then, remove handle housing no. 10.
SMR2002-090_12_04A.FM 12-04-3
ADJUSTMENT
Put shift lever in forward position.
 WARNING
When adjusting reverse cable, assure that le-
ver is well engaged into the spring slot.
Place reverse gate in the up position.

Turn the joint at the end of reverse cable and place
the hole in pivot arm and joint face to face.
Secure with bolt, washers, spacer and elastic stop
nut. Torque to 7 N•m (62 lbf•in).
12-04-4 SMR2002-090_12_04A.FM
Section 13 STEERING SYSTEM
TABLE OF CONTENTS 0
STEERING SYSTEM .............................................................................................................. 13-02-1
DISASSEMBLY................................................................................................................... 13-02-2
ASSEMBLY......................................................................................................................... 13-02-5
OFF-POWER ASSISTED STEERING SYSTEM (O.P.A.S.)................................................ 13-02-7
GENERAL ........................................................................................................................................... 13-02-8
SIDE VANE ......................................................................................................................... 13-02-8
CYLINDER SUPPORT ASSEMBLY ................................................................................... 13-02-9
TIE ROD .............................................................................................................................. 13-02-10
SEALED TUBE ................................................................................................................... 13-02-11
FILTER ................................................................................................................................ 13-02-11
VALVE................................................................................................................................. 13-02-11
WATER HOSE .................................................................................................................... 13-02-12
CROSS SUPPORT PLATE ................................................................................................. 13-02-12
ALIGNMENT .......................................................................................................................... 13-03-1
SMR2002-095_13-01ATOC.FM 13-01-1
Subsection 02 (STEERING SYSTEM)
STEERING SYSTEM 0
All Models
3
2 37 26 Nm
9 (19 lbfft)
11 7 Nm
(62 lbfin) 36
21 19
7 1
5 10 8
15
7 4
6
5 6
10 Nm
(89 lbfin) Loctite 243
13 17
14
18
26
12
29 20
22
Body Synthetic
grease
27
38
Loctite 243
6 Nm 31
(53 lbfin) 28 25
Loctite 243 6 Nm
2.5 Nm (53 lbfin)
3 Nm 30 (22 lbfin)
(26 lbfin)
24
2.5 Nm
6 Nm 23
(53 lbfin) 35
33 34
32 10 Nm
(89 lbfin)
31
F18K09S
SMR2002-091_13_02A.FM 13-02-1
DISASSEMBLY Remove 4 tapping screws no. 7.
Handle Grip and Grip Insert

To remove handle grip no. 1, pull out cap no. 2 and
remove screw no. 3.
Pull out grip and remove grip insert from handlebar
no. 4.
F18K0CA 2 1
1. Tapping screw
2. Handle bar housing
Remove handlebar housing cover no. 8 and throt-

F18K0AA 2 1
tle handle housing no. 11.
1. Handle grip
Unhook throttle cable from throttle handle no. 9.
2. Remove screw Pry out the throttle cable housing from throttle
NOTE: Verify grip insert for damage. handle housing no. 10.
Steering Cover
Remove grips no. 1.
Loosen set screws no. 5 of handlebar housings
no. 6.
F18K0DA 2 1 3
1. Throttle cable
2. Throttle handle housing
3. Throttle cable handle
Remove 6 screws no. 12 and flat washers no. 13

F18K0BA 1
each side of cover.
1. Set screw
13-02-2 SMR2002-091_13_02A.FM
Remove lower steering cover no. 14.

2
F18K0EA 1 2 F18K0GA 1
1. Steering cover 1. Screws
2. Screws 2. Steering padding
Unscrew DESS switch nut using safety lanyard

switch tool (P/N 529 034 600).
Handlebar
Remove upper steering cover no. 15. Remove steering cover and steering padding as
mentioned above.
Remove 4 nuts no. 20 to remove handle bar no. 4
from steering stem no. 22 and steering clamp
no. 21.
F18K0FA 1
1. DESS switch nut 1
Steering Padding
F18K0HA 2 3 4
Remove steering cover as mentioned above.
1. Nuts
Remove 2 screws no. 16 and flat washers no. 18. 2. Handlebar
3. Steering stem
Remove steering padding no. 17. 4. Steering clamp
Cable Support
Loosen bolts no. 22 and remove retaining block
no. 24.
SMR2002-091_13_02A.FM 13-02-3
Remove cable support no. 27.
Steering Support
Cut locking tie securing wiring harness boot.
F18K0IA 1
1. Retaining block
Loosen bolts no. 25 each side of steering support

no. 26.
F07K04A 1 2
1 2
1. Boot
2. Locking tie
Disconnect the throttle and choke cables from car-

buretor levers.
Disconnect the wiring harnesses leading out of
steering stem and cut locking tie.
1 2
F07K02A
1. Steering support
2. Bolt
1 2
F07K05A
1. Tie rap
2. Connectors
F07K03A
1. Steering support
2. Bolts
13-02-4 SMR2002-091_13_02A.FM
Disconnect the steering cable from the steering Steering Stem Arm and Support
stem arm no. 28.
Remove bolts no. 30 retaining steering stem arm
no. 28 to support no. 31.
1 2
1
2
F07K06A
F07K08A 2
1. Steering stem arm
2. Steering cable 1. Steering stem arm
2. Bolts
Remove bolts no. 25 retaining cable support
no. 27 to steering support no. 26. Remove steering stem arm and support.
Remove lock nuts no. 29 from steering retaining Steering Cable
strip studs.
Disconnect steering cable no. 31 from steering
stem arm no. 28.
Remove retaining block no. 24.
Disconnect ball joint no. 35 from jet pump nozzle.
Remove ball joint no. 35 and jam nut from cable.
Loosen nut no. 34, then remove half rings no. 33
and O-ring no. 32.
NOTE: To loosen nut, use steering cable tool (P/N 295
000 145).
Remove steering cable from watercraft.
ASSEMBLY
F18K0JA 2 1 Assembly is essentially the reverse of disassem-
1. Steering support bly procedures. However, pay particular attention
2. Retaining strip studs to the following.
Remove steering support no. 26 with handlebar, CAUTION: Apply all specified torques and ser-
wiring harnesses and cables. vice products as per main illustration at the be-
ginning of this subsection.
SMR2002-091_13_02A.FM 13-02-5
Handle Grip and Grip Insert

When installing the grip insert no. 36 in the han-
dlebar no. 4, ensure that it is properly inserted in
the slot at the end of the handlebar tubing. 2
2
F07K09A
1. Keyways
2. Integrated flat key
Replace lock nuts no. 38 by new ones.

Torque bolts no. 30 of steering stem arm to 6 N•m
(53 lbf•in).
Ball Joint
F02K0JA 1 Secure the steering cable ball joint no. 35 to the
1. Grip insert nozzle as per following illustrations.
Install grip no. 1 on handlebar no. 4 matching it to CAUTION: Ensure the ball joint is parallel (± 5°)
the hex form on the grip insert. to the nozzle arm.
Install flat washer no. 37 and screw no. 3.
Torque screw to 7 N•m (62 lbf•in).
Install cap no. 2.
1 3 5
F02K0KA
2 4
1. Grip insert
2. Grip
3. Flat washer
4. Screw. Torque to 7 N•m (62 lbf•in) F06K01A 1 2
5. Cap
TYPICAL
CAUTION: Ensure to install flat washer other- 1. Ball joint on top of steering arm
wise screw will damage grip end. 2. Torque nut to 7 N•m (62 lbf•in)
Steering Stem Arm and Support Steering Alignment

Position steering stem arm no. 15 and support For steering alignment procedure, refer to ALIGN-
no. 16 onto steering stem. MENT.
 WARNING
Make sure the integrated flat keys of the steering
stem arm and support are properly seated in
steering stem keyways. Steering stem arm must
be locked in place before torquing the bolts.
13-02-6 SMR2002-091_13_02A.FM
OFF-POWER ASSISTED STEERING SYSTEM (O.P.A.S.)
12
19
13 10
1.2 Nm 9
18 (10 lbfin) 11
14 21
Body 12 2.2 Nm
17 36 24
15 25 (19 lbfin)
20
16
22
35
1.7 Nm 5.5 Nm
26 (49 lbfin)
(15 lbfin)
33 Hull
4.5 Nm 26
(40 lbfin) 10 2.2 Nm
1.2 Nm 36 34 (19 lbfin)
(10 lbfin) 31
32 1.7 Nm
9 24 12 (15 lbfin)
2.2 Nm
(19 lbfin) 25 30
23
11 Hull
22 21 27
29
5.5 Nm Hull
(49 lbfin) 2.2 Nm 28 2.2 Nm
8
29 28 6 7 Nm
8 7 (62 lbfin)
23 Hull 1
5
4
6 7
27 3
7 Nm 20 Nm
F18K0KS
(62 lbfin) 2 (15 lbfft)
SMR2002-091_13_02A.FM 13-02-7
GENERAL When throttle is released and engine RPM drops,

the side vanes are automatically lowered thus as-
The Off-Power Assisted Steering (O.P.A.S.) sys- sisting steering control.
tem uses a dual side vanes design that assists the
watercraft steering in deceleration, to redirect water-
craft path when steering is turned after throttle has
been released or engine stopped.
The side vanes on the rear sides of the hull, turn
as the steering is turned to assist the watercraft
turning. At first, carefully experiment turning with
this system.
F18K01A 1
1. Side vane in lower position
F18K03A 1 1
SIDE VANE
1. Side vanes turn following steering movement Disassembly
When engine is running at approximately 75% or Removal procedure for RH and LH side vane no. 9
more RPM, the side vanes are automatically raised is the same.
to upper position since they are not required at that
Turn the steering for removal of tie rod retaining
vehicle speed range.
screw.
Between 30% and 75% engine RPM, side vanes
Remove tie rod retaining screw no. 10 and socket
are gradually raised from lower position to upper
screw no. 11.
position.
F18K0LA 3 4
1. Tie rod screw
F18K02A 1 2. Side vane
3. Cylinder support assembly
1. Side vane in upper position 4. Tie rod retaining stabilizer
13-02-8 SMR2002-091_13_02A.FM
CYLINDER SUPPORT ASSEMBLY

Disassembly
1
Removal procedure for RH and LH cylinder sup-
port assembly is the same.
Remove side vane as mentioned above.
Unscrew bottom nut using OPAS cylinder nut
wrench (P/N 529 035 840).
F18K0MA
1. Socket screw
Lift shaft while holding top of side vane.

