Shop Manual

ManualsBrandsPolaris ManualsOtherShop Manual BRP SEA400 RXT IS 255, GTX Limited IS 255

Summary of content (555 pages)

PAGE 1
PAGE 2
009 Shop Manual RXT® iS™ 255 GTX† LIMITED iS™ 255
PAGE 3
Legal deposit: National Library of Quebec National Library of Canada 2009 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Recreational Products Inc. (BRP) © Bombardier Recreational Products Inc. (BRP) 2009 Printed in Canada Technical Publications Bombardier Recreational Products Inc. (BRP) Valcourt (Quebec) Canada ®™ Trademarks of Bombardier Recreational Products Inc. (BRP) or its affiliates.
PAGE 4
TABLE OF CONTENTS SAFETY NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X VEHICLE INFORMATION. . . . . . . . . . . . .
PAGE 5
TABLE OF CONTENTS 02 ENGINE (cont’d) 04 – SUPERCHARGER (cont’d) TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SUPERCHARGER . . . . . . . . . . . . . . . . . . . . . . .
PAGE 6
TABLE OF CONTENTS 02 ENGINE (cont’d) 09 – COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 7
TABLE OF CONTENTS 03 ELECTRONIC MANAGEMENT SYSTEMS (cont’d) 03 – COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 8
TABLE OF CONTENTS 04 FUEL SYSTEM (cont’d) 03 – FUEL TANK AND FUEL PUMP (cont’d) PROCEDURES (cont’d) FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 05 ELECTRICAL SYSTEM 01 – CONTROLLER AREA NETWORK (CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL . . . . . . . . . . . .
PAGE 9
TABLE OF CONTENTS 05 ELECTRICAL SYSTEM (cont’d) 06 – DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.) (cont’d) PROCEDURES (cont’d) D.E.S.S. POST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07 – GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 10
TABLE OF CONTENTS 06 STEERING AND PROPULSION (cont’d) 03 – JET PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JET PUMP MAIN COMPONENTS . . . .
PAGE 11
TABLE OF CONTENTS 07 BODY AND HULL (cont’d) 02 – BODY (cont’d) PROCEDURES (cont’d) STORAGE COMPARTMENT COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GLOVE BOX COVER . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 12
SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair 2009 Sea-Doo® watercraft as describe in the model list in the INTRODUCTION. This edition was primarily published to be used by watercraft mechanical technicians who are already familiar with all service procedures relating to BRP made watercraft. Mechanical technicians should attend training courses given by BRPTI.
PAGE 13
INTRODUCTION INTRODUCTION This shop manual covers the following BRP made 2009 Sea-Doo watercraft models. MODEL GTX Limited iS COLOR ENGINE MODEL NUMBER Topaz mist metallic 1503 HO (255 HP) 189A, 189B Bright yellow 1503 HO (255 HP) 349A, 349B RXT iS The information and component/system descriptions contained in this manual are correct at time of writing.
PAGE 14
INTRODUCTION The owner/operator is not to, and should not allow anyone to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications.
PAGE 15
INTRODUCTION As many of the procedures in this manual are interrelated, we suggest, that before undertaking any task, you read and thoroughly understand the entire section or subsection in which the procedure is contained. A number of procedures throughout the book require the use of special tools. Before commencing any procedure, be sure that you have on hand all the tools required, or approved equivalents.
PAGE 16
INTRODUCTION TYPICAL PAGE Section 06 ENGINE Subsection 01 (MAGNETO) Subsection title Indicates applicable models. Page heading indicates section and subsection. MAGNETO Models Drop represents a service product to be applied. Loctite 243 Exploded view assists you in identifying parts and their related positions. Model Dotted box contains parts applicable to a specific model. Bold face number is used to identify a part referred to the text.
PAGE 17
INTRODUCTION TYPICAL PAGE Section 03 ENGINE Subsection 09 (MAGNETO SYSTEM) Tittle in bold indicates category of information to be carried out. Reference to a specific section or subsection. GENERAL NOTE: The following procedures can be done without removing the engine. During assembly/installation, use the torque values and service products as in the exploded views. Clean threads before applying a threadlocker.
PAGE 18
INTRODUCTION TIGHTENING TORQUE Tighten fasteners to torque mentioned in exploded views and/or text, When they are not specified, refer to following table. 2. Apply the half of the recommended torque value. NOTICE Be sure to use proper tightening torque for the proper strength grade. NOTE: When possible, always apply torque on the nut. 3. Torque at the recommended torque value. NOTE: Always torque screws, bolts and/or nuts in a crisscross sequence.
PAGE 19
INTRODUCTION FASTENER INFORMATION SELF-LOCKING FASTENERS PROCEDURE 3. Choose proper strength Loctite threadlocker. 4. Fit bolt in the hole. 5. Apply a few drops of threadlocker at proposed tightened nut engagement area. 6. Position nut and tighten as required. Threadlocker Application for Blind Holes 1 A00A6LA 2 TYPICAL — SELF-LOCKING FASTENER The following describes the most common application procedures when working with self-locking fasteners.
PAGE 20
INTRODUCTION 2. Apply LOCTITE PRIMER N (P/N 293 800 041) on threads and allow to dry. 3. Put 2 or 3 drops of proper strength Loctite threadlocker on female threads and in hole. NOTE: To avoid a hydro lock situation, do not apply too much Loctite. 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 uncovered threads. 8. Tighten nuts as required.
PAGE 21
INTRODUCTION 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 STANDARD THREAD REPAIR procedure. Option 2: Apply FORM-A-THREAD on the screw and insert in damaged hole. Permanent Stud Installation (Light Duty) 1. Use a stud or thread on desired length. 2. DO NOT apply release agent on stud. 3. Do a STANDARD THREAD REPAIR. 4. Allow to cure for 30 minutes. 5. Assemble. 5.
PAGE 22
INTRODUCTION Threadlocker Application for Case-In Components (Metallic Gaskets) 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). 3. Apply a strip of proper strength Loctite on leading edge of outer metallic gasket diameter. NOTE: Any Loctite product can be used here. A low strength liquid is recommended as normal strength and gap are required. 4. Install according to standard procedure.
PAGE 23
XX smr2009-011
PAGE 24
Section 01 MAINTENANCE Subsection 01 (MAINTENANCE SCHEDULE) MAINTENANCE SCHEDULE The maintenance schedule should be adjusted according to operating conditions and use. NOTE: The schedule provides an equivalence between number of hours and months/year. Maintenance operations should be carried out following whichever time frame comes due first. IMPORTANT: Watercraft rental operations or intensive use of watercraft, will require greater frequency of inspection and maintenance.
PAGE 25
Section 01 MAINTENANCE Subsection 01 (MAINTENANCE SCHEDULE) A: C: I: L: R: FIRST 10 HOURS Adjust Clean Inspect Lubricate Replace 25 HOURS OR 3 MONTHS 50 HOURS or 6 MONTHS 100 HOURS or 1 YEAR 200 HOURS or 2 YEAR O: Operator D: Dealer TO BE PERFORMED BY PART/TASK NOTE ELECTRICAL SYSTEM Spark plug I I Electrical connections and fastening (ignition system, starting system, fuel injectors etc.) I I D D.E.S.S.
PAGE 26
Section 01 MAINTENANCE Subsection 01 (MAINTENANCE SCHEDULE) A: C: I: L: R: FIRST 10 HOURS Adjust Clean Inspect Lubricate Replace 25 HOURS OR 3 MONTHS 50 HOURS or 6 MONTHS 100 HOURS or 1 YEAR 200 HOURS or 2 YEAR O: Operator D: Dealer TO BE PERFORMED BY PART/TASK NOTE HULL AND BODY Hull I I O Ride plate and water intake grate I I O — (1) The supercharger clutch requires replacement when the SUPERCHARGER MAINTENANCE REQUIRED message is displayed on the information center every 100 hours of ope
PAGE 27
4
PAGE 28
Section 01 MAINTENANCE Subsection 02 (PRESEASON PREPARATION) PRESEASON PREPARATION Proper vehicle preparation is necessary after the winter months or when a vehicle has not been used during several weeks. Any worn, broken or damaged parts found during the storage procedure should have been replaced. If not, proceed with the replacement. WARNING Unless otherwise specified, engine should be turned off during preseason preparation procedure.
PAGE 29
6
PAGE 30
Section 01 MAINTENANCE Subsection 03 (STORAGE PROCEDURE) STORAGE PROCEDURE SERVICE PRODUCTS Description Part Number BRP FUEL STABILIZER ................................................................. DOW CORNING 111 ..................................................................... LOCTITE 767 (ANTISEIZE LUBRICANT) ....................................... XPS LUBE......................................................................................
PAGE 31
Section 01 MAINTENANCE Subsection 03 (STORAGE PROCEDURE) smo2008-001-053_a TYPICAL 1. Flushing adaptor (P/N 295 500 473) 2. Hose 13 mm (1/2 in) 3. Air hose male adapter NOTICE Failure to drain the exhaust manifold may cause severe damage to this components. Engine Coolant Replacement smo2009-002-151_a 1. 2. 3. 4. Hose alignment lines Hose clamp Intercooler outlet hose iS module 4. Start engine and rev up to 4000 RPMs several times. Water will be expelled from intercooler.
PAGE 32
Section 01 MAINTENANCE Subsection 03 (STORAGE PROCEDURE) NOTICE Never cut the locking ties of ignition coil connectors. This would allow mixing the wires between cylinders. 3. Clean ignition coil areas to avoid falling dirt into cylinder. 4. Remove ignition coils. 5. Unscrew spark plugs. 6. Using an ignition coil as a puller, remove spark plugs. ELECTRICAL SYSTEM Battery Removal For battery removal, cleaning and storage, refer to CHARGING SYSTEM subsection.
PAGE 33
10
PAGE 34
Section 01 MAINTENANCE Subsection 04 (SPECIAL PROCEDURES) SPECIAL PROCEDURES SERVICE TOOLS Description Part Number Page LARGE HOSE PINCHER................................................................ 529 032 500 ........................................... 12 SUCTION PUMP ........................................................................... 529 035 880 ...........................................
PAGE 35
Section 01 MAINTENANCE Subsection 04 (SPECIAL PROCEDURES) Supercharger Servicing If there was water in the oil or in the supercharger inlet hose, it is recommended to take the supercharger apart, dry all the components, replace the slip clutch needle bearings and shaft ball bearings. Refer to SUPERCHARGER section. 8. Put a tape at 400 mm (16 in) from the end of the suction pump tube. 9. Insert the tube in the PTO area until the tape reach the cylinder-block edge. Then, siphon contaminated oil out.
PAGE 36
Section 01 MAINTENANCE Subsection 04 (SPECIAL PROCEDURES) 5290325002 WARNING Certain components in the engine compartment may be very hot. Direct contact may result in skin burn. Do not touch any electrical parts or jet pump area when engine is running. smr2009-015-001_a 1. Oil cooler coolant inlet hose 4. Continue to run the engine at 3500 RPM for 15 more minutes (20 minutes total run time). 5. Shut the engine off. 6. Remove the hose pincher on the coolant line going to the oil cooler.
PAGE 37
14
PAGE 38
Section 02 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) ENGINE REMOVAL AND INSTALLATION SERVICE TOOLS Description Part Number ALIGNMENT SHAFT ADAPTER .................................................... ALIGNMENT SHAFT SUPPORT .................................................... ALIGNMENT SHAFT ..................................................................... ENGINE ALIGNMENT PLATE ........................................................ FUEL HOSE DISCONNECT TOOL ...........................
PAGE 39
Section 02 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) 6. Drain cooling system. Refer to COOLING SYSTEM subsection. 7. Cut locking tie securing exhaust water outlet hose and engine blow-by hose. 8. Disconnect the exhaust water outlet hose from the exhaust manifold. 9. Disconnect the hose from the blow-by valve. smr2009-016-005_a 1. Exhaust hose clamp 10.3 Detach retaining strap. smr2009-016-003_a 1. 2. 3. 4. 5.
PAGE 40
Section 02 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) 13. Connect B.U.D.S. Refer to COMMUNICA- TION TOOLS AND B.U.D.S. SOFTWARE subsection. 14. Release fuel pressure using B.U.D.S. 15. Using the FUEL HOSE DISCONNECT TOOL (P/N 529 036 037) disconnect fuel hose from fuel rail. smr2009-016-011_a 1. Ground wires 529036037 19. On top of engine, cut locking ties securing vehicle harness and engine connector to engine. 20. Unplug the "B" connector from the ECM. smr2009-016-009_a 1. Fuel rail 2.
PAGE 41
Section 02 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) smr2009-016-014_a 1. Cut this locking tie 2. MATS sensor 3. Vehicle harness 23. At the rear of engine, unplug the magneto connector and detach connector housing from ECM support. smr2009-016-017_a 1. Ride plate hoses 2. Water pump housing 26. Install a suitable lifting device. smr2009-016-018_a 1. Engine lifting brackets smr2009-016-015_a 1. Magneto connector 2. Connector housing 27. Remove front engine support screw. 24.
PAGE 42
Section 02 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) smr2009-016-023_a 1. Water outlet hose 2. Exhaust manifold smr2009-016-020_a 1. Rear engine support screw on starboard side 2. Water pump housing 29. Cut locking tie from coolant hose alongside throttle body that retains the vehicle harness. smr2009-016-021_a 1. Cut this locking tie 2. Throttle body 3. Coolant hose 33. Slightly lift engine to ease the remaining component removal. 34.
PAGE 43
Section 02 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) smr2009-016-026_a 1. Ground cable screw on cylinder block 37. Carry on engine lifting to remove it from the body opening. NOTICE Be careful not to scratch body or to hit any component. 38. Install the engine on an engine stand. Check tightness and condition of engine rubber mounts. Refer to ENGINE MOUNTS in this subsection. Before completely lowering engine, install ground cable, starter cable and both cooling hoses on exhaust manifold.
