Professional Documents
Culture Documents
HULL
SERVICE PRODUCTS
Description Part Number Page
BRP HEAVY DUTY CLEANER ....................................................... 293 110 001 ................................... 7, 9–10
LOCTITE 5150 (SILICONE SEALANT) ........................................... 296 000 309 ......................... 11–12, 15–16
LOCTITE 5900 ............................................................................... 293 800 066 ................................... 7, 9–11
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Subsection XX (HULL)
15 Nm
(133 lbfin)
8 Nm
(71 lbfin)
NEW
Loctite 16 Nm
5900 (142 lbfin)
8 Nm
(71 lbfin) Loctite 5150
(silicone sealant)
8.5 Nm
(75 lbfin)
9 Nm
(80 lbfin)
Loctite NEW
5150
(silicone 14.5 Nm
sealant) (128 lbfin)
8 Nm
(71 lbfin)
9 Nm
(80 lbfin)
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Subsection XX (HULL)
NEW
5 Nm
(44 lbfin) NEW
5 Nm
(44 lbfin)
7 Nm
(62 lbfin)
NEW
20 Nm
(15 lbfft)
11 Nm
(97 lbfin) NEW
NEW 8 Nm
20 Nm (71 lbfin)
(15 lbfft)
NEW
35 Nm
(25 lbfft)
NEW
35 Nm
Loctite 567 (25 lbfft)
NEW (pipe sealant)
8 Nm
35 Nm (71 lbfin)
(25 lbfft)
smr2010-047-002_a
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Subsection XX (HULL)
4 smr2010-047
Subsection XX (HULL)
RIDE PLATE
Ride Plate Removal
NOTE: The jet pump support and ride plate must
be removed as an assembly. The pump support
is fastened to the ride plate and the forward pump
support mounting screws cannot be accessed
when the ride plate is installed.
NOTICE If the ride plate is replaced, or
removed and installed, the engine/drive
shaft/pump alignment must be checked. Refer
smr2009-043-013_a to ENGINE REMOVAL AND INSTALLATION.
1. Inlet grate screws
2. Inlet grate 1. Remove iBR gate and VTS trim ring, refer to iBR
AND VTS subsection.
NOTICE An impact screwdriver should be
2. Remove jet pump and nozzle, refer to JET
used to loosen screws.
PUMP subsection.
Inlet Grate Installation 3. Drain cooling system, refer to COOLING SYS-
When installing inlet grate, install NEW self-lock- TEM subsection.
ing screws. 4. Remove the battery from the watercraft, refer
to CHARGING SYSTEM subsection.
5. On iS models, move the electrical accessories
support and electrical harness above and to the
right of the resonator for improved access to
the ride plate coolant hoses and fittings.
6. Reach in between the exhaust system res-
onator and hull to loosen the gear clamps and
disconnect both coolant hoses from the ride
plate.
smr2009-043-013_b
1. M8 x 40 screw
2. M8 x 20 screws
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smr2009-043-015_a
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Subsection XX (HULL)
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1. Hose fittings
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Subsection XX (HULL)
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WASHERS LOCATION
RIDE PLATE TORQUE 4. Position ride plate on hull and engage NEW M8
Existing ride plate 7.5 N•m (66 lbf•in) self-locking screws 5 turns by hand.
New ride plate 11 N•m (97 lbf•in) 5. Position inlet grate and engage NEW retaining
screws 5 turns by hand. Refer to INLET GRATE
in this subsection.
6. Push ride plate completely forward and torque
ride plate screws to 35 N•m (26 lbf•ft) as per
following torque sequence.
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Subsection XX (HULL)
smr2009-043-019_a
smr2009-043-019_b
smr2009-043-019_a
THRU-HULL FITTING
The thru-hull fitting is composed of 2 pieces, an
outer fitting, and an inner fitting that screws onto
the outer fitting after the outer fitting is inserted
smr2009-043-021_a
in the hull.
RIDE PLATE
1. Apply Loctite 5900 here
smr2009-043-024_a
1. Outer fitting
smr2009-043-020_a 2. Inner fitting
UNDERSIDE OF JET PUMP SUPPORT
1. Apply Loctite 5900 here Thru-Hull Fitting Removal
3. Torque jet pump support screws as specified in Inner Fitting Removal
exploded view. 1. Remove drive shaft, refer to DRIVE SHAFT sub-
section.