Pull side vane out. 2
Adjustment 1
Put the steering in straight ahead position. 3
Measure the portion of tie rod stabilizing fitting
no. 21 exceeding from cylinder support. F18K0NA 4
The exceeding distance of tie rod stabilizing fitting 1. Bottom nut
2. Cylinder support
no. 21 from the cylinder support should be 42 ± 3. Pivot rod
1 mm (1.65 ± .04 in). 4. OPAS cylinder nut wrench
Remove cylinder assembly out of cylinder support.
F18K0OA 4 3 2 1
A 1. Pivot rod
2. Cylinder cap assembly
3. Piston
F18K0ZA
4. Spring
A. 42 ± 1 mm (1.65 ± .04 in)
Unscrew tie rod stabilizing fitting no. 21 from tie
Assembly rod no. 23.
Unscrew 4 socket screws no. 22.
Assembly is the reverse process of disassembly.
Torque tie rod retaining screw no. 10 to 4.5 N•m
(40 lbf•in).
Torque socket screw no. 11 to 2.2 N•m (19 lbf•in).
SMR2002-091_13_02A.FM 13-02-9
– Socket screws no. 22 should be turned 2-3

turns by hand before tightening with tool.
– Replace the cylinder seal ring whenever servicing.
1 1 TIE ROD
Disassembly
Removal procedure for RH and LH tie rod is the
same.
Remove side vane and cylinder support assembly
F18K0PA as mentioned above.
1. Socket screw Remove OPAS “U” lever screw no. 2, flat washer
no. 3, bushing no. 4 and venturi bushing no. 5
Remove oetiker clamp no. 25 to remove water
from nozzle.
hose no. 26 from the cylinder support no. 12.
Remove jet pump (refer PROPULSION SYSTEM).
Remove screw no. 6 and washers no. 7 to remove
“U” lever no. 1 from tie rod connecting levers
no. 8.
4
3
F18K0QA 3 1 2
1. Oetiker clamp
2. Water hose
3. Cylinder support
F18K0RA 2 1
Assembly 1. “U” lever screw
2. Screw
Assembly is the reverse process of disassembly, 3. Tie rod connecting lever
make sure of the following when doing assembly: 4. Tie rod
– Always discard old threaded coverrod no. 14 Pull tie rod out from jet pump side.
and replace with new one. Unscrew lever from the tie rod.
Assembly
Torque screw no. 6 to 7 N•m (62 lbf•in).
F18K0YA 1 Torque OPAS “U” lever screw no. 2 to 20 N•m
(177 lbf•in).
1. Replace threaded cover
– Check pivot rod no. 13 for cracks or scratches.
Replace pivot road, if necessary.
13-02-10 SMR2002-091_13_02A.FM
SEALED TUBE Assembly

Disassembly
Apply silicone grease on the screws before installing.
Removal procedure for RH and LH sealed tube
Torque Phillips screws no. 28 to 2.2 N•m (19 lbf•in).
no. 27 is same.
Remove side van, cylinder housing assembly and FILTER
OPAS “U” lever as mentioned above.
Remove jet pump (refer PROPULSION SYSTEM). For removal and installation procedure refer to
PROPULSION SYSTEM.
Remove Phillips screws no. 28 and remove rod
grommet no. 29. OPAS filter is part of plastic elbow no. 30. Check
for cleanness. Replace or clean it as necessary.
VALVE
Disassembly
Remove OPAS “U” lever screw no. 2, flat washer
1 no. 3, bushing no. 4 and venturi bushing no. 5
from nozzle.
Remove jet pump, filter and formed hose no. 32
(refer PROPULSION SYSTEM).
Remove gear clamps no. 35 to remove water hos-
es no. 26 from valve.
F18K0SA 2
1. Phillips screws
2. Rod grommet
Pull sealed tube out with tie rod from inside of

bilge towards jet pump side.
2
F18K0UA 3
1. Gear clamps
2. Valve
3. Water hoses
F18K0TA 1 2
1. Sealed tube
2. Tie rod
SMR2002-091_13_02A.FM 13-02-11
Unscrew bottom nut of valve no. 33 using OPAS WATER HOSE

cylinder nut wrench (P/N 529 035 840).
Disassembly
Removal procedure for RH and LH water hose is
the same.
as mentioned above.
Remove gear clamps no. 35 to remove water
hose no. 26 from valve.
Pull out the water hose no. 26 from exterior.
Assembly
Assembly is the reverse process of disassembly,
F18K0VA 1 2 make sure of the following when doing assembly:
1. OPAS cylinder nut wrench
– Water hose must be installed from the out side
2. Valve to the inside of hull by turning it, oriented to-
wards valve.
Remove 2 Phillips screws no. 34 from valve collar.
Tighten gear clamps no. 35 manually to 1.7 N•m
1 (15 lbf•in).
CROSS SUPPORT PLATE

Disassembly
For LH Side Cross Support Plate
Remove gooseneck pipe, exhaust pipe and LH
muffler (refer to EXHAUST SYSTEM).
For RH Side Cross Support Plate
Remove RH muffler (refer to EXHAUST SYSTEM).
For RH and LH Cross Support Plates
F18K0WA
1. Phillips screw as mentioned above.
Remove valve downwards from pump tunnel. Unscrew the screw no. 24.
Assembly
make sure of the following when doing assembly:
– Check for cracks on formed hose no. 32, 1
change if necessary.
– Make sure that valve must be installed in the
right position.
Torque Phillips screws no. 34 to 2.2 N•m (19 lbf•in).
Tighten gear clamps no. 31 manually to 1.7 N•m
(15 lbf•in). F18K0XA
1. Remove screw
13-02-12 SMR2002-091_13_02A.FM
Remove cross support plate no. 36 from the inside

of bilge.
Assembly
make sure of the following when doing assembly:
– Check for cracks and deterioration of screw
threads on cross support plate, change if nec-
essary.
– Apply silicone sealant on cross support plate
when servicing or changing.
1 1
F18K10A
1. Apply silicone sealant
Torque screw no. 24 to 1.2N•m (10 lbf•in).
SMR2002-091_13_02A.FM 13-02-13
Subsection 03 (ALIGNMENT)
ALIGNMENT 0
Position handlebar in straight ahead position by All Models
measuring each side the distance from handlebar Open storage compartment cover and remove bas-
grip end to floorboard. ket (if so equipped).
Loosen 2 bolts retaining block at cable support.
Turn adjustment nut as required.
F01K07A
TYPICAL
1. Measuring handlebar grip end/floorboard distance
1
Check jet pump nozzle position by placing a
straight edge on nozzle outer end. Measure the 3
distance on each side of the straight edge. It must 2
be equalled. F01K18A
ALL MODELS
1. Retaining block
2. Adjustment nut
3. Loosen bolts
All Models
After adjustment, torque retaining block bolts to
6 N•m (53 Ibf•in).
CAUTION: Verify when the handlebar is turned
completely to the left or right side, that there is
no interference with venturi or VTS ring.
1
F01J5ZA
TYPICAL
1. Measure the distance on each side of the straight edge
If necessary, steering alignment adjustment should

be performed at steering cable support.
SMR2002-091_13_03A.FM 13-03-1
Section 14 HULL/BODY
TABLE OF CONTENTS 0
ADJUSTMENT AND REPAIR ................................................................................................ 14-02-1
GLOVE BOX ....................................................................................................................... 14-02-5
FRONT SEAT ADJUSTMENT............................................................................................ 14-02-5
STORAGE COMPARTMENT INNER SHELL ..................................................................... 14-02-5
STORAGE COVER SHOCK ................................................................................................ 14-02-8
STORAGE COMPARTMENT COVER ADJUSTMENT ...................................................... 14-02-9
MIRROR.............................................................................................................................. 14-02-10
INFO CENTER (LCD GAUGES) ......................................................................................... 14-02-10
DEFLECTOR AND/OR UPPER GRILL ................................................................................ 14-02-10
FINITION PLATE................................................................................................................. 14-02-11
INLET GRATE ..................................................................................................................... 14-02-11
RIDING PLATE.................................................................................................................... 14-02-11
JET PUMP SUPPORT ........................................................................................................ 14-02-12
DRAIN PLUG INSTALLATION ........................................................................................... 14-02-13
SEAT COVER REPLACEMENT .......................................................................................... 14-02-13
BUMPER REPLACEMENT ................................................................................................. 14-02-14
SPONSON REPLACEMENT .............................................................................................. 14-02-14
DECALS REPLACEMENT .................................................................................................. 14-02-15
HULL AND BODY REPAIR ................................................................................................. 14-02-15
TOOLS AND MATERIALS LIST ......................................................................................... 14-02-18
SMR2002-095_14-01ATOC.FM 14-01-1
Subsection 02 (ADJUSTMENT AND REPAIR)
ADJUSTMENT AND REPAIR 0

GTX DI and GTX 4-TEC Models (seats)
Loctite
414
Loctite
414
Loctite
414
Loctite
414
Loctite
414
F18L1HS
SMR2002-092_14_02A.FM 14-02-1
GTX DI and GTX 4-TEC Models (Front storage compartment)
Body
Synthetic
Grease
4-TEC Limited Only
Loctite
243
3 Nm
(26 lbfin)
5 Nm
Loctite 243
Loctite
243
F18L1IS
14-02-2 SMR2002-092_14_02A.FM
GTX 4-TEC Model and GTX DI Model (Body-Front View)
GTX 4-TEC
Only
Loctite
29647
7
9
10 12
7 Nm
(62 lbfin)
8
11
Loctite
29647
Body
GTX DI Only
F18L1JS
SMR2002-092_14_02A.FM 14-02-3
GTX 4-TEC Model and GTX DI Model (Body-Rear View)
2.5 Nm
(22 lbfin)
Loctite 29647
6
GTX 4-TEC
Limited Only
GTX 4-TEC
or
GTX DI
Loctite
29647
15 7.5 Nm
(13 lbtin)
2 Loctite
5900
3 Loctite 29647
1 10 Nm
1 (88 lbfin)
Loctite
243
4 8 Nm
F18L1KS
(70 lbfin)
14-02-4 SMR2002-092_14_02A.FM
GLOVE BOX STORAGE COMPARTMENT