PAGE 44
Section 02 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) 529 035 719 295 000 141 529036170 ENGINE ALIGNMENT PLATE Trace two thin lines on alignment shaft. One at 739 mm (29-3/32 in) and the other at 742 mm (29-7/32 in). smr2009-016-027_a 1. Engine alignment plate 2. Engine alignment support smr2009-016-200_a A. 739 mm (29-3/32 in) B. 742 mm (29-7/32 in) 3. Secure the tool on ride plate using jet pump socket screws.
PAGE 45
Section 02 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) NOTE: Use shim(s) (P/N 270 000 770) for the front engine mount and shim(s) (P/N 270 000 762) for the rear engine mounts. Shims location is between engine mount and engine mount plate. NOTICE Whenever shims are used to correct alignment, never install more than 5 shims. smr2009-016-029_a 1. Engine alignment adaptor 5. Carefully slide the ALIGNMENT SHAFT (P/N 295 000 141) into the engine alignment support.
PAGE 46
Section 02 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) When alignment and longitudinal position of engine are correct, tighten engine mount screws. Refer to ENGINE MOUNTS in this subsection. Recheck engine alignment. ENGINE MOUNTS If engine mounts have been removed, apply LOCTITE 243 (BLUE) (P/N 293 800 060) on screw threads or use new screws with self-locking product. Torque all engine mount screws to 25 N•m (18 lbf•ft).
PAGE 47
24
PAGE 48
Section 02 ENGINE Subsection 02 (AIR INTAKE SYSTEM) AIR INTAKE SYSTEM 1.
PAGE 49
Section 02 ENGINE Subsection 02 (AIR INTAKE SYSTEM) 1.2 Nm (11 lbfin) 1.
PAGE 50
Section 02 ENGINE Subsection 02 (AIR INTAKE SYSTEM) GENERAL Rear Ventilation Box Installation During assembly/installation, use torque values and service products as in the exploded views. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete procedure. The installation is the reverse of the removal procedure. However, pay attention to the following.
PAGE 51
Section 02 ENGINE Subsection 02 (AIR INTAKE SYSTEM) Air Intake Duct Installation Install suspension base. Refer to iS SUSPENSION for complete procedure. Install engine. Refer to ENGINE REMOVAL AND INSTALLATION. After deck extension installation, tighten screws retaining the air intake duct to deck extension to 1.2 N•m (11 lbf•in). Tighten clamp to 1.7 N•m (15 lbf•in). AIR INTAKE SILENCER BAFFLE Air Intake Silencer Baffle Removal Remove AIR INTAKE SILENCER COVER, see procedure in this subsection.
PAGE 52
Section 02 ENGINE Subsection 02 (AIR INTAKE SYSTEM) smr2009-017-009_a smr2009-017-007_a 1. Rubber latches 1. Air intake silencer 2. Inlet hose groove Install all other removed parts. Remove air intake tube from vehicle. Air Intake Tube Installation The installation is the reverse of the removal procedure. AIR INTAKE SILENCER Air Intake Silencer Removal Remove: – Deck extension, see BODY subsection for procedure – Air intake cover – Air intake tube. Remove both screws securing air intake silencer.
PAGE 53
30
PAGE 54
Section 02 ENGINE Subsection 03 (INTAKE MANIFOLD) INTAKE MANIFOLD SERVICE PRODUCTS Description Part Number Page LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 35 See ELECTRONIC FUEL INJECTION 9 Nm (80 lbfin) 9 Nm (80 lbfin) Loctite 243 Engine oil 5.
PAGE 55
Section 02 ENGINE Subsection 03 (INTAKE MANIFOLD) GENERAL During assembly/installation, use torque values and service products as in the exploded view. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete procedure. Cut all locking ties securing the harness to the intake manifold. WARNING Torque wrench tightening specifications must be strictly adhered to. Locking devices (e.g.
PAGE 56
Section 02 ENGINE Subsection 03 (INTAKE MANIFOLD) smr2009-018-008_a smr2009-018-005_a 1. Ignition coil connectors 2. Fuel injector connectors Unplug the "B" connector from the ECM by pulling the lock. Refer to WIRING DIAGRAM subsection for procedure. Unplug the manifold air pressure sensor (MAPS), the engine connector and the manifold air temperature sensor (MATS). 1. Engine connector 2. ECM support Unplug the knock sensor (KS), the magneto and the throttle actuator connectors. smr2009-018-009_a 1.
PAGE 57
Section 02 ENGINE Subsection 03 (INTAKE MANIFOLD) Unplug the oil pressure switch (OPS). R1503motr59A smr2009-018-011_a 1. Oil pressure switch (OPS) Lift intake manifold up to pull it out of the mounting brackets. Unscrew ECM retaining screws and remove ECM from its support. R1503motr61A smr2009-018-012_a 1. ECM retaining screws Pull the engine wiring harness with the ECM plugged away from intake manifold. Remove manifold retaining screws and push the oil dipstick tube out of the manifold slot.
PAGE 58
Section 02 ENGINE Subsection 03 (INTAKE MANIFOLD) smr2009-018-013_a 1 R1503motr62A INTAKE MANIFOLD 1. Gaskets First, position intake manifold on front mounting bracket then push manifold toward engine to then proceed with rear mounting bracket. When installing the intake manifold, lift up the oil dipstick tube a little bit to fit in the slot of the manifold. 1 Ensure to properly route and secure wiring harness with locking ties.
PAGE 59
36
PAGE 60
Section 02 ENGINE Subsection 04 (SUPERCHARGER) SUPERCHARGER SERVICE TOOLS Description Part Number 4-PIN SOCKET............................................................................... BEARING SUPPORT/PUSHER ...................................................... CAMSHAFT LOCKING TOOL........................................................ SUPERCHARGER GEAR HOLDER................................................ SUPERCHARGER RETAINING KEY............................................... SUPPORT PLATE...
PAGE 61
Section 02 ENGINE Subsection 04 (SUPERCHARGER) Loctite 243 9 Nm (80 lbfin) Loctite 243 NEW 29 Nm (21 lbfft) NEW NEW 29 Nm (21 lbfft) Loctite 5910 Loctite 243 9 Nm (80 lbfin) Engine oil Loctite 243 Engine oil Engine oil 9 Nm (80 lbfin) Loctite 243 Isoflex grease Topas NB62 Engine oil Super Lube grease NEW Isoflex grease Topas NB62 29 Nm (21 lbfft) smr2009-020-001_a 38 smr2009-020
PAGE 62
Section 02 ENGINE Subsection 04 (SUPERCHARGER) GENERAL During assembly/installation, use the torque values and service products as in the exploded view. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete procedure. WARNING Torque wrench tightening specifications must be strictly adhered to. Locking devices (e.g.: locking tabs, elastic stop nuts, cotter pins, etc.) must be replaced with new ones.
PAGE 63
Section 02 ENGINE Subsection 04 (SUPERCHARGER) Remove supercharger and perform the clutch slipping moment test. Inspect bearings and friction clutch. Replace bearings and clutch components as necessary. Separate supercharger housing. NOTE: Since supercharger is disassembled, it is recommended to completely inspect it. Clean internal housing and turbine using a brush and cleaning solvent to get rid of oil deposits. Blow dry with compressed air. NOTICE Do not let turbine spin when using compressed air.
PAGE 64
Section 02 ENGINE Subsection 04 (SUPERCHARGER) SUPERCHARGER CLUTCH SLIPPING MOMENT (BENCH TEST) Mount supercharger on the SUPPORT PLATE (P/N 529 035 947). smr2009-025-007_b 1. Camshaft locking tool Check slipping moment counterclockwise by using a torque wrench with actual torque viewer. A mirror is useful to see the viewer. 529035947 Use the SUPERCHARGER GEAR HOLDER (P/N 529 036 025) to retain supercharger gear while measuring slipping moment. 529036025 smr2009-020-004_a 1.
PAGE 65
Section 02 ENGINE Subsection 04 (SUPERCHARGER) ENGINE LACKS ACCELERATION OR POWER (DOES NOT REACH MAXIMUM RPM) 1. Supercharger inlet is dirty - Check and clean supercharger inlet. - Check engine oil. Siphon excess of oil. 2. Supercharger slipping clutch defective - Check slipping clutch moment. - Repair supercharger if out of specification. smr2006-074-100_a 1. Torque wrench 2.
PAGE 66
Section 02 ENGINE Subsection 04 (SUPERCHARGER) smr2009-020-012_a 1. Air inlet hose 2. Hose clamp Remove air outlet hose from supercharger. smr2008-012-011_a 1. Rubber adapter 2. Exhaust pipe Loosen clamp securing rubber adapter to exhaust pipe. Detach muffler strap. Move muffler back (± 5 cm (2 in)). Remove retaining screws and pull out the supercharger. smr2009-020-013_a 1. Air outlet hose 2. Hose clamp Unscrew blow-by valve screws and move it aside to make room. smr2009-020-005_a 1.
PAGE 67
Section 02 ENGINE Subsection 04 (SUPERCHARGER) 1 1 1 2 R1503motr250A 1. Upper retaining screw F00B28A Supercharger Disassembly NOTICE Be scrupulous when working on supercharger parts. Supercharger rotation reaches 45 000 RPM. Any modification, improper repair, assembly or damage on the parts, may result in damage of the supercharger. Strictly follow the described procedures. 3 1 1 1. Retaining screws 2. Housing half (intake side) 3. Housing half (engine side) 1.
PAGE 68
Section 02 ENGINE Subsection 04 (SUPERCHARGER) 2 smr2009-020-006_a 1. Cap nut (left-handed thread) 4. Remove washer, turbine, O-ring and step collar from supercharger shaft. F00B2BA 1 1. Nut 2. Retaining key NOTE: There are 40 loose needle bearings under the gear. Do not reuse. 6. Remove L-ring, spring washers, lock washer, drive gear and needle pins by turning the supercharger upside down. smr2009-020-007_a 1. 2. 3. 4. Washer Turbine O-ring Step collar 5.
PAGE 69
Section 02 ENGINE Subsection 04 (SUPERCHARGER) 1 NOTE: It may be necessary to heat the housing with a heat gun to release the retaining disc. F00B2CA 1. Supercharger shaft 8. Remove and discard ball bearing from supercharger shaft by using a press and the SUPERCHARGER RETAINING KEY (P/N 529 036 027). F00B2AA 1 1. 4-pin socket 10. Discard the oil seal. 11. Remove and discard ball bearing from supercharger housing half (engine side) by using a press and a suitable bearing pusher.
PAGE 70
Section 02 ENGINE Subsection 04 (SUPERCHARGER) A B SPRING WASHER PACKAGE HEIGHT C NEW 10.7 mm to 10.9 mm (.4213 in to .4291 in) SERVICE LIMIT 10.2 mm (.4016 in) Supercharger Assembly NOTICE Every time when supercharger shaft has been removed, both ball bearings have to be replaced. R1503motr360A NOTICE Both ball bearings have to be installed with cages facing turbine side. A. Driven plate journal depth B. Drive gear thickness C. Lock washer thickness DRIVEN PLATE JOURNAL DEPTH NEW 14.
PAGE 71
Section 02 ENGINE Subsection 04 (SUPERCHARGER) 1 4 529035947 F00B2FA 1. 2. 3. 4. 2 3 Supercharger shaft Ball bearing Bearing support plate Protrusion of support plate on this side (underneath inner race) 6. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on retaining disc. If a new retaining disc is used, the threads are coated with a self-locking product. 7. Install the retaining disc in supercharger housing half by using the 4-PIN SOCKET (P/N 529 035 948). 8.
PAGE 72
Section 02 ENGINE Subsection 04 (SUPERCHARGER) 529035950 2 3 smr2006-012-032_a 1. 2. 3. 4. 5. F00B2GA Compressor shaft Ball bearing Supercharger housing half Thrust washer Distance sleeve 2 1 1 1. Support plate 2. Bearing support/pusher 3. Protrusion here NOTICE Before pressing in the supercharger shaft, be sure to properly support the inner race of ball bearing in supercharger housing half with the recommended tool.
PAGE 73
Section 02 ENGINE Subsection 04 (SUPERCHARGER) 13. Install step collar, O-ring, turbine and washer on supercharger shaft. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on cap nut and temporary finger tight cap nut. NOTE: The cap nut on the supercharger shaft has a left-handed thread. The Loctite has to be applied in a small dose into the nut. 20. Install the second titanium shim. 21. Install the lock washer. 22. Apply engine oil to the spring washers. 23. Position the spring washers as per illustration.
PAGE 74
Section 02 ENGINE Subsection 04 (SUPERCHARGER) Supercharger Installation 1. Grease sealing surface between supercharger and PTO housing with SUPER LUBE GREASE (P/N 293 550 030). NOTE: Ensure O-rings are installed. 529035949 27. Tighten the cap nut to 29 N•m (21 lbf•ft). 28. Apply LOCTITE 5910 (P/N 293 800 081) on supercharger housing sealing surface. 1 1 R1503motr247A 1. Super Lube grease R1503motr246A 1. Apply Loctite 5910 on sealing surface 29. Assemble supercharger housing halves.
PAGE 75
Section 02 ENGINE Subsection 04 (SUPERCHARGER) NOTICE Not installing the tool as shown will change the torque applied to the screw. Proper torque and tightening sequence are important. 6. After complete installation of the supercharger, the slipping moment has to be rechecked. Refer to SUPERCHARGER CLUTCH SLIPPING MOMENT (ON ENGINE) at the beginning of this subsection.
PAGE 76
Section 02 ENGINE Subsection 05 (INTERCOOLER) INTERCOOLER SERVICE TOOLS Description Part Number Page LARGE HOSE PINCHER................................................................ 529 032 500 ........................................... 55 VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ...........................................