2. Using a heat gun, heat the glue at the joint be-
tween the hull and the inner thru-hull fitting to
soften the glue applied.
smr2010-047 9
Subsection XX (HULL)
smr2009-043-031_a
smr2010-047-011_a
2. Insert the outer fitting into the hull from the jet
pump side of the hull towards the inside. En-
sure fitting is pushed in against the hull.
3. Continue with INNER FITTING INSTALLATION
procedure.
Inner Fitting Installation
1. Apply the SIX10 glue from West System (see
HULL REPAIR at the beginning of this subsec-
smr2009-043-023_a
tion for more information) or an equivalent com-
TYPICAL pletely around the third thread of the fitting.
1. Cut sealant around outer fitting here
10 smr2010-047
Subsection XX (HULL)
smr2010-047-012_a
smr2009-043-023_a
1. Apply glue here TYPICAL
1. Bead of Loctite 5900 all around the outer fitting
2. Screw the inner fitting onto the outer fitting and
torque as specified in the exploded view.
SPONSONS
3. Using a stirring stick (or a tongue depressor),
smooth out glue over the hull and inner fitting NOTE: Removal and installation procedure for RH
joint. and LH sponson is the same.
Sponson Removal
Remove the muffler or the resonator. Refer to the
EXHAUST SYSTEM subsection.
From inside hull, hold sponson nuts while remov-
ing sponson retaining bolts and washers.
smr2009-043-022_a
properly seated against the hull in the jet pump TYPICAL – RH SPONSON SHOWN
1. Sponson
area. Remove excess sealant at the joint be- 2. Retaining bolts
tween the outer fitting and hull.
5. Apply a bead of LOCTITE 5900 (P/N 293 800 066) Sponson Installation
sealant completely around the outer edge of 1. Clean any residues of silicone sealant on hull
the outer fitting to complete the sealing proce- and sponsons.
dure. 2. Apply LOCTITE 5150 (SILICONE SEALANT)
(P/N 296 000 309) on back side of sponson
spacers.
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Subsection XX (HULL)
smr2010-047-004_a
smr2010-047-005_a
1. Starboard bailer
6. Tighten nuts as specified in the exploded view.
7. Reinstall muffler or resonator. Refer to EX- 3. Check if the hole on each bailer hose elbow fit-
HAUST SYSTEM for the procedure. ting is obstructed. Clean both elbow fittings if
necessary.
BAILERS
Two bailer pick ups (one each side), serve to drain
the bilge of the watercraft when it is in operation.
The bailer pick ups are connected through a hose
system to two syphon tubes mounted in the jet
pump venturi that draw the water out of the bilge
through the bailer pick ups. The bailers are also
connected to the bilge drain plugs in the stern.
12 smr2010-047
Subsection XX (HULL)
DRAIN PLUGS
NOTE: The two drain plugs on the stern are each
connected to a bailer. When watercraft is on dry
land, the drain plugs can be removed to manually
drain the bilge.
2. Cut locking tie securing bailer hose to the drain DRAIN NECK REMOVAL
plug assembly.
Drain Plug Neck Installation
1. Install drain neck and torque to 9 N•m
(80 lbf•in).
2. Secure bailer hose to drain neck using a NEW
locking tie.
3. Reinstall all removed parts in the reverse order
of removal.
BOW EYELET
Bow Eyelet Removal
smr2009-043-034_a
iS Models
LEFT SIDE SHOWN (IBR ACTUATOR REMOVED)
1. Cut this locking tie To remove the retaining nuts on the bow moor-
ing eyelet, an access hole must be cut in the neo-
3. Unscrew the drain plug from the drain neck and prene sealing pad. Carry out the following steps.
pull the drain plug out of the neck.