GTX 4-TEC and GTX DI INNER SHELL
Lift the glove box top cover and pull the glove box GTX DI and GTX 4-TEC
locking device.
Removal and Installation
Pull the glove box out of body.
To remove inner shell, proceed as follows:
FRONT SEAT ADJUSTMENT CAUTION: Failure to follow this order may lead
to damaging inner plastic studs.
Seat Retainer – Open storage cover.
NOTE: Apply Loctite 243 on threads of lock pin – Remove access panel.
when the adjustment is required or when the lock
pin is removed then reinstalled. The threads on – Disconnect multi-function connector.
new lock pin are coated with a self-locking 2
product, do not apply Loctite 243 on threads.
A
2
F07L08A
F18L1MA 1
GTX SERIES — FRONT SEAT 1. Access panel
1. Lock pin 2. multi-function connector
2. Adjustment nut (Loctite 243). Torque to 6 N•m (53 lbf•in)
A. 33 ± 1 mm (1.30 ± 3/64 in) – Unlock shock rod from circlip and remove washer.
1
3
2 A 1 2
F18L1NA
1. Shock rod
2. Circlip
3. Washer
F06L03A
GTX SERIES — REAR SEAT

1. Lock pin
2. Adjustment nut (apply Loctite 243). Torque to 6 N•m (53 lbf•in)
A. 33.5 ± 1 mm (1-5/16 ± 3/64 in)
SMR2002-092_14_02A.FM 14-02-5
– Remove one long retaining screw (front). – Use a rubber hammer to remove the inner skin
– Remove two short retaining screws locate in from the cover. If the inner skin is too stiff, install
the back lower side and hold cover firmly. a piece of 2x4 against the inner skin and hit it with
the rubber hammer.
1
3
2
1
F18L1QA
1. Storage cover
2. Inner skin
3. Rubber hammer
F18L1OA 2
– Remove connector harness from the inner skin
1. One long retaining screw (front)
2. Short retaining screw (one on each side in the back) by cutting tie-raps.
– Remove storage cover. 1 3
– Remove seven inner skin short screws (flanged
screws).
– Remove two long inner skin screws (hex screws).
3
3
3
2 3
1 F18L1RA 3 2
F18L1PA 1. Inner skin
2. Storage cover
1. Storage cover 3. Connector harness
2. Inner skin
3. Inner skin short screws (x7)
4. Inner skin long screws (x2)
14-02-6 SMR2002-092_14_02A.FM
– Remove compass by removing dart (2).

– Remove temperature sensor from grommet.
1 2
F18L1UA 1
2. Grommet
F18L1SA 3 Install new inner skin in the reverse process.

1. Inner skin For installation, proceed as follows:
3. Compass – Install the compass and secure it with the two
darts.
– Install the temperature sensor in grommet.
– Install the tie-raps around wire harnesses.
– Align inner skin with storage cover and make
sure that the lateral locking hooks in the inner
skin get engaged in the storage cover locking
bracket. If the two lateral locking hooks get
properly aligned and engaged the storage cover
back locking hook will be engaged properly in
the inner skin back locking bracket.
1
F18L1TA 1 2 1
1. Dart (x2)
2. Compass
1
F18L1PB
1. Inner skin lateral locking hook

2. Inner skin back locking bracket
SMR2002-092_14_02A.FM 14-02-7
1 STORAGE COVER SHOCK

To remove storage cover shock proceed as follows:
 WARNING
2
Make sure to have a 2x4 piece of wood around
the work bench to support the storage cover
while changing the cover shock.
– Unlock shock rod from circlip and remove washer.
F18L1VA 3
1. Storage cover lateral locking bracket
2. Inner skin lateral locking hook
1 2
1
F18L1NA
1. Shock rod
2. Circlip
3. Washer
2
– Release the shock from top linkage bracket and
bottom support bracket by inserting a flat screw-
driver in the shock top and bottom locking devices.
F18L1WA
1. Storage cover back locking hook

2. Inner skin back locking bracket
– Secure the inner skin in the storage cover by 1

using the rubber hammer.
– Fasten the seven inner skin short screws and
the two inner skin long screws.
F18L1YA 2
1. Top linkage bracket
2. Shock top locking device
14-02-8 SMR2002-092_14_02A.FM
STORAGE COMPARTMENT
COVER ADJUSTMENT
NOTE: Apply Loctite 243 on threads of lock pin
when the adjustment is required or when the lock
pin is removed then reinstalled. The threads on
new lock pin are coated with a self-locking
product, do not apply Loctite 243 on threads.
Adjust lock pin no. 3 as per following specifica-
tions:
F18L1ZA 2 1
1. Bottom support bracket
2. Shock bottom locking device A
2
3
1
F16L0UA 3
FLOATING TYPE
1. Lock pin (apply Loctite 243)
2. Rubber washer
3. Lock nut. Torque to 5 N•m (44 lbf•in)
A. 39.2 ± 1 mm (1-35/64 ± 3/64 in)
2 NOTE: Floating type lock pin is used for these mod-

els. It is normal to have a front and aft play of the
lock pin. To adjust, tighten lock pin until any vertical
play is eliminated. Make sure a front and aft play
remains when pressing by hands.
F18L20A
1. Shock absorber
2. Flat screwdriver
3. Shock top locking device
SMR2002-092_14_02A.FM 14-02-9
MIRROR DEFLECTOR AND/OR UPPER

GTX 4-TEC and GTX DI GRILL
Removal and Installation Removal and Installation
To remove mirror proceed as follows: To remove the deflector and/or the upper grill pro-
– Remove storage compartment inner shell from ceed as follows:
storage cover as described earlier in this section. – Remove storage from storage cover compart-
– Remove two hexagonal screws and flat washers. ment inner shell as described earlier in this sec-
– Remove defective mirror with a knive blade. tion to get access.
– Remove the defective deflector and/or the up-
per grill from plastic retaining clip. Use two
screwdrivers to release the deflector or the grill.
2 2
1 2
F18L21A
1. Mirror
2. Knive blade
– Place the mirror frame in hot water to “soften”

the material to allow mirror installation in its frame.
– Reinstall storage compartment inner shell.
INFO CENTER (LCD GAUGES)

F18L22A 1
GTX DI 1. Inner skin
2. Deflector retaining clips
Info gauges can be pulled directly out from the
storage cover.
GTX 4-TEC
Removal and Installation

To remove the Info center (Speedometer and LCD
Info gauge) proceed as follows:
– Remove storage compartment inner shell from
storage as described earlier in this section to
get access.
– Push Info Center (LCD Gauges) from the stor-
age cover. If the Info center does not come out
easily use liquid soap.
– Refer to ELECTRICAL section to unplug gauges
from harnesses. F18L23A
– Reinstall new Info center. RELEASE DEFLECTOR

– Reinstall storage compartment inner shell.
14-02-10 SMR2002-092_14_02A.FM
FINITION PLATE INLET GRATE

Removal and Installation Removal and Installation
For GTX 4-TEC and GTX DI Loosen screws and remove inlet grate.
Removal procedure for RH finition with grill and LH NOTE: An impact screwdriver should be used to
finition with grill is same. loosen tight screws.
Remove two darts holding the grill with body. When reinstalling inlet grate, apply Loctite 271 on
Make a hole in the luggage compartment as shown threads.
in the illustration below to get access of finition Follow this sequence referring to the illustration:
plate screw. Hand tighten screw numbers ➀, ➁, ➂ then ➃.
Torque screw numbers ➀, ➁ and ➂ to 11 N•m
(97 lbf•in).
Ø 25 mm
(1 in) Torque screw number ➃ to 26 N•m (19 lbf•ft).
55 mm
(2.2 in) 1
155 mm
(6.1 in)
4 2
F18L29A
3
Remove the screw and remove finition plate.
After installing finition plate, plug (P/N 291 000 279) F18L24A
the finition plate screw hole.

RIDING PLATE
Removal
All Models
Remove inlet grate.
Remove jet pump. Refer to JET PUMP.
Remove the speed sensor from the riding plate (if
applicable).
Loosen riding plate screws.
NOTE: An impact screwdriver should be used to
loosen tight screws.
F18L2AA 1 Using a low height hydraulic bottle jack and 2 steel
1. Plug (P/N 291 000 279) plates, pry out riding plate.
For GTX 4-TEC Limited Edition
Removal procedure for RH finition, deflector with
grill and LH finition, deflector with grill is same.
Finition plate is mounted on deflector.
Remove three darts holding deflector and grill.
SMR2002-092_14_02A.FM 14-02-11
6 4
8 2
7 1
F18L25A 1 2
1. Hydraulic bottle jack
2. Riding plate F18L27A 5 3
Cleaning GTX DI MODEL
– Scrape off all excess of sealant from riding plate NOTE: Apply Loctite RTV silicone sealant (P/N 293
and hull. 800 066) as indicated by the shaded area.
– Clean hull surface with acetone based solvent to
eliminate grease, dust and any residue of sealant. JET PUMP SUPPORT
Installation Removal
All Models – Remove jet pump. Refer to JET PUMP.
Apply Loctite RTV silicone sealant (P/N 293 800 066) – Remove inlet grate and riding plate.
as indicated by the shaded areas in the next illustra- – Remove ball joint, boot, nut, half rings and O-rings
tions. Follow also the torquing sequence as shown from steering cable.
in the same illustrations.
6 4
8 2
F05K02A 1
TYPICAL
1. Unscrew nut
7 1
– Remove ball joint, boot, nut, half rings and O-rings
from reverse cable.
F18L26A 5 3
GTX 4-TEC MODEL
14-02-12 SMR2002-092_14_02A.FM
– Disconnect water supply hose, water return

hose and bailer hoses.
– Remove nuts, lock washers and flat washers
3
retaining jet pump support.
2 1
F00L2RA
1. Drain plug
2. Silicone sealant (P/N 293 800 086) around the middle hole and in
the screw holes
3. Torque screws to 2.2 N•m (19 lbf•in)
F07L0AA 1 SEAT COVER REPLACEMENT