PAGE 77
Section 02 ENGINE Subsection 05 (INTERCOOLER) GENERAL Intercooler Cleaning During assembly/installation, use torque values and service products as in the exploded view. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete procedure. If temperature in intake manifold is too high or if engine is down in performance, intercooler may require to be cleaned.
PAGE 78
Section 02 ENGINE Subsection 05 (INTERCOOLER) smr2009-019-009_a 1. Garden hose installed on water outlet 2. High and regular water flow 7. Perform a leak test before installing the intercooler in the watercraft. 529021800 BLEED HOSE FITTING Pressurize the intercooler. PRESSURE TEST Intercooler Leak Test Using a LARGE HOSE PINCHER (P/N 529 032 500), block intercooler water inlet and outlet hoses. 69 kPa (10 PSI) for 10 minutes min.
PAGE 79
Section 02 ENGINE Subsection 05 (INTERCOOLER) smr2009-019-005_a FIXED DECK REMOVED FOR CLARITY PURPOSE 1. iS module 2. Retaining latch smr2009-019-003_a 1. Intercooler air inlet hose 2. Intercooler air outlet hose Cut locking ties securing wiring harness to iS module support and front attachment. Detach both intercooler straps. smr2009-019-006_a smr2009-019-004_a 1. Intercooler straps Remove the iBR actuator. Refer to iBR AND VTS subsection. Remove the intercooler from vehicle by the LH opening. 1.
PAGE 80
Section 02 ENGINE Subsection 05 (INTERCOOLER) Remove plastic rivets and rubber pad. smr2009-019-050_a THROUGH THE LH REAR OPENING 1. Plastic rivet 2. Rubber pad Remove and discard screw securing the attachment to the hull. smr2009-019-051_a THROUGH THE LH REAR OPENING 1. Retaining screw 2. Washer 3. LH rear attachment Install a new attachment using a NEW screw. Tighten screw to 8 N•m (71 lbf•in). Install all other removed parts.
PAGE 81
58
PAGE 82
Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) EXHAUST SYSTEM SERVICE TOOLS Description Part Number Page FLUSHING CONNECTOR ADAPTER ............................................ 295 500 473 ........................................... 62 SERVICE PRODUCTS Description Part Number Page LOCTITE 243 (BLUE)..................................................................... 293 800 060 ...........................................
PAGE 83
Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) 9 Nm (80 lbfin) 11 Nm (97 lbfin) 16 Nm (142 lbfin) Loctite 243 Loctite 567 (pipe sealant) 7.
PAGE 84
Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) GENERAL During assembly/installation, use torque values and service products as in the exploded view. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete procedure. WARNING Torque wrench tightening specifications must be strictly adhered to. Locking devices (e.g.: locking tabs, elastic stop nuts, cotter pins, etc.) must be replaced with new ones.
PAGE 85
Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) help to clean up sand, salt, shells or other particles in water jackets (exhaust system, intercooler and hoses. Exhaust system flushing 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. NOTICE Failure to flush the system, when necessary, will severely damage intercooler and exhaust system. Make sure engine operates during entire procedure.
PAGE 86
Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) 4. Gently disconnect the hose from blow-by valve. smr2009-016-005_a 1. Exhaust hose clamp smr2009-016-003_a 1. 2. 3. 4. 5. 8. Detach retaining strap. Cut this locking tie Water outlet hose (exhaust system) Blow-by hose Blow-by valve Exhaust manifold 5. Unscrew exhaust clamp. NOTICE Do not use pneumatic or electrical tools as seizure may occur. smr2009-016-006_a 1. Muffler retaining strap 9. Remove the LH rear storage basket. 10.
PAGE 87
Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) smr2008-013-025_a 1. Exhaust manifold mark 2. Exhaust pipe mark smr2008-013-026_a Step 1: Lift adjuster tab Step 2: Move adjuster outward Using the rear opening, slide the muffler in hull. Align the exhaust pipe flange to the exhaust manifold. Rotate and move muffler so that the exhaust pipe flange makes perfect contact with exhaust manifold. Slide both adjuster blocks against muffler to support it in position.
PAGE 88
Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) Move the coolant expansion tank aside and cut locking tie retaining the starter cable (RED) to exhaust hose. Remove exhaust hose from resonator. Cut locking tie retaining bailer hose elbow fittings to exhaust hose. Remove front exhaust hose from vehicle. When reinstalling exhaust hose, make sure to attach elbow fittings at the highest position that you can on the exhaust hose. Tighten retaining clamps to 4 N•m (35 lbf•in). Install all other removed parts.
PAGE 89
Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) smr2008-013-035_a 1. Bulge 2. Middle of the opening Install the rubber adapter on exhaust pipe. Ensure rubber adapter is properly seats against exhaust pipe shoulder. smr2008-013-037_a 1. Middle of rubber adapter strip 2. Center of the muffler bulge opening Using a caliper, measure the distance between the exhaust pipe shoulder and the outside of the muffler bulge. Position the muffler to 95 mm ± 2 mm (3.74 in ± .079 in).
PAGE 90
Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) 3. Disconnect the exhaust manifold water outlet hose. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on threads of screws. To help holding the manifold while installing screws, first insert the exhaust manifold into the exhaust pipe then, install the upper front screw. Continue with the remaining screws. Torque screws to 9 N•m (80 lbf•in) as per following illustrated sequence. Repeat the procedure, torquing screws again to 9 N•m (80 lbf•in).
PAGE 91
Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) Resonator Installation Installation is the reverse of the removal procedures. However, pay attention to the following. After installation, ensure there is no water or exhaust gas leak when the engine is running. Test run the engine while supplying water to the exhaust system. NOTICE Never run engine without supplying water to the exhaust system when watercraft is out of water.
PAGE 92
Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) PTO HOUSING AND MAGNETO SERVICE TOOLS Description Part Number 3-PIN MAGNETO HARNESS ADAPTER........................................ BLIND HOLE BEARING PULLER SET........................................... HANDLE ........................................................................................ IMPELLER REMOVER/INSTALLER ............................................... OETIKER PLIERS.............................................................
PAGE 93
Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) Oil 9 Nm (80 lbfin) 9 Nm (80 lbfin) Loctite Loctite 243 243 Oil Isoflex grease Topas NB 52 Loctite 243 9 Nm (80 lbfin) Isoflex grease Topas NB 52 NEW NEW 15 Nm (133 lbfin) +50° Oil Loctite 648 250 Nm (184 lbfft) smr2008-014-007_b 70 smr2009-022
PAGE 94
Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) GENERAL NOTE: It is good practice to check for fault codes using the B.U.D.S. software as a first troubleshooting step. Refer to the MONITORING SYSTEM AND FAULT CODES subsection. Always carry out electrical tests on components before removing or installing them. During assembly, use torque values and service products as in the exploded view. Clean threads before applying a threadlocker.
PAGE 95
Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) WARNING Always disconnect battery cables exactly in the specified order, BLACK negative cable first. 2. Remove the moving deck and deck extension. Refer to BODY subsection. 3. Drain the engine oil. Refer to LUBRICATION SYSTEM subsection. 4. Remove the cylinder head cover. Refer to CYLINDER HEAD subsection. 5. Using SUCTION PUMP (P/N 529 035 880), insert the tube in the lower area of the timing chain. Syphon remaining oil. smr2009-020-005_b 1.
PAGE 96
Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) Slightly lift aft end of engine and insert a safely block under the engine to secure it in this position. Remove LH rear engine support. smr2009-016-015_b 1. Magneto connector 2. ECM 3. Throttle body Place rags under PTO housing to prevent oil spillage. NOTE: Up to 250 ml (8 U.S. 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.
PAGE 97
Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) PTO Housing Inspection Inspect PTO housing for cracks or any other damages. Replace if necessary. Inspect the needle bearing in the PTO housing used to support the starter drive assembly shaft. NOTE: Clean all disassembled metal components in a non-ferrous metal cleaner. WARNING smr2009-022-001_a 1. PTO housing 2. CPS harness retaining clamp 3.
PAGE 98
Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) smr2005-034-100_a TYPICAL 1. Thrust washer 2. Disc springs 3. Starter drive assembly NOTE: When installing a NEW starter drive assembly, oil the shaft and gear splines with engine oil. Install a new PTO housing gasket. NOTE: When installing the PTO housing, you will need to rotate the oil/water pump shaft slightly to align it with the balance shaft for proper insertion. smr2009-022-001_b 1. Screws M6 x 35 2.
PAGE 99
Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) Reinstall LH engine support. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on screw threads then torque to 24 N•m (18 lbf•ft). Remove block under engine. Install both rear engine support screws. Carry out an engine alignment, refer to the ENGINE REMOVAL AND INSTALLATION subsection. NOTICE An engine alignment procedure must be carried out to ensure proper engine alignment or severe component damage may occur.
PAGE 100
Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) Crimp Oetiker clamp using OETIKER PLIERS (P/N 295 000 070). PTO COUPLING PTO Coupling Removal Lock crankshaft. Refer to CYLINDER BLOCK subsection for the procedure. Remove PTO seal as described in previous procedure. Unscrew coupling from crankshaft using IMPELLER REMOVER/INSTALLER (P/N 529 035 820). R1503motr49A PTO Coupling Installation For installation, reverse the removal procedure. However, pay attention to the following.
PAGE 101
Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) smr2009-016-015_b 529036117 Starter Drive Bearing Installation Prior to assembly grease starter drive bearing with ISOFLEX GREASE TOPAS NB 52 (P/N 293 550 021). Install starter drive bearing in PTO housing using the STARTER DRIVE SEAL PUSHER (P/N 420 876 502) and the HANDLE (P/N 420 877 650). 420876502 420877650 1. Magneto connector 2. ECM 3. Throttle body Install the 3-PIN MAGNETO HARNESS ADAPTER (P/N 529 036 016) onto the magneto connector.
PAGE 102
Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) STATOR OUTPUT VOLTAGE TEST TEST ENGINE SPEED TERMINAL VOLTAGE (AC) 1 and 2 4000 RPM 1 and 3 Approx. 50 Vac 2 and 3 If voltage is lower than specification, carry out a STATOR CONTINUITY TEST and a STATOR INSULATION TEST. See procedures in this subsection. Stator Continuity Test Disconnect the magneto wiring harness connector. This connector is located between the ECM and the throttle body. smr2009-022-101_b STATOR CONTINUITY TEST 1.
PAGE 103
Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) smr2009-022-101_c STATOR INSULATION TEST 1. Connect adapter to magneto stator connector 2. Leave vehicle harness disconnected Read resistance. STATOR INSULATION TEST TERMINAL RESISTANCE @ 20°C (68°F) Any YELLOW wire and engine ground Infinity (open circuit) smr2009-022-012_a 1. Stator screws 2. Stator Stator Installation For installation, reverse the removal procedure. However, pay attention to the following.
PAGE 104
Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) Recheck reading on reference tooth to ensure gauge has not changed position (gauge should still read zero). NOTE: The maximum allowable difference between teeth is 0.15 mm (.006 in). If the reading exceeds the maximum allowable difference, straighten the tooth or replace the trigger wheel. smr2009-022-009_b TYPICAL 1.
PAGE 105
Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) 4 3 3 2 2 1 1 1 R1503motr53A TYPICAL 1. Rotor retaining screws 2. Rotor 3. Trigger wheel Rotor and Trigger Wheel Installation For installation, reverse the removal procedure. However, pay attention to the following. Align the trigger wheel to the crankshaft using the location pin on the crankshaft end. Install NEW OEM rotor screws and torque them to 15 N•m (133 lbf•in) using a crisscross pattern.
PAGE 106
Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) STARTER DRIVE Starter Drive Removal Remove the PTO housing and ring gear as described in this subsection. Remove starter drive assembly. If any part of the assembly shows signs of abnormal wear, cracks, broken teeth or malfunction (sprag clutch), replace the faulty part. Starter Drive Installation For installation, reverse the removal procedure. However, pay attention to the following.
PAGE 107
84
PAGE 108
Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) LUBRICATION SYSTEM SERVICE TOOLS Description Part Number ADAPTER HOSE ........................................................................... ECM ADAPTER TOOL................................................................... FLUKE 115 MULTIMETER ............................................................ OIL SEAL GUIDE........................................................................... PRESSURE GAUGE........................................
PAGE 109
Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) 9 Nm (80 lbfin) NEW Engine oil Loctite 243 NEW Loctite 243 9 Nm (80 lbfin) Engine oil 16 Nm (142 lbfin) 18 Nm (159 lbfin) NEW 9 Nm (80 lbfin) Loctite 243 Engine oil Loctite 243 NEW 9 Nm (80 lbfin) Engine oil Loctite 243 Engine oil 9 Nm (80 lbfin) smr2009-023-001_a 86 smr2009-023
PAGE 110
Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) 9 Nm (80 lbfin) Engine oil Loctite 243 9 Nm (80 lbfin) NEW 11 Nm (97 lbfin) Engine oil 9 Nm (80 lbfin) 3 Nm (27 lbfin) Left hand thread Loctite 243 Loctite 243 NEW NEW Loctite 243 9 Nm (80 lbfin) Engine oil 19 Nm (14 lbfft) Engine oil Loctite 243 Engine oil 13 Nm (115 lbfin) Loctite 5910 Loctite 243 Loctite 243 9 Nm (80 lbfin) smr2009-023-002_a smr2009-023 87
PAGE 111
Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) ENGINE LUBRICATION CIRCUIT Legend 1 2 Pressurized oil Scavenged oil Blow-by gas 3 4 5 6 8 7 9 10 11 12 13 smr2009-023-100_en 1. Oil dipstick 2. Rocker arm (intake) 3. Rocker arm (exhaust) 4. Hydraulic valve lifter 5. Camshaft 6. Piston pin 7. Into PTO cover 8. From oil filter 9. Piston cooling 10. Connecting rod 11. Balance shaft 12. Crankshaft 13.