1. Remove splash deflector.
1.1 Drill all rivets holding the splash deflector.
smr2009-043-032_a
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Subsection XX (HULL)
ssi2010-016-006_a
CUTTING PATTERN
ssi2010-016-020
ssi2010-016-011_a
1. Rubber washer
2. Large washer
3. Elastic nut
4. Screw
14 smr2010-047
Subsection XX (HULL)
smr2007-034-110_a
TYPICAL
1. Bow eyelet
2. Small washer
3. Nylon washer
4. Loctite 5150 (silicone sealant) here
5. Rubber washer
6. Large washer
7. Elastic stop nut
iS Models
1. The installation is the reverse of the removal
procedure. However, pay attention to the fol-
lowing.
2. Inside hull, apply LOCTITE 5150 (SILICONE
smr2010-047-006_a
SEALANT) (P/N 296 000 309) around eyelet
INSIDE HULL
1. Eyelet retaining nuts mounting holes.
3. Install rubber washers, large washers and NEW
4. Remove the bow eyelet from the vehicle. elastic stop nuts.
5. Clean any residue of silicone sealant from the 4. Torque elastic nuts to 14.5 N•m (128 lbf•in).
hull.
5. Reinstall the splash deflector on the fixed deck
Bow Eyelet Installation using 6 rivets.
All Models NOTICE Ensure neoprene gasket edges have
1. Inside hull, apply LOCTITE 5150 (SILICONE not been damaged during the installation pro-
SEALANT) (P/N 296 000 309) around eyelet
cedure before reinstalling the splash deflector.
mounting holes. If gasket is damaged, replace by a new one.
2. Install small washers and nylon washers on
bow eyelet and insert it through hull holes.
STERN EYELETS
3. Inside hull, install rubber washers, large wash- Stern Eyelet Removal
ers and NEW elastic stop nuts. 1. On iS models, open the boarding platform and
4. Torque nuts to 14.5 N•m (128 lbf•in). remove the applicable storage tray. On mod-
els without iS, remove the applicable access
cover.
2. Inside hull, unscrew and discard elastic stop
nuts securing the stern eyelet to hull.
3. Pull stern eyelet to remove it from watercraft.
4. Clean any residue of silicone sealant from the
hull.
smr2010-047 15
Subsection XX (HULL)
smr2009-043-026_a
TYPICAL
1. Blind hole insert
TYPICAL
threads are damaged beyond use.
1. Stern eyelet NOTE: Inserts should only be replaced as a last
2. Small washer
3. Nylon washer resort. First try passing a tap, cleaning the hole,
4. Loctite 5150 (silicone sealant) here and using a NEW self-locking screw. If fastener
5. Rubber washer
6. Large washer can be tightened to the specified torque, do not
7. Elastic stop nut change insert. If torque cannot be applied, drill
4. Torque retaining nuts to 14.5 N•m (128 lbf•in). and tap insert one size larger before trying to
change an insert.
HULL INSERTS Insert Removal
Metal inserts (brass) of various types and sizes 1. Heat the insert using a heat gun to soften the
are screwed into the hull at various locations. A glue securing the insert into the hull.
threaded hole in the insert is used for fastening 2. Remove any excess glue from around the head
various parts and equipment onto the hull. of the insert that would prevent proper insertion
Some inserts pass completely through the hull, of the socket used to remove the insert.
while others do not (blind hole inserts).
smr2009-043-026_b
16 smr2010-047
Subsection XX (HULL)
Insert Installation
1. Clean the insert hole in the hull to remove any
dirt or loose glue using clean, dry, oil free fil-
tered air.
NOTICE Do not use a metal tool to clean or
remove the glue inside the hull insert hole to
prevent damaging the threads in the hull ma-
terial. The glue that is properly bonded to the
hull does not need to be removed.
2. If the insert passes completely through the hull,
screw a stud of appropriate size into the insert
(M6 or M8) to prevent any glue from seeping
into the fastener threads in the insert. Apply
the SIX10 glue from West System (see HULL
REPAIR at the beginning of this subsection for
more information) or an equivalent to the outer
threads of the insert.
NOTE: Apply a sufficient amount of glue thru the
full length of the insert threads to ensure excess
glue will come out of the hole as the insert is
screwed into the hull.
3. If the insert screws into a blind hole, apply the
SIX10 glue or an equivalent to the threads in the
hull.
4. Screw the insert in the hull boss and torque to
25 N•m (18 lbf•ft). Ensure the flanged portion
of the insert makes contact with the boss it is
being screwed into.
smr2010-047 17