TYPICAL Install staples with an electric tacker such as Arrow
1. Remove nuts tacker no. ETN-50 or with a manual tacker such as
– Using a heat gun, heat jet pump support until it Arrow tacker no. T-50.
is possible to pull it. NOTE: For an easier installation, it’s highly recom-
NOTE: Shims may have been installed between mended to use an electric tacker.
support and body. Do not remove these shims, Ensure that the seat rest firmly against a hard sur-
otherwise jet pump alignment will be altered. face such as a piece of wood. This is done to get
the staples completely pushed in place.
Installation
Apply Loctite RTV silicone sealant (P/N 293 800 066)
as indicated by the shaded areas in the next
illustrations. Follow also the torquing sequence as
shown in the same illustrations.
1 2
3
F18L28A 4
GTX DI AND GTX 4-TEC MODELS
1
DRAIN PLUG INSTALLATION F01L3YA 2
Refer to the following illustration to install drain plug TYPICAL
no. 15. 1. Piece of wood
2. ETN-50 (electric) or T-50 (manual)
SMR2002-092_14_02A.FM 14-02-13
After cover installation cut all around the excess

of material.
BUMPER REPLACEMENT
Remove trim no. 1 from side bumper rail no. 2.
Remove screws no. 4 to remove side bumper rail
no. 2.
Mark hole positions on body straight and bow sec-
tions.
1 2
F18L2BA 2 1
1. Sponson
2. Sponson cover
Slide sponson cover towards front to about 15 mm

F18L01A 4 3 and pull it out from sponson.
TYPICAL Unscrew nut no. 10 and remove sponson no. 8.
1. Front bumper
2. Corner bumper 2
3. Straight section
4. Bow section
Slide bumper rail no. 2 under front bumper no. 6.

Using a 4.80 mm (3/16 in) drill bit, drill first hole
through bumper rail no. 2 at front of bow section.
CAUTION: When drilling, be careful not to
damage bumper rail and/or hull.
Position bumper rail no. 2 properly onto body and
cut excess length if necessary.
F18L2CA 1
Slide bumper rail no. 2 in corner bumper no. 3.
1. Sponson
Install trim no. 1 using soapy water. 2. Nuts
Repeat procedure for the other side. Clean any residues of sealant adhesive on hull.
On installation of sponson, apply silicone sealant
SPONSON REPLACEMENT (P/N 293 800 086) around sponson studs.
Removal and installation procedure for RH and LH Apply Loctite 29647 on sponson studs.
sponson is same. Install sponsons no. 8 on hull.
Remove screws no. 11. Tighten nuts no. 10 to 7 N•m (62 lbf•in).
Pryout sponson cover from backend with screw- Clean hull and sponsons of any sealant adhesive
driver. surplus.
 WARNING
Recommended torques and use of Loctite
must be strictly followed.
14-02-14 SMR2002-092_14_02A.FM
DECALS REPLACEMENT For better adhesion a dry application is recom-

mended, however, to ease decal installation a mild
Removal solution of soapy water can be sprayed over sur-
face where decal will be installed.
Using a heat gun warm up one end of decal for a
few seconds until decal can roll off when rubbing Remove back protective film from decal and align
with your finger. decal with marks. When well aligned squeegee
decal beginning at center and working outward us-
Pull decal slowly and when necessary apply more ing firm, short, overlapping strokes.
heat to ease removal on the area that has to be
peeled off. Remove front protective film once decal has ad-
hered to hull.
If decal tears while pulling off, it has to be heated
for a few seconds longer. If decal tends to stretch INSTALLATION ON PLASTIC
while pulling off, stop heating and wait a few sec- (storage cover)
onds to let it cool, then peel it off. Clean surface with isopropyl alcohol.
Using a pencil and the decal as a template, mark
Installation the area where decal will be located.
There are 2 types of decals used on watercraft. One Apply an activator (P/N 293 530 036) to prepare the
has a protective film on back side and the other has surface using a clean cloth. After a few seconds,
a protective film on both sides. They are used on 3 when the activator evaporates, the surface is ready.
types of materials; plastic, gelcoat and metal.
CAUTION: Do not use soapy water to locate de-
DECALS HAVING A PROTECTIVE FILM ON cal on plastic parts.
BACK SIDE ONLY
Remove back protective film from decal and care-
These decals usually contain written information fully align decal with marks. When well aligned
(ex.: warning) and are used on gelcoat or metal. squeegee decal beginning at center and working
Clean surface with a good solvent such as ACRYLI- outward using firm, short, overlapping strokes.
CLEAN DX 330 from PPG or equivalent (refer to Remove front protective film once decal has ad-
manufacturer instructions). hered.
Using a pencil and the decal as a template, mark
the area where decal will be located. HULL AND BODY REPAIR
Remove half of the decal back protective film and
align decal with marks. Start sticking it from center General
and remove the other half of the film to stick it Gelcoat is the smooth and durable cosmetic finish
completely. Carefully squeegee decal beginning at which coats the fiberglass hull and body of a Sea-
center and working outward using, firm, short, Doo watercraft. It also provides a protective barri-
overlapping strokes. er against water and sun. It consists of a mixture
DECALS HAVING A PROTECTIVE FILM ON of resin, pigment (coloring), fillers, monomers and
BOTH SIDES catalyst which is sprayed into the mold.
These decals usually contain graphics and are used The body and hull of the Sea-Doo are constructed
on gelcoat or plastic. of chopped fiberglass, saturated with resin. It is
sprayed on the layer of gelcoat along with pieces
INSTALLATION ON GELCOAT of fiberglass mat, cloth and woven rowing which
Clean surface with a good solvent such as ACRYLI- are added at required areas. This type of construc-
CLEAN DX 330 from PPG or equivalent (refer to tion is very accommodating for high quality re-
manufacturer instructions). pairs. With patience, the proper techniques and
For best result apply an activator (P/N 293 530 materials, a damaged area can be restored to an
036) to prepare the surface using a clean cloth. original finish.
After a few seconds, when the activator evapo-
rates, the surface is ready.
Using a pencil and the decal as a template mark
the area where decal will be located.
SMR2002-092_14_02A.FM 14-02-15
NOTE: Fiberglass repair kit is available through au- SANDING

tomotive or marine suppliers. Gelcoat repair kits Begin block sanding the patch with 320-grit sand-
are available directly to GELCOTE INTERNATION- paper until you come close to the original surface.
AL LTD. Remove dust with a water soaked cloth and con-
tinue sanding with a 400-grit wet paper. Finish wet
 WARNING sanding with a 600-grit to remove deeper scratch-
Protect skin, wear gloves when in contact with es. If needed you can wet sand with finer grit pa-
resin, hardeners and gelcoat. A barrier skin per such as 1000-grit.
cream may also be used. Do not expose area
BUFFING AND WAXING
to open flame or lit cigarette. Some of the ma-
terials are flammable. Protect eyes, wear safety Buff the surface using a heavy duty polisher with
glasses when grinding, sanding or spraying. a buffing pad. Make sure the pad is free of dirt or
Use a dust mask when sanding or grinding. you may damage the gelcoat. Carefully begin buff-
When spraying wear a respirator or paint ing with a white medium compound. Finish off us-
mask. Always read warning labels on products. ing a fine compound. While buffing, pay close at-
tention to avoid overheating the surface.
Air Bubbles Blisters
Possible cause: Possible causes:
– Air pocket trapped between layers of laminate – Insert catalyst.
and gelcoat.
– Improper catalyst/gelcoat ratio.
PREPARATION OF SURFACE A blister is a visible bump on the watercraft surface
Remove all of the damaged gelcoat surrounding that may not necessarily come right through the
the air bubble with a putty knife or preferably a gelcoat layer. In the case of only a few blisters, follow
carbide grinding tip. Make sure all loose and weak the same repair procedure as for air bubbles. If they
areas are completely removed. Sand a small area are numerous and in close concentration, spray liquid
of the gelcoat surface with 220-grit sandpaper. If gelcoat to achieve proper repair. This procedure is
needed, sand the cavity itself. These areas must covered in MINOR GELCOAT FRACTURES.
have a rough surface to allow the gelcoat putty to
bond properly. Minor Gelcoat Fractures
FILLING THE CAVITY Possible causes:
The prepared surface must be cleaned with ace- – Flexing of fiberglass laminate.
tone on a cloth. Use a gelcoat repair kit. Follow the – Gelcoat thickness.
mixing instructions in the kit when preparing the
gelcoat putty. – Direct result of impact.
Carefully mix the required amount while making In case of fractures which have not penetrated
sure there are no air bubbles in the mixture. With past the gelcoat layer, the repair concerns the
a putty knife, fill the repair area and cover with gelcoat only. If flex cracking or impact are evident,
plastic film. Curing time may depend on tempera- then additional reinforcement may be necessary.
ture, amount of putty and percentage of catalyst. This subject will be covered in COMPOUND
After 2 hours, press lightly on the surface with fin- FRACTURES.
gers to test the hardness. When the area becomes PREPARING THE SURFACES
hard, remove the plastic film.
Small Fractures
Open the cracks up with a sharp triangular can
opener or preferably a carbide tipped die grinder.
The V groove will provide a good bonding area for
the gelcoat. With 220-grit sandpaper, sand the
sides of the notched out areas.
14-02-16 SMR2002-092_14_02A.FM
Numerous Fractures Compound Fractures