PAGE 112
Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) ENGINE LUBRICATION CIRCUIT (CONT'D) 1 34 4 6 3 2 3 5 7 8 9 10 12 11 13 15 14 16 18 17 19 20 21 22 23 24 25 28 29 26 30 27 31 Legend Pressurized oil Scavenged oil Blow-by gas 32 33 smr2009-023-101_en 1. To air intake silencer 2. Rocker arm (intake) 3. Rocker arm (exhaust) 4. Rocker arm axle 5. Camshaft 6. Pressure relief valve 7. Oil separator 8. Cylinder head 9. Blow-by valve 10. Supercharger (if so equipped) 11. Oil filter 12.
PAGE 113
Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) GENERAL During assembly/installation, use torque values and service products as in the exploded views. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete procedure. WARNING Torque wrench tightening specifications must be strictly adhered to. Locking devices (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pins, etc.
PAGE 114
Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) lmr2007-053-100_a 1. Full 2. Add 3. Operating range Otherwise, add oil until its level is between marks as required. To add oil, unscrew oil cap. Place a funnel into the oil filler neck opening and add the recommended oil to the proper level. Do not overfill. smo2009-002-002_a 1. Rear ventilation box 2. Deck extension 3. Retaining clips 6. Wait at least 30 seconds for the oil to settle in the engine, then pull dipstick out and wipe clean.
PAGE 115
Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) NOTICE Never crank or start engine when suction pump tube is in dipstick hole. Never start engine when there is no oil in engine. NOTE: So that suction pump tube is located at the proper height to siphon oil, it is suggested to put some electrical tape on tube at 475 mm (18-11/16 in) from its end. Then, insert the tube until you reach the tape. 2 smr2009-023-003_a 1. Oil filter screw 2. Oil filter cover 3.
PAGE 116
Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) Apply engine oil on filter ring, filter cover O-rings and on oil filter screw O-ring. NOTE: In salt water area, it is recommended to coat mating surface of cover with SUPER LUBE GREASE (P/N 293 550 030). Torque oil filter screw to 9 N•m (80 lbf•in).
PAGE 117
Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) Reinstall oil pressure switch. Test at the Cylinder Head Location The oil pressure may be measured from cylinder head if desired. Remove plug located on cylinder head and install gauge. 4. Oil pressure regulator valve sticks open, or spring load is too small. - Clean oil regulator piston and its bore. Replace if necessary. - Measure spring free length. Replace if too small. 5. Oil pump(s) worn or damaged.
PAGE 118
Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) PROCEDURES ENGINE RUNNING OIL PRESSURE SWITCH (OPS) Oil Pressure Switch Operation The oil pressure switch activates if engine oil pressure falls between 180 kPa and 220 kPa (26 PSI and 32 PSI). TEST PROBES OPS connector (pin 1) Engine ground RESISTANCE ( ) Infinitely high (OL) when pressure reaches 180 kPa (26.11 PSI) and 220 kPa (32 PSI) smr2009-023-102_a If resistance values are incorrect, replace OPS.
PAGE 119
Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) OPS CONNECTOR Pin 1 ECM ADAPTER RESISTANCE Pin E3 Close to 0 (continuity) PTO OIL STRAINER NOTE: The oil strainer does not need to be cleaned at every oil change. Clean it during other inspections, especially when the engine is disassembled. PTO Oil Strainer Removal Remove engine oil. See procedure in OIL CHANGE in this subsection. Remove the PTO housing. Refer to PTO HOUSING AND MAGNETO subsection. Remove the oil strainer.
PAGE 120
Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) R1503motr118A 1 1. Oil inlet to the oil pump smr2006-014-022_a PTO Oil Strainer Installation For installation, reverse the removal procedure. However, pay attention to the following. Clean cylinder block to remove all remaining silicone residues in oil strainer area. Apply a thin layer of LOCTITE 5910 (P/N 293 800 081) on oil strainer side. Install it in the PTO housing.
PAGE 121
Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) smr2009-023-007_a 1. Oil inlet 2. Oil outlet Suction Pump Oil Strainer Installation For installation, reverse the removal procedure. However, pay attention to the following. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on threads of the suction pump cover screws and tighten them to 9 N•m (80 lbf•in). Position screws according to their length as shown.
PAGE 122
Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) Oil Pressure Pump Removal 1. Remove engine oil. See procedure in OIL CHANGE in this subsection. 2. Remove the PTO housing. Refer to PTO HOUSING AND MAGNETO subsection. 3. Remove water pump housing and the impeller. Refer to COOLING SYSTEM subsection. 4. Remove screws securing the oil pump cover. 2 smr2007-015-005_b TYPICAL 1. Valve piston guide 2. Valve piston 3. Compression spring 4. Oil pressure regulator plug 5.
PAGE 123
Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) 1 R1503motr129A 1. Pittings on the teeth Using a feeler gauge, measure the clearance between inner and outer rotors. R1503motr127A TYPICAL NOTICE Be careful not to damage the surface of the rotary seal bore in PTO housing cover. B 8. Remove and discard the oil seal behind rotary seal. A 1 C 2 R1503motr130A 1 1. Outer rotor 2. Inner rotor R1503motr128A OUTER AND INNER ROTOR CLEARANCE 1.
PAGE 124
Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) 1 R1503motr131A 2 1 1. PTO housing surface 2. Vernier depth gauge R1503motr128A 1. Oil seal Install the new rotary seal by using the WATER PUMP SEAL PUSHER (P/N 529 035 823). 529035823 R1503motr132A 2 1 1. Oil pump outer rotor surface 2. Vernier depth gage NOTICE Never use a hammer for the rotary seal or water/oil pump shaft installation. Only use a press to avoid damaging the ceramic component.
PAGE 125
Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) R1503motr142A 2 1 3. Remove the air intake silencer. Refer to AIR INTAKE SYSTEM subsection. 4. Detach the muffler from the exhaust manifold and move muffler backwards. Refer to EXHAUST SYSTEM subsection. 5. Remove engine support mount screws. 6. Move engine backwards, just enough to reach oil suction pump cover screws. 7. Remove retaining screws from oil filler tube. 1. Oil seal guide 2.
PAGE 126
Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) 1 R1503motr137A smr2008-015-006_a TYPICAL 1. Oil pump cover 2. Oil pump screws 1. Pittings on the teeth Using a feeler gauge, measure the clearance between inner and outer rotors. 13. Remove oil pump shaft. 14. Remove outer rotor. A B C 1 2 R1503motr138A 1. Outer rotor 2. Inner rotor smr2006-014-023_a TYPICAL 1. Oil pump shaft 2.
PAGE 127
Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) R1503motr139A 1 2 smr2009-023-008_a 1. Screws M6 x 25 2. Screws M6 x 45 1. Oil pump housing surface 2. Vernier depth gage Tighten suction pump cover screws as per following sequence. R1503motr140A 1 2 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 the complete oil pump assembly.
PAGE 128
Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) smr2008-015-007_a 1. 2. 3. 4. Banjo bolt Oil spray nozzle Oil spray nozzle support Torx screw Oil Spray Nozzle Inspection Check oil spray nozzle for: – Dirt – Bend – Other damages. Replace if necessary. smr2008-015-008_a A. 1 mm (0.039 in) NOTE: Make sure that the oil spray nozzle is facing to the center of the tool. Not following this procedure will lead to an insufficient oiling of the supercharger and a supercharger failure can occurs.
PAGE 129
Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) NOTE: When the scope of repair work obligates you to split the cylinder block, take this opportunity to clean the oil spray nozzles. Oil Spray Nozzle Removal Remove cylinder block lower half. Refer to CYLINDER BLOCK subsection. Remove oil spray nozzle and Banjo fitting from cylinder block upper half. Oil Spray Nozzle Installation NOTICE At assembly make sure the contact surface of the oil spray nozzle is well fitted onto the cylinder block.
PAGE 130
Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) NOTE: Make sure not to loose thrust washer when removing it from oil separator cover, otherwise thrust washer would fall into the PTO housing. smr2006-014-067_a 1. Camshaft 2. Oil separator cover NOTE: Be careful not to break the holding clips from oil separator cover when its removed from the timing gear. smr2009-023-016_a 1. Thrust washer 2. Oil separator cover 5. Remove spark plug tube. 6.
PAGE 131
Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) BLOW-BY VALVE Blow-by Valve Description The blow-by valve has two main functions: – It recirculates oil vapors. – It protects the engine in the event the watercraft tip over. To a accomplish the second function, the blow-by valve has a tip over protection switch (TOPS). smr2009-023-019_a NORMAL OPERATION smr2009-023-018_a 1. 2. 3. 4. 5. 6.
PAGE 132
Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) NOTE: After voltage test, clear the fault codes in the ECM using the B.U.D.S. software. Blow-By Valve TOPS Switch Output Voltage Test Remove the blow-by valve. Back-probe TOPS connector and check voltage using the FLUKE 115 MULTIMETER (P/N 529 035 868). NOTE: To easily probe wire terminals through the back of the connector, use the FLUKE RIGID BACK PROBES (P/N TP88) or an equivalent.
PAGE 133
Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) smr2009-023-051 529036166 Check continuity of the blow-by valve TOPS switch circuit as per following table. TOPS SWITCH CONNECTOR ECM ADAPTER Pin 1 Pin F4 Pin 2 Pin G1 Pin 3 Pin C4 When installing the TOPS switch, make sure printed information is visible. RESISTANCE Close to 0 (continuity) smr2009-023-052_a 1. TOPS valve inscriptions Blow-By Valve Removal smr2009-023-103_b 1. Pin 1 2. Pin 2 3. Pin 3 If continuity test is good, check ECM.
PAGE 134
Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) Disconnect the TOPS switch connector of the blow-by valve. Unscrew and remove the blow-by valve. Blow air through inlet port. Air must flow freely to the outlet port. smr2009-023-023_a smr2009-023-014_a 1. TOPS switch connector 2. Retaining screws Turn valve upside down and blow air again. Air must not flow out. Remove O-ring and V-ring. NOTE: The blow-by valve can not be disassembled. smr2009-023-024_a If test fails, replace blow-by valve.
PAGE 135
Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) R1503motr148A 1 1. O-rings smr2009-023-025_a 1. Oil cooler Oil Cooler Removal Remove engine from vehicle. Refer to ENGINE REMOVAL AND INSTALLATION subsection. Disconnect cooling hoses from oil cooler. Remove screws securing oil cooler. Oil Cooler Inspection If O-rings are brittle, cracked or hard, replace them. Clean both contact surfaces of oil cooler. Check and clean the oil inlet and outlet area for dirt and other contaminations.
PAGE 136
Section 02 ENGINE Subsection 09 (COOLING SYSTEM) COOLING SYSTEM SERVICE TOOLS Description Part Number OETIKER PLIERS........................................................................... OIL SEAL GUIDE........................................................................... TEST CAP ...................................................................................... VACUUM/PRESSURE PUMP ........................................................ WATER PUMP SEAL PUSHER...............................
PAGE 137
Section 02 ENGINE Subsection 09 (COOLING SYSTEM) CLOSED LOOP COOLING SYSTEM Expansion coolant tank Coolant temperature sensor (CTS) activates when temperature exceeds 100°C (212°F) Bleed hose from cylinder head to expansion coolant tank Coolant housing including thermostat opens at 87°C (188°F) and water pump impeller Coolant flows to ride plate Oil cooler Coolant returns from oil cooler Coolant flows to oil cooler Ride plate (operates as heat exchanger) Coolant returns from ride plate smr2009-02
PAGE 138
Section 02 ENGINE Subsection 09 (COOLING SYSTEM) VEHICLE COMPONENTS 1.7 Nm (15 lbfin) 1.7 Nm (15 lbfin) NEW NEW 1.7 Nm (15 lbfin) 1.7 Nm (15 lbfin) 1.7 Nm (15 lbfin) 1.7 Nm (15 lbfin) 1.7 Nm (15 lbfin) NEW 5 Nm (44 lbfin) 1.
PAGE 139
Section 02 ENGINE Subsection 09 (COOLING SYSTEM) ENGINE COMPONENTS NEW 17 Nm (150 lbfin) NEW 9 Nm (80 lbfin) 9 Nm (80 lbfin) Loctite 243 9 Nm (80 lbfin) Loctite 243 Left hand threads 3 Nm (27 lbfin) NEW NEW Engine oil Engine oil 9 Nm (80 lbfin) Loctite 243 NEW NEW Engine oil Loctite 243 9 Nm (80 lbfin) Loctite 243 NEW 9 Nm (80 lbfin) smr2009-024-001_a 116 smr2009-024
PAGE 140
Section 02 ENGINE Subsection 09 (COOLING SYSTEM) GENERAL During assembly/installation, use torque values and service products as in the exploded view. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete procedure. WARNING Torque wrench tightening specifications must be strictly adhered to. Locking devices (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pins, etc.
PAGE 141
Section 02 ENGINE Subsection 09 (COOLING SYSTEM) NOTICE Pure antifreeze will freeze at a higher temperature than the optimal water/antifreeze mix. A blend of 40% antifreeze with 60% demineralized water will improve the cooling efficiency. Using water tap instead of demineralized water, would contribute to make deposits in cooling system and to reduce antifreeze efficiency. This could lead to engine overheating. To prevent antifreeze deterioration, always use the same brand.
PAGE 142
Section 02 ENGINE Subsection 09 (COOLING SYSTEM) INSPECTION COOLING SYSTEM LEAK TEST WARNING To avoid potential burns, do not remove the expansion tank cap or loosen the ride plate drain plug if the engine is hot. smo2009-002-137_a 1. Level between marks when engine is cold Remove the deck extension. Refer to BODY subsection. Install the TEST CAP (P/N 529 035 991) on the coolant expansion tank. Do not install pressure cap at this time. Start engine and let run for a maximum of 2 minutes.