Using a grinder with a 24-grit disk, remove the Possible causes:
gelcoat. Sand the area edge with 220-grit sand-
– Thickness of fiberglass laminate.
paper.
– Direct result of impact.
FILLING THE REPAIR AREA
Compound fractures are those that have gone
Small Fractures past the gelcoated surface and in through the lay-
Refer to the same procedure as in the AIR BUB- ers of fiberglass laminate. Two types of repairs
BLES. have to be performed. The first is to restore the
structural integrity of the damaged area. Fracture
Numerous Fractures Over Large Surface: types can vary from a simple crack to a large hole.
Prepare the area for spray application of liquid Usually, fiberglass reinforcement becomes neces-
gelcoat. Wipe down the surface with acetone. sary, especially if the fracture can be attributed to
Mask the area off to protect the watercraft from weakness. The final part of the repair is the
overspray. gelcoating, which cannot be done until the interior
Mix the needed quantity of gelcoat and catalyst and exterior laminate surfaces have been repaired.
according to suppliers recommendations. The Outside
gelcoat can be thinned with acetone up to 10%. If
Remove the damaged gelcoat and fiberglass with
it needs more consistency you can add cabosil.
a 24-grit disk using a power sander. Grind outward
Make sure that the air supply is free of oil, dirt and at least 2 inches from the fracture to allow the
water. patch to bond to strong material. Cut enough piec-
Test spray the gelcoat mixture on paper to verify es of fiberglass mat necessary to build up the area.
its consistency and pattern. You may have to apply The pieces should be cut so they overlap each oth-
5 or 6 coats to cover the area properly. Overlap er by at least a half inch. For a smoother finish, the
each coat further than the last, leaving at least 30 last layer should be fiberglass cloth. If the fracture
seconds between passes. Avoid trying to coat the is small enough all you may have to do is fill the
surface with only a few heavy coats, this will not area with an epoxy filler.
allow the gelcoat to dry properly. Inside
Apply a coat of polyvinyl alcohol to seal off the air For the interior repair, you can grind more. This will
and protect the gelcoat surface from dust. PVA allow for more fiberglass material which will
speeds up the curing process because gelcoat will strengthen the area. If the fracture opening is too
not cure properly when exposed to air. large after surface preparation, you may need a
SANDING backing support to cover the opening. Cut alternat-
ing pieces of fiberglass mat and cloth in overlap-
Wash the polyvinyl alcohol off with water. De-
ping sizes.
pending on the size of the area repaired, you can
either block sand as per previous procedure or you PATCHING THE REPAIR AREA
may use an air sander. Sand the surface down with
Outside
progressively finer grits of sandpaper until the de-
sired finish is achieved. The outside should be done first. Wipe clean the
area with acetone on a cloth, then mask off area.
BUFFING AND WAXING For a small crack use an epoxy filler in the same
Buff the surface using a heavy duty polisher with way you would use gelcoat repair putty. When lay-
a buffing pad. Make sure the pad is free of dirt or ing up a larger area you will use mat, cloth and
you may damage the gelcoat. Carefully begin buff- fiberglass resin and hardener. Use a clean contain-
ing with a white medium compound. Finish off user to mix the resin, mix only what you will need.
ing a fine compound. While buffing, pay close at- Follow the recommended catalyst ratio.
tention to avoid overheating the surface.
SMR2002-092_14_02A.FM 14-02-17
Using a clean paintbrush, brush the mixed resin on TOOLS AND MATERIALS LIST
the surface. Place the smallest piece of mat over
the fracture and then wet out the mat. Follow with Tools
the remaining pieces of mat and final layer of
cloth. While wetting the pieces make sure you – safety glasses
work the air bubbles out and saturate all the pieces – air mask
evenly. Try to work quickly, you may only have 15 – white cloths
or 20 minutes. You may clean the brush with ace-
tone. – sanding block
Wait until the repair has hardened before moving – putty knife
on to the interior repair. If the size of the opening – plastic film
is too large for the pieces to maintain the proper – stirring stick
shape, you will have to use a backing support. It is
a shaped piece of cardboard that fits flush to the – cover sheets (for Sea-Doo)
interior surface and has a plastic layer on the repair – scissors
side. It is held in place by tape or a support. – buffing pad
Inside – heavy-duty polisher
Wipe down the area with acetone on a cloth. Ap- – power sander
ply the same procedure as for outside repair when
– paint brush
laminating the alternating pieces of fiberglass ma-
terial. If a backing support was used, remove it – plastic container (mixing)
before starting the repair. After the area has hard- – spray gun
ened, remove sharp edges of material from sur-
– plastic squeegee.
face. If required paint the surface.
SANDING Materials
Outside – fiberglass mat
This surface will have to be prepared for applica- – fiberglass cloth
tion of gelcoat. The size of the area will determine – polyester resin
the gelcoating procedure to be used. Refer to the
repair procedure for MINOR GELCOAT FRAC- – cardboard
TURES. – masking tape
BUFFING AND WAXING – sandpaper (100-grit, 220-grit, 320-grit, 400-grit,
600-grit, 1000-grit)
Refer to the buffing and waxing for MINOR
GELCOAT FRACTURES. – 24-grit sanding disks
– gelcoat putty
– liquid gelcoat
– acetone
– cabosil
– epoxy filler
– medium compound (white)
– fine compound (white)
– wax.
14-02-18 SMR2002-092_14_02A.FM
Section 15 TECHNICAL DATA
Subsection 01 (GTX DI MODELS)
GTX DI MODELS 0
ENGINE GTX DI
Engine type BOMBARDIER-ROTAX 947 DI, 2-stroke
Induction type Reed valve
Type Water cooled, water injected with regulator
Water injection fitting (head) 3.5 mm (.139 in)
Exhaust system
Water injection fitting (cone) Not applicable
Water injection fitting (muffler) 3 mm (.118 in)
Exhaust valve RAVE
Starting system Electric start
Fuel/oil mixture VROI (Variable Rate Oil Injection)
Oil injection pump Direct driven
Lubrication
Oil injection type BOMBARDIER
Formula XP-S DI (synthetic DI injection oil only)
Number of cylinders 2
Standard 88 mm (3.465 in)
Bore First oversize 88.25 mm (3.474 in)
Second oversize Not applicable
Stroke 78.20 mm (3.079 in)
Displacement 951.2 cm³ (58 in³)
Corrected compression ratio 6.0: 1
Cylinder head volume 50.76 ± 0.6 cc
Cylinder head warpage (maximum) 0.10 mm (.004 in) total
Piston ring type and quantity 2 semi-trapez chrome coated steel rings
New 0.55 - 0.7 mm (.022 - .028 in)
Ring end gap
Wear limit 1.1 mm (.043 in)
Ring/ New 0.044 - 0.089 mm (.002 - .003 in)
piston groove clearance Wear limit 0.22 mm (.0087 in)
Piston/ New (minimum) 0.12 mm (.0047 in)
cylinder wall clearance Wear limit 0.22 mm (.0087 in)
Cylinder taper (maximum) 0.10 mm (.004 in)
Cylinder out of round (maximum) 0.08 mm (.003 in)
Connecting rod big end New 0.390 - 0.737 mm (.015 - .029 in)
axial play Wear limit 1.2 mm (.047 in)
Crankshaft deflection MAG side: 0.050 mm (.002 in); PTO side: 0.030 mm (.001 in)
Opening Not applicable
Rotary valve timing
Closing Not applicable
Rotary valve duration Not applicable
Rotary valve/cover clearance Not applicable
Connecting rod/ New 0.017 - 0.034 mm (.0006 - .0013 in)
crankshaft pin radial
clearance Wear limit 0.050 mm (.002 in)
Connecting rod/piston pin New 0.001 - 0.014 mm (.00039 - .00055 in)
radial clearance Wear limit 0.017 mm (.00067 in)
Type Piston
Displacement 43 cm³ (2.6 in³)
Air compressor Drive Balancing shaft
Intake side Reed valves
Exhaust side Reed valves
ADDITIONAL INFORMATION:
SMR2002-093_15_01A.FM 15-01-1
ELECTRICAL GTX DI
Magneto generator output 270 W @ 6000 RPM
Ignition system type Digital Inductive
Make and type NGK ZFR4F
Spark plug
Gap 1.1 mm (.04 in)
5.39 ± 0.30 (.212 ± .011) (direct)
measured through direct injector hole
mm (in) 7.87 ± 0.30 (.310 ± .011) (indirect)
TDC setting (BTDC)
measured through spark plug hole
Degrees 27 ± 1.5 @ 1450 RPM
Generating coil 190 - 300 Ω
Battery charging coil 0.1 - 1 Ω
Trigger coil Not applicable
Primary 0.45 - 0.55 Ω
Ignition coil
Secondary 6.8 - 10.2 kΩ without high tension leads
Engine rev limiter setting 7300 ± 50 RPM
Battery 12 V, 19 A•h (Yuasa/Exide)
Main 30 A
Injection system (INJ) 15 A
Charging system (REG) 25 A
Fuses Information center (ACC) 2A
Fuel pump (FP) 15 A
Battery 25 A
VTS system (VTS) Not applicable
FUEL SYSTEM GTX DI

Fuel injection type Orbital Direct Fuel Injection,
twin throttle body (46 mm (1.81 in))
Fuel pressure 105.2 PSI - 108 PSI
Idle speed (in water/out of water) 1450 ± 50 RPM
Throttle Position Sensor (TPS) 1.6 kΩ - 2.4 kΩ
Crankshaft Position Sensor (CPS) 5 volts
Manifold Air Temperature Sensor (MATS) 2.28 kΩ - 2.74 kΩ
Water Temperature Sensor (WTS) 2.28 kΩ - 2.74 kΩ
Exhaust Gas Temperature Sensor (EGT) 2.28 kΩ - 2.74 kΩ
Manifold Air Pressure Sensor (MAPS) 0 Ω (continuity between terminals 3 and 1)
Knock Sensor (KS) 5 MΩ
RAVE solenoid 24 Ω
Fuel injector 1.7 Ω - 1.9 Ω
Direct injector 1.0 Ω - 1.6 Ω
Type Regular unleaded gasoline
Fuel
Minimum octane no. 87
15-01-2 SMR2002-093_15_01A.FM
COOLING GTX DI
Type Open circuit — Direct flow from jet propulsion unit
Thermostat None
Monitoring beeper setting 75 - 80°C (167 - 176°F)
PROPULSION GTX DI
Propulsion system BOMBARDIER Formula pump
Jet pump type Axial flow single stage
Impeller rotation (seen from rear) Counterclockwise
Transmission Direct drive
Coupling type Crown splines
SEA-DOO JET PUMP SYNTHETIC
Oil type POLYOLESTER OIL 75W90 GL5
Steering nozzle pivoting angle 20°
Minimum required water level 90 cm (35 in)
Drive shaft deflection (maximum) 0.5 mm (.020 in)
Impeller outside diameter 155.6 mm (6.126 in)
New 0.0 - 0.4 mm (.000 - .016 in)
Impeller/wear ring clearance
Impeller shaft end play (new) 0
Impeller shaft side play 0.05 mm (.002 in)
Impeller pitch/material Progressive pitch/stainless steel
ADDITIONAL INFORMATION: Do not mix different brands or oil types.
DIMENSIONS GTX DI
Number of passenger (driver incl.) 3
Overall length 331 cm (130 in)
Overall width 122 cm (48 in)
Overall height 113 cm (44 in)
Dry weight 363 kg (800 lb)
Load limit (passenger and 10 kg (22 lb) luggage) 272 kg (600 lb)
CAPACITIES GTX DI
Fuel tank (including reserve) 56.5 L (15 U.S. gal)
Fuel tank reserve (from low level signal) 9.8 L (2.6 U.S. gal)
Oil injection reservoir 6 L (1.6 U.S. gal)
Jet pump impeller shaft Capacity 115 mL (3.88 U.S. oz)
reservoir Oil level height Up to plug
SMR2002-093_15_01A.FM 15-01-3
MATERIALS GTX DI
Hull Composite
Inlet grate Aluminum
Impeller housing/stator/venturi/nozzle Plastic/plastic/aluminum/aluminum
Air intake silencer Thermoplastic
Flame arrester Tubular wire screen
Steering padding Thermoplastic
Fuel tank Polyethylene
Oil injection reservoir Polyethylene
Seat Polyurethane foam
PERFORMANCE GTX DI
Estimated pump power 52.2 kW (70 HP)
Maximum fuel consumption at wide open throttle 47 L/h (12.4 U.S. gal/h)
Fuel tank without reserve 60 minutes
Cruising time at full throttle Fuel tank reserve 12 minutes
(from low level signal)
15-01-4 SMR2002-093_15_01A.FM
Subsection 02 (GTX 4-TEC MODELS)
GTX 4-TEC MODELS 0

ENGINE GTX 4-TEC
BOMBARDIER-ROTAX 1503 4-TEC, 4-stroke,
Engine type Over Head Camshaft (OHC), liquid cooled
Number of cylinders 3
Number of valves 12 valves with hydraulic lifters (no adjustment)
Bore Standard 100 mm (3.9 in)
Stroke 63.4 mm (2.49 in)
Displacement 1493.8 mm (58.81 in)
Compression ratio 10.6 ± 0.4
Maximum HP RPM 7300 ± 100 RPM
Lubrication Dry sump with replaceable oil filter
Oil filter CHAMPION
Exhaust system Type Water cooled, water injected with regulator
Intake valve opening 10° BTDC
Intake valve closing 45° ABDC
Exhaust valve opening 50° BBDC
Exhaust valve closing 5° ATDC
Starting system Electric start
New minimum 5.961 mm (.2347 in)
Intake New maximum 5.975 mm (.2352 in)
Valve stem diameter
Exhaust New maximum 5.960 mm (.2346 in)
Valve guide diameter New maximum 6.018 mm (.2369 in)
New nominal 41.02 mm (1.615 in)
Inner
Wear limit 38.8 mm (1.499 in)
Valve spring free length
New nominal 45.45 mm (1.789 in)
Outer
Wear limit 43 mm (1.693 in)
New nominal 1.1 to 1.3 mm (.043 to .051 in)
Intake
Valve seat contact width
New nominal 1.25 to 1.55 mm (.049 to .061 in)
Exhaust
Rocker arm bore diameter New maximum 20.020 mm (.7881 in)
Rocker arm shaft diameter New maximum 19.993 mm (.7871 in)
Cylinder head screw Service limit 148.5 mm (5.846 in)
1st Rectangular
Piston ring type and quantity 2nd Taper-face
3rd Oil scraper ring
SMR2002-093_15_02A.FM 15-02-1
ENGINE GTX 4-TEC

Rectangular 0.15 mm (.006 in)
Taper-face New minimum 0.15 mm (.006 in)
Oil scraper ring 0.15 mm (.006 in)
Ring end gap Rectangular 0.3 mm (.012 in)
Taper-face New maximum 0.3 mm (.012 in)
All Wear limit 1.5 mm (.06 in)
Rectangular 0.025 mm (.001 in)
Taper-face New minimum 0.015 mm (.0006 in)
Ring/ Rectangular 0.07 mm (.0028 in)
piston groove clearance
Taper-face New maximum 0.06 mm (.0024 in)
All Wear limit 0.15 mm (.006 in)
New (minimum) 0.024 - 0.056 mm (.001 - .0022 in)
Piston/cylinder wall clearance
Cylinder taper (maximum) 0.03 mm (.0011 in)
Cylinder out of round (maximum) 0.008 mm (.0003 in)
Front New maximum 24.960 mm (.9827 in)
Camshaft bearing journal
New minimum 39.892 mm (1.5705 in)
PTO and center New maximum 39.905 mm (1.5711 in)
Front New maximum 25.013 mm (.9848 in)
Camshaft bore
PTO and center New maximum 40.016 mm (1.5754 in)
Intake New maximum 31.590 mm (1.2437 in)
Cam lobe
Exhaust New maximum 31.809 mm (1.2523 in)
Crankshaft axial clearance
New maximum 0.22 mm (.0087 in)
Connecting rod big end clearance Wear limit 0.09 mm (.0035 in)
Crankshaft journal diameter New maximum 50.000 mm (1.9685 in)
Crankshaft radial clearance Wear limit 0.007 mm (.0028 in)
Connecting rod big end diameter Service limit 45.080 mm (1.7740 in)
Connecting rod big end clearance Service limit 0.09 mm (.0035 in)
Connecting rod big end axial play New maximum 0.287 mm (.0113 in)
Crankshaft deflection 0.050 mm (.002 in)
15-02-2 SMR2002-093_15_02A.FM
ENGINE GTX 4-TEC

Connecting rod small end diameter New maximum 23.020 mm (.9063 in)
Piston pin diameter New maximum 23.000 mm (.9055 in)
Piston pin bore clearance Wear limit 0.080 mm (.0035 in)
Balance shaft journal diameter New maximum 32.000 mm (1.2598 in)
Balance shaft radial clearance Wear limit 0.07 mm (.0028 in)
Balance shaft axial clearance
New maximum 0.25 mm (.0098 in)
ELECTRICAL GTX 4-TEC

Magneto generator output 380 W @ 6000 RPM
Ignition system type DI (Digital Induction)
Ignition timing Not adjustable
Make and type NGK DCPR8ES
Spark plug
Gap 0.75 mm (.030 in)
Generating coil N.A.
Battery charging coil 0.1 - 1.0 Ω
Primary 0.45 - 0.55 Ω
Ignition coil
Secondary 6.8 - 10.2 kΩ
Engine RPM limiter setting 7650 RPM
Battery 12 V, 30 A•h
TOPS 10 A
Battery fuse 30 A
Cylinder 1, ignition coil and injection 10 A
Electric bilge pump (optional) 3A
Fuse
Starting system, electric fuel pump 10 A
EMS, start/stop circuit 5A
Main 30 A
MPEM 5A
Charging system 30 A
Information center 1A
SMR2002-093_15_02A.FM 15-02-3
FUEL SYSTEM GTX 4-TEC

Rotax EMS (engine management system)
Fuel injection type Multipoint Fuel Injection.
Single throttle body (52 mm (2.05 in))
Fuel pressure 42 PSI - 45 PSI
Idle speed (in water/out of water) 1800 ± 50 RPM
Throttle Position Sensor (TPS) 1.6 kΩ - 2.4 kΩ
Crankshaft Position Sensor (CPS) 5 volts
Camshaft Position Sensor (CAPS) 12 volts
Camshaft Position Sensor (CAPS) 1.2 kΩ
Manifold Air Temperature Sensor (MATS) 2.28 kΩ - 2.74 kΩ
Coolant Temperature Sensor (CTS) 2.28 kΩ - 2.74 kΩ
Exhaust Gas Temperature Sensor (EGT) 2.28 kΩ - 2.74 kΩ
Manifold Air Pressure Sensor (MAPS) 0 Ω (continuity between terminals 3 and 1)
Knock Sensor (KS) 5 MΩ
Oil Pressure Switch (OPS) 0 Ω, if oil pressure is greater than 26 - 32 PSI
Oil Separator Pressure Switch (OSPS) 0 Ω, if blow-by pressure is less than 6 PSI
TOPS valve 1.27 Ω - 2.47 Ω
Fuel injector 11.4 Ω - 12.6 Ω
Type Super unleaded gasoline
Fuel
Minimum octane no. 87
COOLING GTX 4-TEC

Type Liquid cooled. Closed loop for engine - open loop
for exhaust system
Ethylene-glycol 50%/50% antifreeze/water.
Coolant Coolant containing corrosion inhibitors for internal
combustion aluminum engines
Thermostat 87°C (188°F)
Monitoring beeper setting 110°C (230°F)
15-02-4 SMR2002-093_15_02A.FM
PROPULSION GTX 4-TEC