PAGE 143
Section 02 ENGINE Subsection 09 (COOLING SYSTEM) PROCEDURES PRESSURE CAP Pressure Cap Inspection Using a pressure cap tester, check pressure cap efficiency. If the efficiency is feeble, install a new 90 kPa (13 PSI) cap (do not exceed this pressure). CLAMPS Clamp Replacement To cut or secure Oetiker clamps of cooling system hoses, use the OETIKER PLIERS (P/N 295 000 070). smr2009-024-004_a 1.
PAGE 144
Section 02 ENGINE Subsection 09 (COOLING SYSTEM) WATER PUMP HOUSING smr2009-024-105_a 1. Expansion tank hose Disconnect exhaust hose from the resonator. Place hose over muffler. smr2009-024-004_b 1. Water pump housing Water Pump Housing Removal Remove the moving deck. Refer to BODY subsection. Remove the air intake silencer. Refer to AIR INTAKE SYSTEM subsection. Remove both air hoses from intercooler to reach supercharger. smr2009-024-106_a 1. Exhaust hose 2. Cut these locking ties 3.
PAGE 145
Section 02 ENGINE Subsection 09 (COOLING SYSTEM) Check if thermostat is in good condition. Refer to THERMOSTAT in this subsection. Water Pump Housing Leak Test Plug the connections of the oil cooler return hose, coolant tank hose, ride plate return hose and cylinder head return hose with a rag. smr2009-024-006_a 1. 2. 3. 4. Water pump housing Cylinder head hose Oil cooler inlet hose Oil cooler outlet hose 4 Remove water pump housing screws. 2 F18E12A 1. 2. 3. 4.
PAGE 146
Section 02 ENGINE Subsection 09 (COOLING SYSTEM) 2 1 1 1 F18E10A F18E13A 1. Screws M6 x 25 2. Screws M6 x 105 1. Impeller NOTICE To prevent leaking, take care that the gaskets are exactly in groove when you reinstall the water pump housing. Tighten screws to 9 N•m (80 lbf•in) using the following sequence. 7 8 NOTICE Coolant/oil pump shaft and impeller have left-hand threads. Remove by turning clockwise and install by turning counterclockwise.
PAGE 147
Section 02 ENGINE Subsection 09 (COOLING SYSTEM) Thermostat Installation 2 For installation, reverse the removal procedure, paying attention to the following details. Refer to WATER PUMP HOUSING in this subsection. ROTARY SEAL Rotary Seal Inspection 1 Check leak indicator hole for oil or coolant leak. F18E14A 1. Oil pump cover screws 2. Oil pump cover Remove oil pump cover. Remove outer oil pump rotor. 1 smr2009-024-004_a 1.
PAGE 148
Section 02 ENGINE Subsection 09 (COOLING SYSTEM) 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 a press and the WATER PUMP SEAL PUSHER (P/N 529 035 823). 1 F18E16A 1. Pusher 2. Coolant/oil pump shaft 529035823 NOTICE Never use a hammer for the rotary seal or water/oil pump shaft installation. Only use a press to avoid damaging the ceramic component.
PAGE 149
Section 02 ENGINE Subsection 09 (COOLING SYSTEM) 2 1 F18E1AA 1. Oil seal protector 2. Coolant/oil pump shaft Using the WATER PUMP SEAL PUSHER (P/N 529 035 823) to support the PTO cover, install the coolant/oil pump shaft. 1 2 F18E1BA 1. Coolant/oil pump shaft with oil seal protector 2. Rotary seal installer Install all other removed parts.
PAGE 150
Section 02 ENGINE Subsection 10 (CYLINDER HEAD) CYLINDER HEAD SERVICE TOOLS Description Part Number CAMSHAFT LOCKING TOOL........................................................ DRIVE SHAFT ADAPTER............................................................... ENGINE LEAK DOWN TEST KIT ................................................... VALVE GUIDE PUSHER (6 MM) .................................................... VALVE GUIDE REMOVER (6 MM) ................................................
PAGE 151
Section 02 ENGINE Subsection 10 (CYLINDER HEAD) Isoflex grease Topaz NB52 9 Nm (80 lbfin) See LUBRIFICATION SYSTEM 9 Nm (80 lbfin) NEW Engine oil NEW Engine oil NEW Loctite 243 Loctite 243 NEW 9 Nm (80 lbfin) Loctite 243 9 Nm (80 lbfin) 20 Nm (15 lbfft) + 90o Engine oil Engine oil 9 Nm (80 lbfin) Loctite 243 11 Nm (97 lbfin) Engine oil Loctite 243 NEW 40 Nm (30 lbfft) +120° + 90o See ELECTRONIC FUEL INJECTION Engine oil Loctite 243 9 Nm (80 lbfin) NEW smr2009-025-001
PAGE 152
Section 02 ENGINE Subsection 10 (CYLINDER HEAD) GENERAL WARNING NOTE: When diagnosing an engine problem, always perform an engine leak test. This will help pin-point a problem. Refer to ENGINE LEAK TEST in this subsection for procedures. Always place the vehicle on level surface. Always disconnect the negative wire from the battery before working on the engine. Even if the removal of many parts is not necessary to reach another part, it is recommended to remove these parts in order to check them.
PAGE 153
Section 02 ENGINE Subsection 10 (CYLINDER HEAD) Leak Test Procedure smr2009-025-003_a 1. Ignition coil 2. Spark plug NOTE: Cylinder numbers are molded on cylinder head cover. 1. Rotate engine crankshaft counterclockwise until the cylinder no. 1 is at Top Dead Center (TDC) compression stroke. 1.1 As the engine crankshaft is turned over, observe the movement of intake rocker arm of the cylinder to be checked. 1.2 After piston completes its cycle and the intake valve closes, observe the piston. 1.
PAGE 154
Section 02 ENGINE Subsection 10 (CYLINDER HEAD) OBSERVATION 1 3 2 Air escaping on intake port Leaking intake valve(s) Air escaping on exhaust port Leaking exhaust valve(s) Air escaping into crankcase Excessively worn and/or broken piston rings Air bubbles out of coolant tank Leaking cylinder head gasket Air/water escaping from cylinder-block/head Damaged gasket and/or loosened screws Coolant escaping from water pump housing Damaged gasket and/or loosened screws (refer to COOLING SYSTEM) Cool
PAGE 155
Section 02 ENGINE Subsection 10 (CYLINDER HEAD) 4. Rocker arm screw not properly tightened - Retighten screws with recommended torquing procedure. 4. Broken rocker arm(s) - Replace defective parts. 5. Faulty chain tensioner - Replace chain tensioner. PROCEDURES 6. Chain guide is worn out - Replace chain guide. 7. Stretched timing chain or worn out sprocket - Replace timing chain and sprocket. 8. Camshaft is worn out - Check if camshaft radial clearance is out of specification.
PAGE 156
Section 02 ENGINE Subsection 10 (CYLINDER HEAD) Torque screws to 9 N•m (80 lbf•in) as per following illustrated sequence. 7 5 1 3 9 11 smr2008-017-005_a 1. Cylinder head cover screws 5. Remove the cylinder head cover and its gasket. R1503motr152A 8 6 4 2 10 12 CYLINDER HEAD COVER Cylinder Head Cover Removal 1. Open seat. 2. Remove the rear ventilation cover. 3. Unplug and remove ignition coils. smr2006-016-028_a 1. Cylinder head cover 2.
PAGE 157
Section 02 ENGINE Subsection 10 (CYLINDER HEAD) smr2005-036-001_a TYPICAL 1. Spark plug tube 2. Seal to the cylinder head cover 3. Seal to the cylinder head Spark Plug Tube Installation smr2006-016-026_a Torque screws to 9 N•m (80 lbf•in). For installation, reverse the removal procedure. Pay attention to the following detail. Apply engine oil on seals. SPARK PLUG TUBES Spark Plug Tube Removal Remove the CYLINDER HEAD COVER, see procedure in this subsection. Pull spark plug tubes to remove them.
PAGE 158
Section 02 ENGINE Subsection 10 (CYLINDER HEAD) 1 3 A R1503motr90A A. Measure rocker arm shaft diameter here ROCKER ARM SHAFT DIAMETER 2 R1503motr84A 1. Rocker arm shaft 2. Rocker arms (exhaust side) 3. Rocker arm (intake side) Rocker Arm Inspection Inspect each rocker arm for cracks and scored friction surfaces. If so, replace rocker arm assembly. Check the rocker arm rollers for free movement, wear and excessive radial play. Replace rocker arm assembly as necessary. NEW 19.980 mm - 19.993 mm (.
PAGE 159
Section 02 ENGINE Subsection 10 (CYLINDER HEAD) 6 smr2009-025-006_a 5 1 3 2 4 R1503motr93A 1. Position lines 3. Apply engine oil on rocker arm shaft. 4. Position the rocker arm shaft with the notches on top. 2 7. Retorque screws to 20 N•m (15 lbf•ft). 8. Finish tightening screws turning an additional 90° rotation with a torque angle gauge. 2 1 1 R1503motr92A R1503motr91A 1. Rocker arm shaft 2. Rocker arm shaft notches 5. Install NEW rocker arm shaft screws.
PAGE 160
Section 02 ENGINE Subsection 10 (CYLINDER HEAD) Remove the chain tensioner. Refer to CYLINDER BLOCK subsection. Remove the chain guide. Remove the Allen screws securing the camshaft timing gear. Remove the camshaft timing gear. 1 2 smr2008-017-007_a 1. Chain guide 2. Allen screws 3. Camshaft timing gear NOTE: Secure timing chain with a retaining wire. Camshaft Timing Gear Inspection Check camshaft timing gear for wear or deterioration.
PAGE 161
Section 02 ENGINE Subsection 10 (CYLINDER HEAD) 1 1 Camshaft Removal Remove the CAMSHAFT TIMING GEAR, see procedure in this subsection. Remove the ROCKER ARM, see procedure in this subsection. Remove the camshaft lock to remove the camshaft. 1 2 R1503motr95A 1. Position lines NOTICE Ensure to remove locking tools when finished. Install all other removed parts. CAMSHAFT Camshaft Locking Procedure 1. Remove CYLINDER HEAD COVER, see procedure in this subsection. 2.
PAGE 162
Section 02 ENGINE Subsection 10 (CYLINDER HEAD) Drain coolant, refer to COOLING SYSTEM subsection. Unscrew blow-by valve from cylinder head. Refer to LUBRICATION SYSTEM subsection. Unplug the camshaft position sensors (CAPS). Unplug the coolant temperature sensor (CTS). Disconnect bleeding hose. Disconnect the cylinder head outlet hose. CAMSHAFT BEARING JOURNAL 39.892 mm - 39.905 mm NEW (1.5706 in - 1.5711 in) 39.860 mm (1.5693 in) SERVICE LIMIT CAMSHAFT BEARING JOURNAL (ENGINE FRONT) 24.939 mm - 24.
PAGE 163
Section 02 ENGINE Subsection 10 (CYLINDER HEAD) 1 smr2009-025-010_a 1. Oil orifices R1503motr98A 1. Cylinder head screws M6 Remove the cylinder head screws M11 securing cylinder head to cylinder block. Cylinder Head Inspection Check for cracks between valve seats or other damages, if so, replace cylinder head. Check cylinder head mating surface for flatness, using a straight edge. 1 R1503motr99A smr2006-016-063_a 1. Cylinder head screws M11 Pull up cylinder head. Remove gasket.
PAGE 164
Section 02 ENGINE Subsection 10 (CYLINDER HEAD) NOTICE 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. 2 1 Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on threads of screws M6. Install screws M6 and manually tighten them. Install NEW screws M11and tighten them manually. NOTICE This assembly uses stretch screws.
PAGE 165
Section 02 ENGINE Subsection 10 (CYLINDER HEAD) 2 1 smr2008-017-009_a 1. 2. 3. 4. Valve cotters Valve spring retainer Inner valve spring Outer valve spring Valve Spring Inspection R1503motr103A 1. Valve spring compressor clamp 2. Valve spring compressor cup R1503motr104A LOCATE VALVE SPRING COMPRESSOR CLAMP IN CENTER OF THE VALVE Remove valve cotters. Withdraw valve spring compressor, valve spring retainer and valve springs. Check valve springs for rust, corrosion or other visible damages.
PAGE 166
Section 02 ENGINE Subsection 10 (CYLINDER HEAD) NOTE: Valve cotters must be properly engaged in valve stem grooves. 1 R1503motr105B 1. Position of the valve spring VALVES R610motr125A Valve Removal Valve Inspection Remove valve spring. Push valve stem then pull valves out of valve guides. 1 2 R1503motr106A 1. Intake valve 38 mm 2. Exhaust valve 31 mm Valve Stem Seal Inspection of valve stem seals is not needed because NEW seals should always be installed whenever cylinder head is removed.
PAGE 167
Section 02 ENGINE Subsection 10 (CYLINDER HEAD) Valve Face and Seat 2 3 A 1 R1503motr107A R610motr126A A. Valve stem diameter VALVE STEM DIAMETER NEW Exhaust 5.946 mm - 5.960 mm (.2341 in - .2346 in) Intake 5.961 mm - 5.975 mm (.2347 in - .2352 in) SERVICE LIMIT Exhaust Intake 5.93 mm (.233 in) Replace valve guide if it is out of specification or has other damages such as wear or friction surface. Refer to valve guide replacement below. VALVE GUIDE INNER DIAMETER 1. Valve seat 2.
PAGE 168
Section 02 ENGINE Subsection 10 (CYLINDER HEAD) INTAKE 55° B A 35° A 45° 35° 45° 55° R1503motr260A A. Valve seat outer diameter INTAKE V01C1HA VALVE SEAT OUTER DIAMETER A. Valve face contact width B. Valve seat contact width Valve Seat Grinding NOTE: The valve seats may be reground with a valve seat grinder which centers on the valve guide. 1. Grind the valve seat at 45°. Remove no more material than absolutely necessary to clean the seat up. 2.
PAGE 169
Section 02 ENGINE Subsection 10 (CYLINDER HEAD) VALVE GUIDES 1 Valve Guide Replacement NOTICE Do not heat cylinder head for this procedure. NOTICE The sharp edge near the top of the valve guide must be machined away. Otherwise it will foul the valve guide hole in the cylinder head and destroy the cylinder head, as the valve guide is removed. Use a special reamer as far as the top of the notch. R1503motr254A 1. Valve stem seal Apply engine oil on valve stem and install valve.
PAGE 170
Section 02 ENGINE Subsection 10 (CYLINDER HEAD) 1 A R1503motr255A TYPICAL 1. Punch Check valve guide bore for abreased material. The inlet and exhaust valve guides have the same length and are interchangeable. NOTE: If valve guide has caused scoring during extraction, replace the cylinder head. Grease the bore in cylinder head and the leading end of valve guide with MOLYKOTE G-N (P/N 420 297 433). R1503motr257A TYPICAL A. Protrusion VALVE GUIDE PROTRUSION MINIMUM 12.4 mm (.4882 in) MAXIMUM 12.
PAGE 171
148
PAGE 172
Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) CYLINDER BLOCK SERVICE TOOLS Description Part Number CRANKSHAFT LOCKING TOOL .................................................... HANDLE ........................................................................................ PISTON CIRCLIP INSTALLER........................................................ STARTER DRIVE SEAL PUSHER................................................... 529 420 529 420 035 877 035 876 821 650 765 502 Page .................
PAGE 173
Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) Loctite 243 Engine oil Isoflex grease Topas NB 52 9 Nm (80 lbfin) 23 Nm (17 lbfft) 21 Loctite 243 Engine oil 22 Loctite 243 19 20 19 23 Nm (17 lbfft) 17 Nm (150 lbfin) 18 Engine oil 9 Nm (80 lbfin) Loctite 243 Engine oil 16 Loctite 243 17 19 Nm (168 lbfin) 23 Nm (17 lbfft) Loctite 243 23 Nm (17 lbfft) Loctite 243 Engine oil 9 Nm (80 lbfin) Loctite 243 1 7 23 Nm (17 lbfft) 2 3 40 Nm + 55 Nm (30 lbfft) (41 lbfft) 2
PAGE 174
Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) 9 8 Engine oil 10 8 Engine oil Engine oil 4 260 Nm (191 lbfft) 23 Engine oil 4 Loctite anti-seize Engine oil Engine oil Engine oil 12 Engine oil Engine oil 45 Nm 11 (33 lbfft) + 90° 6 13 Engine oil 6 Engine oil 5 Engine oil 15 Engine oil Engine oil Engine oil 14 15 smr2009-026-001_a smr2009-026 151
PAGE 175
Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) GENERAL 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 within the group of parts.
PAGE 176
Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) Timing Chain Removal 2 3 Remove: – Engine oil (refer LUBRICATION SYSTEM subsection) – Engine from vehicle (refer to ENGINE REMOVAL AND INSTALLATION subsection) – Cylinder head (refer to CYLINDER HEAD subsection) – PTO housing (refer to PTO HOUSING AND MAGNETO subsection) – Crankshaft (refer to CRANKSHAFT in this subsection) – Timing chain.
PAGE 177
Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) 1 1 3 R1503motr27A R1503motr08A 1. Connecting rod screws NOTE: Before removing the connecting rod caps, mark them to remember the right position when reassembling. 3. Pull piston with connecting rod out of the cylinders. 4. Remove one piston circlip no. 8 and discard it. 1. Piston 2. Piston pin 3. Circlip 6. Detach piston no. 10 from connecting rod no. 5.
PAGE 178
Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) 2 1 A R610motr76A R610motr73A A. Connecting rod big end bearing 1. Bore gauge 2. Connecting rod CONNECTING ROD BIG END DIAMETER CONNECTING ROD SMALL END DIAMETER NEW 23.01 mm - 23.02 mm (.9059 in - .9063 in) SERVICE LIMIT 23.07 mm (.908 in) If the connecting rod small end diameter is out of specification, replace small end bearing sleeve. NOTE: For small end bearing sleeve replacement contact a machine shop.
PAGE 179
Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) 1 PISTON PIN DIAMETER NEW 22.996 mm - 23.000 mm (.905 in - .906 in) SERVICE LIMIT 22.990 mm (.905 in) Measure connecting rod small end diameter (refer to CONNECTING RODS INSPECTION above) to check connecting rod small end radial play. Piston Inspection Inspect piston for scoring, cracking or other damages. Replace piston and piston rings if necessary. Using a micrometer, measure piston at 18 mm (.709 in) perpendicularly (90°) to piston pin axis.
PAGE 180
Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) NOTE: Make sure the cylinder bore gauge indicator is set exactly at the same position as with the micrometer, otherwise the reading will be false. Position the dial bore gauge 62 mm (2.44 in) above cylinder base, measuring perpendicularly (90°) to piston pin axis. Read the measurement on the cylinder bore gauge. The result is the exact piston/cylinder wall clearance. 1 2 PISTON/CYLINDER CLEARANCE NEW NOMINAL 0.044 mm - 0.076 mm (.0017 in - .
PAGE 181
Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) NOTICE Failure to strictly follow this procedure may cause screw to loosen and lead to engine damage. Knowing that the screws have been stretched from the previous installation, it is very important to use new screws at assembly. 1 1 R1503motr30A 1. Arrow toward exhaust side 2. Correctly install bearings and carefully clean split surface on both sides (cracked area). 3 1 2 R1503motr31A 1.
PAGE 182
Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) 1 2 2 3 A31C2NA 1. Rectangular ring 2. Taper-face ring 3. Oil scraper ring 1 R1503motr32A NOTICE Ensure that top and second rings are not interchanged. 1. Piston 2. Filler gauge Ring End Gap RING END GAP NEW RECTANGULAR TAPER-FACE 0.35 mm - 0.50 mm (.014 in - .02 in) 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.
PAGE 183
Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) Remove: – Intake manifold (refer to INTAKE MANIFOLD subsection) – Spark plugs – Cylinder head cover (refer to CYLINDER HEAD subsection – Crankshaft access plug screw. smr2009-026-004_a 1. Position lines Use a small screwdriver to check if the groove in the crankshaft is aligned with the hole. In this position, lock the crankshaft using the CRANKSHAFT LOCKING TOOL (P/N 529 035 821). smr2009-026-002_a 1. Crankshaft access plug screw 2.
PAGE 184
Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) 1 NOTE: Before removing the connecting rod caps, mark them to remember the right position when reassembling. It is recommended to measure connecting rod big end axial play prior to remove connecting rod. Refer to PISTONS AND CONNECTING RODS in this subsection for the procedure. R1503motr05A ENGINE UPSIDE DOWN 1. Oil reservoir plug screw with O-ring 10. Remove cylinder block screws no. 3 and no. 7. R1503motr07A 1 1 1. Mark on connecting rod 13.
PAGE 185
Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) 1 1 2 R1503motr13A R1503motr10A 1. Micrometer 2. Crankshaft area for bearing 1. Crankshaft Crankshaft Inspection Crankshaft Gear Inspection Replace crankshaft if the gears are worn or otherwise damaged. 2 CRANKSHAFT JOURNAL DIAMETER NEW 49.991 mm - 50.01 mm (1.9681 in - 1.9689 in) SERVICE LIMIT 49.95 mm (1.9665 in) CRANKSHAFT JOURNAL RADIAL CLEARANCE 0.07 mm (.0028 in) SERVICE LIMIT Crankshaft Pin Measure all crankshaft pin diameters.
PAGE 186
Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) CRANKSHAFT PIN RADIAL CLEARANCE SERVICE LIMIT 0.09 mm (.0035 in) Crankshaft Axial Clearance When assembling the cylinder-block, measure the crankshaft axial clearance. 1 R1503motr17A 1 2 1. Mark on balancer shaft 2. Mark on crankshaft For correct installation of the connecting rods, refer to PISTONS AND CONNECTING RODS in this subsection. 2 R1503motr41A 1. Dial gauge 2. Crankshaft CRANKSHAFT AXIAL CLEARANCE NEW 0.08 mm - 0.22 mm (.003 in - .
PAGE 187
Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) 1 1 2 R1503motr16A R1503motr18A 1. Thrust washer 2. Sealing surface 1. Crankshaft locking tool Install cylinder block lower half. Refer to CYLINDER BLOCK in this subsection. Install the crankshaft cover before mounting the engine bracket. Apply engine oil on O-ring and press cover in. Crankshaft cover has to be flush with cylinder block surface. 1 R1503motr19A BALANCER SHAFT Balancer Shaft Removal 1.
PAGE 188
Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) 1 2 1 R1503motr109A 1. Screws R1503motr23A 11. Remove cylinder block lower half. 12. Remove thrust washers no. 6. 1. Micrometer 2. Balancer shaft area for bearing BALANCER SHAFT SEAT DIAMETER 1 NEW 31.984 mm - 32.000 mm (1.2592 in - 1.2598 in) SERVICE LIMIT 31.960 mm (1.2583 in) BALANCER SHAFT SEAT RADIAL CLEARANCE SERVICE LIMIT 0.07 mm (.
PAGE 189
Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) Balancer Shaft Installation 2 For installation, reverse the removal procedure. Pay attention to following details. NOTICE Balancer shaft and crankshaft marks have to be aligned. 1 R1503motr22A 1. Thrust washer 2. Sealing surface Install cylinder block lower half. Refer to CYLIN- DER BLOCK in this subsection. R1503motr17A 1 Install the crankshaft cover before mounting the engine bracket. Apply engine oil on O-ring and press cover in.
PAGE 190
Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) 1 1 R1503motr18A 1.
PAGE 191
Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) Close puller claws so that they can be inserted in end bearing. Holding claws, turn puller shaft clockwise so that claws open and become firmly tight against bearing. Slide puller 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. Cylinder Out of Round Measure cylinder diameter in piston axis direction from top of cylinder.
PAGE 192
Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) CRANKSHAFT BEARING INSIDE DIAMETER 50.1 mm (1.9724 in) SERVICE LIMIT Correctly install bearings. Top crankshaft bearing halves have a bore which has to be placed in the upper cylinder block. 1 2 3 R1503motr35A R1503motr34A 1 1. Cylinder block upper half 2. Oil bore in cylinder block 3. Oil bore in bearing ENGINE UPSIDE DOWN 1. Bore gauge BALANCER SHAFT BEARING INSIDE DIAMETER SERVICE LIMIT 32.11 mm (1.
PAGE 193
Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) Clean oil passages and make sure they are not clogged. Clean all metal components in a solvent. Cylinder block mating surfaces are best cleaned using a combination of the LOCTITE CHISEL (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). NOTICE Do not wipe with rags. Use a new clean hand towel only.
PAGE 194
Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) Install the crankshaft cover before mounting the engine bracket. Apply engine oil on O-ring and press cover in. Crankshaft cover has to be flush with cylinder block surface. 1 R1503motr19A 2 1. O-ring 2. Crankshaft cover Install the CRANKSHAFT LOCKING TOOL (P/N 529 035 821) right away to position crankshaft at TDC before installing the camshaft and the rocker arms (refer to CYLINDER HEAD subsection). 529035821 1 R1503motr18A 1.
PAGE 195
172
PAGE 196
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 01 (ENGINE MANAGEMENT SYSTEM) ENGINE MANAGEMENT SYSTEM FRONT 1 2 B 3 A MAPS KS ETA OPS CTS TOPS CPS CAPS MATS ECM INJECTOR 1, 2, 3 IGNITION COIL 1, 2, 3 EGTS A B CAPS CPS CTS ECM EGTS Engine Wiring Harness Connector Vehicule Wiring Harness Connector Camshaft Position Sensor Crankshaft Position Sensor Coolant Temperature Sensor Engine Control Module Exhaust Gas Temperature Sensor KS OPS MAPS MATS ETA TLS TOPS Knock Sensor Oil Pressure Sensor
PAGE 197
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 01 (ENGINE MANAGEMENT SYSTEM) 1503 4-TEC CONTROL SYSTEM INPUTS OUTPUTS Relay Throttle accelerator sensor (TAS) Fuel pump Throttle position sensor (TPS) Crankshaft position (CPS) Camshaft position (CAPS) Starter solenoid ENGINE CONTROL MODULE (ECM) Ignition coil (3) Coolant temperature (CTS) Fuel injector (3) Manifold absolute pressure (MAPS) Electric throttle actuator (ETA) Manifold air temperature (MATS) Exhaust gas temperature (EGTS) Control
PAGE 198
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 01 (ENGINE MANAGEMENT SYSTEM) GENERAL SYSTEM DESCRIPTION There are 7 main systems in interaction with the engine management system: 1. Electronic fuel injection 2. D.E.S.S. system 3. Ignition system 4. Starting system 5. O.T.A.S. (Off-Throttle Assisted Steering) 6. Lubrication system (T.O.P.S. (Tip-Over Protection System)) 7.
PAGE 199
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 01 (ENGINE MANAGEMENT SYSTEM) in limp home mode. Refer to MONITORING SYSTEM AND FAULT CODES subsection for more information.
PAGE 200
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 02 (iCONTROL SYSTEM) iCONTROL SYSTEM GENERAL The iControl (intelligent Control) system consist of the following systems: – Intelligent Throttle Control (iTC) – Intelligent Brake and Reverse (iBR) – Intelligent Suspension (iS). The gauge is used with the iControl system to navigate through and select several functions, modes of operation and change certain settings and system parameters using the appropriate handlebar control s.
PAGE 201
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 02 (iCONTROL SYSTEM) For a comprehensive and complete description of this system, refer to IBR and VTS subsection in the PROPULSION section. iS (INTELLIGENT SUSPENSION) The intelligent suspension is a mechanical system of one spring and one shock absorber installed in the lower fixed deck connecting to the upper moving deck to isolate the riders from the rough water.