Propulsion system BOMBARDIER Formula pump
Jet pump type Axial flow single stage. Greased bearings
Impeller rotation (seen from rear) Counterclockwise
Transmission Direct drive
Coupling type Crown splines
Reverse system Yes
O.P.A.S. system Yes
Sea-Doo grease (P/N 293 550 032),
Grease type 10 mL front bearing, 50 mL rear of bearing,
50 mL in pump cap
Steering nozzle pivoting angle 20°
Minimum required water level 90 cm (35 in)
Drive shaft deflection (maximum) 0.5 mm (.020 in)
Impeller outside diameter 155.3 ± 0.3 mm (6.122 ± .0118 in)
New 0.0 - 0.4 mm (.000 - .016 in)
Impeller/wear ring clearance
Impeller shaft end play (new) 0
Impeller shaft side play 0.75 mm (.029 in)
Impeller material Stainless steel
ADDITIONAL INFORMATION: Do not mix different brands or oil types.
DIMENSIONS GTX 4-TEC

Number of passenger (driver incl.) 3
Overall length 331 cm (130 in)
Overall width 122 cm (48 in)
Overall height 113 cm (44 in)
Dry weight 378 kg (834 lb)
Load limit (passenger and 10 kg (22 lb) luggage) 272 kg (600 lb)
CAPACITIES GTX 4-TEC

Engine oil 3 L (3.2 U.S. gal) oil change w/filter
4.5 L (1.5 U.S. gal) total
Cooling system (coolant) 5.5 L (4.8 U.S. qrt) total
Fuel tank (including reserve) 60 L (15.3 U.S. gal)
Fuel tank reserve (from low level signal) 15 L (4 U.S. gal)
SMR2002-093_15_02A.FM 15-02-5
MATERIALS GTX 4-TEC

Hull Composite
Inlet grate Aluminum
Steering cover Thermoplastic
Impeller housing/stator/venturi/nozzle Plastic/stainless steel/aluminum/aluminum
Air intake silencer N.A.
Flame arrester Tubular wire screen
Steering padding N.A.
Fuel tank Polyethylene
Oil injection reservoir Polyethylene
Seat Polyurethane foam
PERFORMANCE GTX 4-TEC

Estimated pump power 57 kW (76.44 HP)
Maximum fuel consumption at wide open throttle 41.1 L/h (10.8 U.S. gal/h)
Fuel tank without reserve 55 minutes
Cruising time at full throttle Fuel tank reserve
(from low level signal) 17 minutes
15-02-6 SMR2002-093_15_02A.FM
Section 16 WIRING DIAGRAMS
Subsection 01 (WIRING DIAGRAMS)
WIRING DIAGRAMS 0
WIRE COLOR CODES DEUTSCH CONNECTORS
First color of a wire is the main color. Second color Removal
is the tracer.
To remove Deutsch connectors from engine con-
Example: YELLOW/BLACK (YL-BK) is a YELLOW
nector bracket, remove coolant container, slide a flat
wire with a BLACK tracer.
screwdriver between the connector bracket and the
Deutsch connectors and remove connectors.
WIRE DIGIT CODES
MPEM and Vehicle Electrical System
First number indicates in which connector the
wire is plugged in.
Second number indicates the position of the wire
in the connector.
The letter at the end of the number (if applicable)
indicates a common circuit in the MPEM printed
circuit with another wire bearing the same letter.
Example: 2-18 (g)
The first number indicates that the wire is posi-
tioned in the connector no. 2 of the MPEM. 2 1
F18Z0IA
The second number indicates that the wire is po-

1. Coolant plastic container bracket
sitioned in the terminal no. 18. 2. Coolant plastic container
The letter (g) indicates a common circuit with an-
other wire(s) bearing the same letter (g) in the cir- 2
cuit.
EMS ECU
GTX 4-TEC Models
On the EMS ECU, circuits are identified by a letter
followed by a number.
The letter indicates in which connector the wire is
plugged in.
The number indicates the position of the wire in
the connector.
The connector “A” is connected to the engine wir-
ing harness. F18Z0JA 1
The connector “B” is connected to the watercraft 1. Engine connector bracket
wiring harness. 2. Deutsch connectors
SMR2002-094_16_01A.FM 16-01-1
3 2 2
F18Z0KA 1 F18Z0MA 1 2
1. Engine connector bracket 1. Release button
2. Deutsch connectors 2. Deutsch connectors
3. Flat screwdriver
To disconnect two Deutsch connectors, slide a flat

screwdriver between each other to disengage,
press the release button and disconnect them.
1
F18Z0NA 2 1
1. Deutsch connectors
2. Press release button
All Models
F18Z0LA 2 Deutsch connectors are used to connect wiring
harness to the magneto and to the VCK.
1. Flat screwdriver
2. Deutsch connectors
3 1
3
2
4
F00H1CA
1. Male housing
2. Female housing
3. Secondary lock
4. Sealing cap
16-01-2 SMR2002-094_16_01A.FM
CAUTION: Do not apply dielectric grease on con- – Pry back the retaining tab while gently pulling
tacts inside plug connector. wire back until contact is removed.
To remove wire contacts from housing, proceed
1
as follows:
– Using a long nose pliers, pull out the lock.
V01G0QA 1
FEMALE CONNECTOR HOUSING
1. Retaining tab
To install:
– For insertion of signal contact, make sure the
V01G0OA 1 lock is removed.
FEMALE HOUSING – Insert contact into appropriate circuit cavity and
1. Female lock push as far as it will go.
– Pull back on the contact wire to be sure the re-
tention fingers are holding the contact.
– After all required contacts have been inserted,
the lock must be installed.
1 1
V01G0PA 1
MALE HOUSING
1. Male lock F04H6LA
NOTE: Before extraction, push wire forward to re- 1. Wire identification numbers
lieve pressure on retaining tab.
– Insert a 4.8 mm (.189 in) wide screwdriver blade
inside the front of the contact cavity.
SMR2002-094_16_01A.FM 16-01-3
Deutsch 6 pin Connector Electrical Box

 WARNING
Ensure all terminals are properly crimped on
wires and connector housings are properly fas-
tened.
AMP PLUG CONNECTOR

All Models
1 1
These connectors are found on the MPEM.
When servicing electrical system, special care
must be taken when working with AMP Plug Con-
nectors in order to prevent any malfunction of the
system.
F04H6KA
Description
6-PIN CONNECTOR
1. Wires identification numbers 5
PACKARD CONNECTOR 9
Packard connectors are used to connect electrical
harnesses and gauges. 1
7 4
1 3
89
F00H0WB 6
C B A
AMP PLUG CONNECTOR
1. Plug assembly
2. Cover assembly
3. Mating seal
F04H45A 4. Wedge lock
5. Header assembly
VIEW OF A 3-POSITION PACKARD CONNECTOR 6. Seal plug
7. Power wire
1. Identification letters 8. Signal wire
9. Locking tab
To remove terminal from Packard connector hous-
ing, use Snap-on TT600-4 tool.
F01B1JA
16-01-4 SMR2002-094_16_01A.FM
Removal
To remove the plug connector from the header as-
sembly, press both tabs and pull plug.
F00H0NA
Step 1 : Press tabs (both sides)

Step 2 : Pull plug
Installation
Apply a thin coat of DEOXIT contact lubricant (P/N F00H12A 1
293 550 015) to the pins of the header on the
1. Mechanically keyed
MPEM only.
Contact Removal
Signal Wire
Insert a screwdriver blade between the connector
and the wedge lock tab.
Release the locking tab and at the same time, pry
open the wedge lock to open position.
CAUTION: The wedge lock should never be re-
moved from the connector for insertion or re-
moval of the signal wire contacts.
1 2
1
F00H11A
1. Apply a thin coat of DEOXIT contact lubricant
CAUTION: Do not apply lubricant excessively.

Care must be taken so that the lubricant will not
come in contact with the mating seal; the seal
may loose its sealing capacities. Do not apply
lubricant on contacts inside plug connector.
Each plug assembly is mechanically keyed to mate
only with identical mechanical keyed header on
the MPEM.
F00H0OA
1. Screwdriver between wedge lock and connector

2. Locking tab
SMR2002-094_16_01A.FM 16-01-5
Repeat the same steps for the other locking tab

1
retaining the wedge lock.
The wedge lock is now in the open position.
F00H0RA
F00H0PA
1. Pull locking tab (both sides)

1. Wedge lock opened
Before extraction, push wire forward to relieve pres-
While rotating the wire back and forth over a half sure on retaining tab.
turn (1/4 turn in each direction), gently pull the wire
until the contact is removed. Insert a 4.8 mm (.189 in) wide screwdriver blade
inside the front of the contact cavity.
F00H0QA
1. Rotate wire back and forth

2. Pull wire
Power Wire Contact

NOTE: The wedge lock must be removed to ex-
tract power contact.
Open the wedge lock.
Pull both locking tabs and remove wedge lock
from plug assembly. F00H0ZA
Pry back the retaining tab while gently pulling wire

back until contact is removed.
16-01-6 SMR2002-094_16_01A.FM
Contact Crimping 1
The size of the wires must be 20 to 16 AWG with
a wire insulation diameter having a minimum di-
mension of 1.7 mm (.067 in) and a maximum di-
mension of 2.78 mm (.106 in).
The wire strip length shall be 5.1 mm (13/64 in).
NOTE: When stripping wires, ensure conductor is
not nicked, scrapped or cut. Wire stripping tool
jaws may leave marks on the surface of the wire
insulation. If these marks occur at the location of
the wire seal, leakage may result. Insulation sur-
face within 25 mm (1 in) from the tip of the con-
tact must be smooth.
All contacts in AMP plug connectors must be
crimped using the crimping tool (P/N 295 100 164).
F00H10A 2
CAUTION: If contacts are not crimped using the
1. Seal plug
proper crimping tool, the wire seal may be dam- 2. Wire seal
aged.
CAUTION: Do not pierce the diaphragm with a
sharp point for electrical troubleshooting. The
resulting pinholes in the insulation will allow
moisture to penetrate the system and possibly
result in system failure.
Contact Installation
For insertion of signal contact, make sure the wedge
lock is in the open position.
NOTE: For insertion of power contact, the wedge
lock may or may not be on the open position.
F00B0EA
Insert contact into appropriate circuit cavity and
push as far as it will go.
CRIMPING TOOL (P/N 295 100 164)
Pull back on the contact wire to be sure the reten-
All circuits are sealed by a diaphragm in the rubber tion fingers in the housing are holding the contact
wire seal. When installing wire contacts in plug properly.
connector, the diaphragm is pierced as the contact After all required contacts have been inserted, the
passes through it. wedge lock must be closed to its locked position.
If the diaphragm is pierced and the cavity is not
used, install a seal plug, large end first, into circuit
cavity as far as it will go.
NOTE: It is suggested that all unused circuit cavi-
ties be sealed with a seal plug, even if they are not
pierced.
SMR2002-094_16_01A.FM 16-01-7
IDENTIFICATION OF MAIN FUSE HOLDER JOINT