PAGE 202
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE) COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE SERVICE TOOLS Description Part Number Page MPI-2 DIAGNOSTIC CABLE.......................................................... 710 000 851 ......................................... 182 MPI-2 INTERFACE CARD .............................................................. 529 036 018 .........................................
PAGE 203
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE) CAN LIGHT STATUS WHAT TO DO Light is OFF Check connection between MPI-2 and diagnostic connector of vehicle. Light is RED Check CAN wires/connectors on vehicle. Light is GREEN Connections are GOOD. Communication can take place on CAN side. Communication Problems with B.U.D.S. Missing Module If an “X” is shown in the status bar, it means that no "ECU" is communicating with the MPI.
PAGE 204
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE) Message Box: "Some of the Information Normally Displayed..." If the following message box is displayed in B.U.D.S.: NOTE: Never use the D.E.S.S. POST INTERFACE. smr2009-028-016 1. Click on the OK button in B.U.D.S. 2. Remove and reinstall the D.E.S.S. key to make a good contact with its post. 3. Briefly press the vehicle START button to activate the ECM. Do not hold START button to avoid engine starting.
PAGE 205
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE) ssi2009-002-004_a 1. Diagnostic connector Connect the MPI-2 DIAGNOSTIC CABLE (P/N 710 000 851) to vehicle connector. 529036018 NOTE: An optional MALE-FEMALE EXTENSION SERIAL CABLE (P/N DB9) available at electronic retail outlets can be used between diagnostic cable and MPI-2 interface. Do not exceed 7.6 m (25 ft).
PAGE 206
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE) Reading Data in ECM Read ECM by clicking the Read Data button. vmr2006-012-100_aen mmr2006-079-200 MPI-2 INTERFACE CARD CONNECTED TO USB PORT B.U.D.S. is now ready to use. CAUTION If the computer you are using is connected to the power outlet, there is a potential risk of electric shock when working in contact with water. Be careful not to touch water while working with the computer. Use B.U.D.S.
PAGE 207
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE) NOTE: When selecting the update menu in B.U.D.S., a dialog box will appear and the update file description may give some clue to find the vehicle-related information in BOSSWeb. smr2009-028-003 1. If the Update option is greyed out, no update file is available for this module. 2. If the Update option is black, an update file is available for this module. mbg2008-022-100_a TYPICAL 1.
PAGE 208
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE) NOTE: If there is still a communication problem, refer to COMMUNICATION PROBLEMS WITH B.U.D.S. in this subsection. After the write operation, remove D.E.S.S. key from watercraft D.E.S.S. post to complete the operation. Disconnect MPI connections and reconnect vehicle harness in protective cap. ssi2009-002-004_a 1.
PAGE 209
186
PAGE 210
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) MONITORING SYSTEM AND FAULT CODES GENERAL MONITORING SYSTEM A system monitors the electronic components of the EMS (engine management system), iBR, information center, iS and other components of the electrical system to ascertain they are not faulty or defective. This system comes active when the START button is pressed.
PAGE 211
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) – Start engine. – Check if fault code disappeared. The electronic system will react differently depending on the fault type. In severe failure, the engine may not be allowed to be started. In other cases, the engine will operate in limp home mode (reduced speed). Limp Home Mode When a major component of the EMS or the iBR is not operating properly the limp home mode will be set.
PAGE 212
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) PILOT LAMPS (ON) MESSAGE DISPLAY DESCRIPTION MAINTENANCE REMINDER Maintenance required LOW or HIGH BATTERY VOLTAGE Low/high battery voltage LOW-FUEL Low fuel level, approx. 25% tank capacity, 14 L (3.7 U.S. gal.) or fuel level sensor disconnected HIGH TEMPERATURE Engine or exhaust system overheating CHECK ENGINE or LIMP HOME MODE Check engine (minor fault req. maint.) or LIMP HOME MODE (major eng.
PAGE 213
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) Beeper Signals When one of the below conditions occurs, the monitoring system emits the following beep signals. BEEPER CODES Wrong D.E.S.S. key. Use a D.E.S.S. key that has been programmed for the watercraft. Defective D.E.S.S. key. Use another programmed D.E.S.S. key. Dried salt water in D.E.S.S. key. Clean D.E.S.S. key with fresh water to remove salt water. Defective D.E.S.S. post. Check.
PAGE 214
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) Fault Code Types There are 4 types of fault codes used on the vehicle: – “B” for information center and switches faults (Bxxxx) – “C” for iBR and iS faults (Cxxxx) – “P” for power train faults (Pxxxx) – “U” for CAN communication faults (Uxxxx).
PAGE 215
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) This will reset the appropriate counter(s) and will also record that the problem has been fixed in the related module memory. SPECIFIC FAULT CODES Several Fault Codes are Active at once If this occurs, check the following: – Check the 30 A fuses in fuse box 2. – Check the bus bar condition and connections in fuse box(es). – Check the diagnostic connector for the presence of water or corrosion. – Check the CAN wires.
PAGE 216
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT CODE TABLE FAULT MODULE CODE POSSIBLE CAUSE SERVICE ACTION Cluster Left keypad fault (switch kept activated more than 60 seconds) Problem with left keypad The switch may be defective, verify the functionality of the switch or the wires. Refer to the Shop Manual for switch diagnosis/testing procedure.
PAGE 217
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION Damaged sensor, damaged circuit wires, damaged connector or damaged iBR pins. Fault detected when the engine is running or stopped Check system circuits C03-6pos and C01-12pos. Check for 0.5 to 3 V on pin F and 0.25 to 1.5 on pin C.
PAGE 218
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE DESCRIPTION Unexpected battery power lost iBR Motor current software breaker Motor current too high Clean and check for damage in the iBR gate and nozzle area. Refer to the Service Manual for more details. iBR iBR DC motor shorted to ground or 12 V iBR motor failure. iBR motor wires damaged Check iBR circuit A and B. Refer to the Service Manual for more details.
PAGE 219
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION iBR System disabled and need activation System is locked. Need activation Use B.U.D.S. iBR unlock function. Refer to the Service Manual for more details. iBR Water temperature sensor overheat iBR cooling system failure. iBR unit failure Check iBR cooling circuit. Replace iBR unit. Refer to the Service Manual for more details.
PAGE 220
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION Check for 12 volts on sensor connector pin A. Check continuity for circuits B-H1, B-H3. Check fuse 10 (refer to WIRING DIAGRAM) refer to the Service Manual for more details.
PAGE 221
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE P0113 P0116 P0117 P0118 P0122 198 ECM ECM ECM ECM ECM DESCRIPTION Intake manifold temperature sensor open circuit or shorted to battery Engine temperature sensor functional problem Engine temperature sensor voltage too low Engine temperature sensor voltage too high TAS (Throttle Accelerator sensor) 1 fault (short circuit to GND) POSSIBLE CAUSE SERVICE ACTION Damaged sensor, damag
PAGE 222
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE P0123 P0127 P0201 P0202 P0203 smr2009-029 ECM ECM ECM ECM ECM DESCRIPTION POSSIBLE CAUSE SERVICE ACTION TAS (Throttle Accelerator sensor) 1 fault (short circuit to battery) Damaged sensor, damaged circuit wires, damaged connector or damaged ECM pins. Check system circuits B-E1, B-K1, B-K3. Check for 0 volt on sensor connector pin E. Check for 5 volts on sensor connector pin D.
PAGE 223
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE P0217 P0222 P0223 P0231 P0232 200 ECM ECM ECM ECM ECM DESCRIPTION High engine coolant temperature detected TAS (Throttle Accelerator sensor) 2 fault (short circuit to GND) TAS (Throttle Accelerator sensor) 2 fault (short circuit to battery) Fuel pump open circuit or short to ground Fuel pump short circuit to battery POSSIBLE CAUSE SERVICE ACTION Engine overheated or damaged senso
PAGE 224
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE P0261 P0262 P0264 P0265 P0267 smr2009-029 ECM ECM ECM ECM ECM DESCRIPTION Injector 1 open circuit or shorted to ground Injector 1 shorted to battery Injector 2 open circuit or shorted to ground Injector 2 shorted to battery Injector 3 open circuit or shorted to ground POSSIBLE CAUSE SERVICE ACTION Damaged injector, damaged circuit wires, damaged connector or damaged ECM output pi
PAGE 225
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE DESCRIPTION Damaged injector, damaged circuit wires, damaged connector or damaged ECM output pins Knock sensor fault Damaged sensor, damaged circuit wires, damaged connector or damaged ECM output pins Bring engine to 5000 RPM. If fault code appears then check for approximately 5 Mohms between system circuits A-C3 and A-G2. Refer to the Service Manual for more details.
PAGE 226
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE P0352 P0353 P0354 P0355 P0356 P0357 smr2009-029 ECM ECM ECM ECM ECM ECM DESCRIPTION Ignition coil 2 open circuit or shorted to ground or to battery Ignition coil 3 open circuit or shorted to ground or to battery Ignition Power Stage fault - short circuit to GND/Cylinder 1 Ignition Power Stage fault - short circuit to GND/Cylinder 2 Ignition Power Stage fault - short circuit to GND
PAGE 227
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE P0358 P0359 ECM ECM DESCRIPTION POSSIBLE CAUSE SERVICE ACTION Damaged coil, damaged circuit wires, damaged connector or damaged ECM output pins Check for 0.85 to 1.15 ohms between engine connector pin 1 and ECM connector pin A-M2. Check for 12 volts on pin 2 of coil connector. Check fuse 8 (refer to WIRING DIAGRAM). Refer to the Service Manual for more details.
PAGE 228
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE P0545 P0546 P0560 DESCRIPTION POSSIBLE CAUSE SERVICE ACTION Check for approximately 2280 to 2736 ohms at temperature of 19 to 21°C (66 to 70°F) between system circuits A-H4 and A-J4. Refer to the Service Manual for more details.
PAGE 229
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE DESCRIPTION P062F ECM ECM EEPROM fault exchange ECM P06B6 ECM ECM Fast ADC fault (knock detection line) ECM P1120 P1264 P1502 P1503 P1504 P1505 ECM ECM ECM ECM ECM POSSIBLE CAUSE SERVICE ACTION Damaged ECM. Replace ECM.
PAGE 230
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE P160E P1610 P1611 P1612 P1613 P1614 P1615 P1616 P1619 P1620 smr2009-029 DESCRIPTION POSSIBLE CAUSE SERVICE ACTION Throttle Actuator - Controller Fault digital position control below limit Damaged throttle actuator, damaged circuit wires, damaged connector or damaged ECM Check system circuit, perform closed throttle with B.U.D.S. Replace throttle actuator, replace ECM.
PAGE 231
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE P1621 P1622 P1654 P1657 P1658 DESCRIPTION POSSIBLE CAUSE ECM Throttle Actuator Abortion of adaptation Damaged throttle actuator, damaged circuit wires, damaged connector or damaged ECM Check system circuit, perform closed throttle with B.U.D.S. Replace throttle actuator, replace ECM.
PAGE 232
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION P16C5 ECM Safety fuel cut off activ - Monitoring level 1 P16C6 ECM Safety fuel cut off activ - Monitoring level 2 ECM Monitoring fault due to throttle valve plausibility check Damaged throttle actuator, damaged circuit wires, damaged connector or damaged ECM Check system circuit, perform closed throttle with B.U.D.S.
PAGE 233
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE P2428 P2620 P2621 ECM ECM ECM DESCRIPTION POSSIBLE CAUSE SERVICE ACTION High exhaust temperature detected Exhaust overheat, damaged sensor or damaged circuit wires. Check cooling system for blockage. Check if the exhaust injection valve is properly calibrated. Refer to the Service Manual for more details.
PAGE 234
Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE CODE U16A1 U16A2 U16A3 U16A4 U16A5 U16A6 U16A7 U16A8 U16A9 smr2009-029 DESCRIPTION POSSIBLE CAUSE SERVICE ACTION ECM Cluster CAN Time out error-Missing CAN ID 514h Cluster fault detected by ECM CAN circuit failure, Instrument cluster or ECM failure Check CAN circuits wires. Replace instrument Cluster. Refer to the Service Manual for more details.
PAGE 235
212
PAGE 236
Section 04 FUEL SYSTEM Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC)) INTELLIGENT THROTTLE CONTROL (iTC) SERVICE TOOLS Description Part Number Page DIAGNOSTIC HARNESS ............................................................... 529 036 179 ......................................... 215 FLUKE 115 MULTIMETER ............................................................ 529 035 868 ................................. 215, 217 SERVICE PRODUCTS Description Part Number Page DIELECTRIC GREASE ..........
PAGE 237
Section 04 FUEL SYSTEM Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC)) While the throttle lever might be fully depressed and held, the ECM could close the throttle plate, instead of opening it, if the iBR lever were depressed. Then, the ECM could open the throttle plate to accelerate the engine to increase the braking effect. All those different throttle plate movements could be achieved while the throttle lever was still fully depressed. This is one of the great flexibility of the iTC.
PAGE 238
Section 04 FUEL SYSTEM Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC)) smr2009-042-005_c smr2009-030-033_a 1. 8-pin connector 2. 12-pin connector Connect the DIAGNOSTIC HARNESS (P/N 529 036 179) to make an in-line connection between the disconnected connectors. Test on the 12-pin Connector of Diagnostic Harness 12-PIN CONNECTOR IDLE POSITION PIN WIDE OPEN POSITION VOLTAGE (Vdc) 10 11 11 12 4.9 - 5.1 0.4 - 0.6 2.9 - 3.1 529036179 NOTE: Plug only the connectors that have been disconnected.