CONNECTOR PINS CONNECTOR
AMP Connectors of MPEM DI Models
The fuse holder is located in the rear electrical box.
26 25 24
F12H0ZA 1
23 16 1. Main fuse holder joint connector
15 9 NOTE: In the following illustrations, the joint insu-

lator has been removed for clarity purpose only. It
8 1 is not necessary to remove it to separate the joint.
The same procedure is to be used each side of the
joint.
Insert the Deutsch joint connector tool (no. 114010)
F04H6RA
on the wire and push tool toward the joint to re-
lease it. While holding the joint insulator, push the
AMP Connectors of Wiring Harness tool until it bottoms. It is now unlocked. Maintain-
ing the pressure with the tool, pull the wire out.
F12H10A
1. Deutsch joint connector tool (no. 114010)
F04H6GA
2 1
F12H11A
1. Hold the insulator

2. Push the tool until it bottoms
16-01-8 SMR2002-094_16_01A.FM
Crimping and Installation Tools

Required
To install EMS ECU connector terminal pins or ter-
minal wire, three tools are required; EMS ECU
crimping tool, EMS ECU extraction tool and a stan-
F12H12A 1 2 dard flat screwdriver.
1. While holding tool pressure, pull wire until terminal releases
2. Joint connector
For installation, simply push the wire in the con-

nector. You should hear a locking “click”. Try to
pull the wire out to ensure terminal is properly
locked. If not, remove the wire and bend the tabs
inside the joint connector to allow proper locking. 3
Recheck.
2
EMS ECU CONNECTORS
1
4-TEC Models Only
F18Z03A
There are two EMS ECU connectors used on the
4-TEC models and they are connected on the 1. EMS ECU crimping tool
2. EMS ECU connector terminal extraction tool
EMS ECU. The engine harness female connector 3. Standard flat screwdriver
is connected on the module male connector “A”
and the watercraft system control harness female Defective Terminal Removal
connector is connected to the module male con-
Unlock the terminal cover by disengaging the ter-
nector “B”. The engine connector has 41 pins.
minal cover locking device on both side with a flat
screwdriver.
1
1
F18Z02A
1. EMS ECU
2. A connector (engine harness)
3. B connector (watercraft system harness) F18Z04A
1. Terminal connector cover

2. Terminal cover locking device
SMR2002-094_16_01A.FM 16-01-9
Lift wire harness and note the terminal pinout

number.The EMS ECU connector has 41 termi-
nals. The pins are splited in three groups; 1 to 13,
1 14 to 28 and 29 to 41. Make sure you have located
the proper terminal.
F18Z05A
1. Terminal connector cover

2. Terminal cover locking device 2
Lift the cover by pushing it forward.
F18Z08A
1. Wire harness
2. Terminal pinout numbers
1 Once the defective terminal is identified, unlock

the red terminal locking plate by using the flat
screwdriver and release the locking device at each
end of the connector. Remove the red terminal
locking plate by sliding it outside the connector.
F18Z06A
1. Cover
Cut both tie raps.
2 1
F18Z09A
1. First locking device

2. Red terminal locking plate
F18Z07A
1. Tie raps
16-01-10 SMR2002-094_16_01A.FM
Release the defective terminal from connector

with the extraction tool. Align the extraction tool
pin properly with the terminal cavity and push the
tool downward. That will release the wire with the
terminal.
1 2
2
1 3
F18Z0AA
1. Second locking device

F18Z0DA
1. Terminal cavity
2. Extraction tool
1 3. Extraction tool pin
F18Z0BA
Remove the red terminal locking plate and acquire

the EMS ECU extraction tool.
2
1
F18Z0EA
1. Extraction tool
2. Connector terminal housing
F18Z0CA 1
2. EMS ECU extraction tool
SMR2002-094_16_01A.FM 16-01-11
2
3
1
F18Z0HA
1 1. Crimping tool swivel

2. Crimping tool
3. Wire
F18Z0FA 2
1. Connector terminal housing
CAUTION: Probe on top of terminal only. Do not
2. Defective wire and terminal try to probe inside terminal or to use a paper
clip to probe inside terminal, it can damage the
If the wire is in good condition but the terminal is square-shaped terminal.
rusted or corroded, remove defective terminal and
crimped a new one. If wire and terminal are defec- CAUTION: Do not disconnect the EMS ECU con-
tive, acquire a new genuine wire and new terminal nector needlessly. They are not designed to be
and crimp them together as follow. disconnected/reconnected frequently.
IMPORTANT: Use genuine wires only. Otherwise Lubrication
wires will not fit properly.
Apply a thin coat of DEOXIT contact lubricant (P/N
Terminal and Wire Crimping 293 550 015) to the pins of the header on the EMS
ECU only.
To crimp a new terminal to a good wire, acquire
the EMS ECU crimping tool. Install the new termi-
nal in the crimping tool swivel. Close the swivel in
place. Place the wire on terminal barrel and crimp
the wire firmly.
2 3
1
F18Z0GA Callout
1. New terminal
2. Crimping tool swivel
3. Crimping tool
16-01-12 SMR2002-094_16_01A.FM
GTX DI MODEL
12 VOLTS DISTRIBUTION
MODEL GTX DI 2002
F18Z0P
GTX 4-TEC MODEL
MODEL GTX 4-TEC 2002 TOPS VALVE
12 VOLTS DISTRIBUTION
INFORMATION
CENTER
OPS
(NORMALY OPEN) OSPS
(NORMALY CLOSED)
CPS IDLE BY PASS
VALVE
COMMUNICATION LINK
D.E.S.S. AUXILIARY MODULE
TPS
MAPS
CTS
EMS MATS
ENGINE
CONNECTOR ECU
EGT
COMMUNICATION LINK
TOPS VALVE
COMMUNICATION LINK
F18Z0O

2002 Seadoo

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GTX DI, GTX 4-TEC

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SECTION SUBSECTION PAGE

SAFETY NOTICE .................................................................................................................................. III

01 SERVICE TOOLS 01 - Table of contents ...................................................................... 01-01-1

03 TROUBLESHOOTING 01 - Troubleshooting chart ............................................................... 03-01-1

04 ENGINE (DI) 01 - Table of contents ...................................................................... 04-01-1

05 ENGINE (4-TEC) 01 - Table of contents ...................................................................... 05-01-1

07 ENGINE 01 - Table of contents ...................................................................... 07-01-1

08 COOLING SYSTEM 01 - Table of contents ...................................................................... 08-01-1

09 FUEL SYSTEM 01 - Table of contents ...................................................................... 09-01-1

10 LUBRICATION 01 - Table of contents ...................................................................... 10-01-1

11 ELECTRICAL 01 - Table of contents ...................................................................... 11-01-1

12 PROPULSION 01 - Table of contents ...................................................................... 12-01-1

13 STEERING 01 - Table of contents ...................................................................... 13-01-1

14 HULL/BODY 01 - Table of contents ...................................................................... 14-01-1

15 TECHNICAL DATA 01 - GTX DI model ........................................................................... 15-01-1

16 WIRING DIAGRAMS 01 - Wiring diagrams........................................................................ 16-01-1

1. Hull Identification Number (H.I.N.)

The Hull Identification Number is composed of 12

*A letter may also be used as a digit.

ENGINE IDENTIFICATION ARRANGEMENT OF THIS

Bold face number

Page numbering system:

Sub-title with part

Section 06 FUEL SYSTEM

Title indicates main

Sub-sub-title in this All Others Models

Letters are used for

Bold numbers in the

LIST OF ABBREVIATIONS USED OPS Oil Pressure Sensor

GENERAL INFORMATION As many of the procedures in this manual are in-

EPA Emission Regulations LOCTITE APPLICATION

VIA U.S. POSTAL SERVICE:

Blind Holes 1. Clean threads (stud and hole) with solvent.

1. Clean threads (bolt and hole) with solvent.

Stud in Blind Holes 2

Adjusting Screw Standard Thread Repair

STRIPPED THREAD REPAIR GASKET COMPOUND

1. Remove old gasket and other contaminants

NOTE: Avoid grinding. Mounting in Tandem

1. Clean inner housing diameter and outer gasket

TIGHTENING TORQUES N•m

FASTENER SIZE FASTENER SIZE

OPTIONAL SERVICE TOOLS ................................................................................................ 01-03-1

SERVICE PRODUCTS ............................................................................................................ 01-04-1

MANDATORY SERVICE TOOLS 0

Puller Alignment support plate kit VCK (Vehicle Communication Kit)

Screw M8 x 35 (3) APPLICATION

155.6 mm jet pump. APPLICATION

Handle Polygonal wrench APPLICATION

Crankshaft looking tool

Oil pressure gauge (1 to 8 bars)

P/N 295 000 070 P/N 529 035 714

All models. 947 DI engine. APPLICATION

Fuel pressure gauge 1 APPLICATION

Impeller shaft holder F08B014

Impeller shaft guide

Jet pump bearing remover APPLICATION

NEW NEW NEW

Drive shaft/floating ring Shaft pusher Pressure cap