PAGE 239
Section 04 FUEL SYSTEM Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC)) smr2009-030-100_a Step 1: Pry out Step 2: Pull out sensor Revert removal procedure for installation. Pay attention to the following. Align sensor pins into their holes. smr2009-030-102_a 1. Route harness here When installation is completed, ensure throttle lever works properly.
PAGE 240
Section 04 FUEL SYSTEM Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC)) smr2009-042-002_a smr2009-036-002_b 1. 2. 3. 4. Read Data Monitoring tab Cluster tab Cruise indicator light If the test succeeded, the switch and wiring are good and the problem may be related to the information center or ECM. Check for related fault codes. Refer to MONITORING SYSTEM AND FAULT CODES. 1. Gauge connector 2. Pull out to unlock connector 6. Use the FLUKE 115 MULTIMETER (P/N 529 035 868). 7.
PAGE 241
Section 04 FUEL SYSTEM Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC)) 10 12 1 12. Reconnect gauge connector. 13. Properly insert cruise switch wiring in slot in switch support before installing MODE/SET and UP/DOWN arrow switches. 11 smr2009-036-003_a GAUGE CONNECTOR PIN-OUT 3. Attach a string approximately 1.2 m (4 ft) to the end of the wires which will be used for drawing the new switch wires through the harness protective sheath. 4. Remove steering cover. Refer to STEERING AND O.T.A.S.
PAGE 242
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) ELECTRONIC FUEL INJECTION (EFI) SERVICE TOOLS Description Part Number Page DIGITAL INDUCTION TACHOMETER ........................................... 529 014 500 ......................................... 222 ECM ADAPTER TOOL................................................................... 529 036 166 ........................ 225, 235, 242, 246–247, 249, 251 FLUKE 115 MULTIMETER .......................................................
PAGE 243
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) WARNING If any gasoline leak and/or odor are present, do not start the engine. Repair the leak. SYSTEM DESCRIPTION The electronic fuel injection system (EFI) on this engine is based on the open-loop Bosch ME-Motronic system. It comprises all the sensors for detecting the ongoing operating from the engine and watercraft and comprises all the actuators that perform the required adjustment to the engine.
PAGE 244
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Flame Arrester The flame arrester is a tube inside the intake manifold. It prevents flames leaving through the intake system if the engine backfires. EFI Sensors smr2009-030-019_a 1. 2. 3. 4. 5. 6. 7. 8. 9.
PAGE 245
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Use a DIGITAL INDUCTION TACHOMETER (P/N 529 014 500). Install the D.E.S.S. key on its post. Briefly press the START button to wake up the ECM. Engine must not crank. In B.U.D.S., click on the Reset button. 529014500 Wrap the tachometer's wire a few times around the protruding part of ignition coil. smr2009-030-002_a SETTING AND ECM TABS 1. Click Reset button The following message will confirm the operation.
PAGE 246
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) It is important to ensure that the mechanical integrity of the engine/propulsion system are intact. For diagnostics purposes, use B.U.D.S. software. See COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE subsection. After a problem has been solved, ensure to clear the fault(s) in the ECM using the B.U.D.S. software. WARNING All electrical actuators and electronic modules are powered as soon as the START button is depressed.
PAGE 247
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) ECM Power Supply Troubleshooting ECM Power Supply Diagram Battery A1 FB#2 Fuse F17 FB#2 Bus bar (Vdc) B2 B7 B8 FB#2 Relay B12 B5 D1 A12 FB#2 Fuse F21 D2 B10 A10 D6 FB#1 2 Start switch Bus bar (Vdc) D4 1 D3 Fuse F20 FB#2 A4 B-M4 Switched power ECM Signal Wake up B-H2 B-D1 B-L1, B-M2, B-M3 E9, E11, E10 FB#2 Bus bar (ground) FB = Fuse box smr2009-030-001_en ECM Wake Up Basics When the START button is depre
PAGE 248
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) – Relay and wiring. Refer to POWER DISTRIBU- TION – ECM power supply wires and ground wires. See below. ECM Power Supply Test Remove cover of fuse box #2 (FB). Refer to POWER DISTRIBUTION subsection. Install the D.E.S.S. key on its post. Briefly press the START button to wake up the ECM. Use the FLUKE 115 MULTIMETER (P/N 529 035 868) and select Vdc. Probe the fuse F20 as shown. NOTE: This will validate the fuse at the same time.
PAGE 249
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) smr2009-030-010_a If measurement is out of specification, check ground bus bar in fuse box #2 and continuity of its wires and connections with the engine grounds. Also check battery ground and engine grounds. smr2009-016-026_b LH SIDE OF ENGINE 1. Battery ground cable 2. Exhaust manifold water inlet fitting If everything tests good and ECM does not power up, try a new ECM. Refer to ECM REPLACEMENT.
PAGE 250
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) NOTICE Always replace ECM by the same part number or by an approved equivalent. Reconnect ECM connectors to ECM. Reconnect battery cables. If a new ECM is installed, refer to ECM REPLACEMENT in this subsection. Briefly press the START button to wake up the ECM. Engine must not crank. From B.U.D.S., choose ECM, Replace under Module menu.
PAGE 251
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Click on the Open button. mmr2009-023-080 Click once on the Folder Up button in the Open box. smr2009-030-006 IMPORTANT: Ensure to use the file that specifically matches the vehicle you are servicing. NOTE: The file name structure is as follows: BUDS version_VIN_date read (yyyymmdd)_hour read (hhmmss).mpem Example: P2.3.22.12_2BPSBK8C68V000168_20090206_111640.mpem Therefore: B.U.D.S. version: P2.3.22.
PAGE 252
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Entering the Collected Information Into the ECM Remove the faulty ECM. Install and connect the new ECM. Use the B.U.D.S. software. Refer to COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE subsection. Install the D.E.S.S. key on its post. Briefly press the START button to wake up the ECM. Engine must not crank. In B.U.D.S., click the Read Data button to read the new “empty” ECM. 1 vmr2006-012-100_aen F18D03A 1.
PAGE 253
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) 3. Customer name 4. Enter the old ECM serial number in the Part Replacement under History tab. Click on Add Part in History. Perform the Closed throttle reset. Refer to Closed Throttle Reset (TPS) in ADJUSTMENTS in this subsection. Reinstall remaining removed parts. FUEL RAIL Fuel Rail Removal Open seat. Remove rear ventilation box. Refer to AIR INTAKE SYSTEM. Remove deck extension. Refer to BODY.
PAGE 254
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Fuel Rail Removal Cut locking ties retaining engine harness to fuel rail. smr2009-030-027_a 1. Fuel rail Unplug all injector connectors. Pull fuel rail out with fuel injectors. Fuel Rail Installation smr2009-030-011_b 1. Cut locking ties Remove retaining screws of fuel rail. Reverse the removal procedure. However, pay attention to the following. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on fuel rail retaining screws.
PAGE 255
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) FUEL INJECTOR Fuel Injector Operation Test with B.U.D.S. (Dynamic) 1. Connect B.U.D.S. Refer to COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE. 2. Start engine. 3. Using the B.U.D.S. software, shut down each engine cylinder, one at a time. smr2009-030-011_b 1. New locking ties Fuel Rail Hose Connection 1. Apply engine oil on O-rings of fitting. mmr2009-120-006_a MONITORING AND ECM TABS 1.
PAGE 256
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) 5. Fuel pressure must be within specification. Refer to FUEL TANK AND FUEL PUMP subsection. Re-activate fuel pump as necessary. 6. In B.U.D.S., energize the fuel injector no. 1. smr2009-030-013_a ACTIVATION AND ECM TABS 1. Injector of cylinder no. 1 shown Listen to the injector. If you can hear the injector, it validates its operation. Carry out the FUEL INJECTOR BALANCE TEST.
PAGE 257
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Fuel Injector Input Voltage Test Open seat. Remove rear ventilation box. Refer to AIR INTAKE SYSTEM. Disconnect fuel injector connectors. NOTE: Push against tab underneath connector as shown to unlock it. smr2009-030-029_a If input voltage is good, carry out the INJECTOR CONTROL CIRCUIT TEST. If input voltage is not good, check continuity between fuse box #1 and injector as follows. Remove cover of fuse box 1.
PAGE 258
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Disconnect the ECM A connector. Install ECM ADAPTER TOOL (P/N 529 036 166) on ECM connector. Remove the long bus bar from fuse box #1. smr2009-030-015_j If continuity is good, wiring and connectors are functional. If continuity is faulty, repair/replace wiring from fuse box terminal to injector. Reinstall bus bar and cover. Fuel Injector Control Circuit Test Disconnect ECM A connector.
PAGE 259
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) INJECTOR PIN 1 RESISTANCE @ 20°C (68°F) 2 See above Insert the fuel injector in place on fuel rail. Secure injector to fuel rail with its clip. Install fuel rail. Refer to FUEL RAIL in this subsection. THROTTLE BODY smr2009-030-030_a If readings are out of specifications, replace injector. If readings are good, repair/replace wiring/connectors from ECM to injector. Fuel Injector Removal Remove fuel rail.
PAGE 260
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Throttle-Body Faults and Effects NOTE: Among other things, a weak or broken spring and a sticky throttle plate (carbon build-up, dried salt water etc) are validated by the throttle body diagnostic mode. smr2009-030-032_a CONNECTOR PIN-OUT Throttle Actuator Operating Positions Two torsional springs are connected with the throttle plate. A main spring and another one in a plunger mechanism.
PAGE 261
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) NOTICE Only use an appropriate throttle body cleaner that will not damage O-rings and EFI sensors. WARNING Use the product in well ventilated area. Refer to product manufacturer's warnings. Wipe off any product leakage in bilge. To avoid getting dirt into engine, spray cleaner on a clean rag (outside the bilge) then rub rag against throttle plate and bore. A toothbrush works well too. WARNING First ensure ECM is off.
PAGE 262
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Throttle plate must fully open and when released, must return freely to the rest position (slightly opened). Push throttle plate where shown. It must completely close and when released, freely return to the rest position (slightly opened). smr2009-030-024_a 1. Throttle body 2. Inlet hose 3. Connector 4. Remove retaining screws from throttle body. smr2009-030-016_c 1.
PAGE 263
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Install the D.E.S.S. key on its post. Briefly press the START button to wake up the ECM. Do not start engine. Connect B.U.D.S. Refer to COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE. In B.U.D.S., select the Monitoring tab then the ECM tab. Use the Throttle Opening. smr2009-030-016_b 1. Push here mmr2009-120-001 MONITORING AND ECM TABS Slowly and regularly depress the throttle lever. Observe the needle movement.
PAGE 264
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) vmr2008-022-005_a If any resistance value is incorrect, check wire continuity between ECM and throttle body. If continuity is good, replace throttle body. If resistance values are correct, try a new ECM. Refer to ENGINE CONTROL MODULE (ECM) in this subsection. CRANKSHAFT POSITION SENSOR (CPS) smr2008-023-016_a TYPICAL Install the D.E.S.S. key on its post. Briefly press the START button to wake up the ECM.
PAGE 265
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Remove deck extension. Refer to BODY. Remove air intake silencer. Refer to AIR INTAKE SYSTEM. Drain oil from PTO housing. Refer to PTO HOUSING AND MAGNETO. NOTE: It is not necessary to drain oil from engine. Disconnect CPS connector. lmr2006-021-002_b TYPICAL If resistance is not within specifications, replace the CPS. If resistance tests good, reconnect the CPS and disconnect the ECM connector A on the ECM.
PAGE 266
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Trigger Wheel Inspection Refer to PTO HOUSING AND MAGNETO in the ENGINE section. CAPS CONNECTOR MEASUREMENT PIN VOLTAGE 1 3 Battery voltage CAMSHAFT POSITION SENSOR (CAPS) smr2009-030-035_a smr2006-020-057_a TYPICAL 1. CAPS CAPS Voltage Test (Harness Side) First check fuse F2 in fuse box #1 (FB). To gain access to the CAPS, remove the required parts as described in CAPS REPLACEMENT. Disconnect CAPS connector.
PAGE 267
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) vmr2007-050-004 They can be inserted at the end of the standard probes of the FLUKE 115 MULTIMETER (P/N 529 035 868). smr2009-027-011_f 1. Pull out Use the FLUKE 115 MULTIMETER (P/N 529 035 868) and select . Read resistance of the CAPS circuit.
PAGE 268
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) smr2009-030-034_a 1. CAPS connector smr2007-021-009_c 1. Metallic object If voltage is appropriate, check/repair wiring/connector between sensor and ECM. If it is good, check ECM. Refer to ENGINE CONTROL MODULE (ECM). If voltage is wrong, try a new CAPS. CAPS Replacement Unscrew the retaining screw. Pull out CAPS from engine. Install the CAPS. Ensure to reinstall O-ring.
PAGE 269
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) TEMPERATURE °C - 30 - 20 °F - 22 - 4 RESISTANCE (OHMS) NOMINAL 12600 11400 LOW 11800 11000 HIGH 13400 11800 - 10 14 9500 8000 11,000 0 32 5900 4900 6900 10 50 3800 3100 4500 20 68 2500 2200 2800 30 86 1700 1500 1900 40 104 1200 1080 1320 50 122 840 750 930 60 140 630 510 750 1. MATS connector 70 158 440 370 510 Use the FLUKE 115 MULTIMETER (P/N 529 035 868) and select .
PAGE 270
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) COOLANT TEMPERATURE SENSOR (CTS) If resistance tests good, reconnect the CTS connector and disconnect the ECM connector A on the ECM. Using a multimeter and the ECM ADAPTER TOOL (P/N 529 036 166), check the circuit resistance as per table. ECM ADAPTER MEASUREMENT PIN A-A1 RESISTANCE A-J2 See table below TEMPERATURE smr2006-020-057_b TYPICAL 1.
PAGE 271
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Remove rear ventilation box. Refer to AIR INTAKE SYSTEM. Remove deck extension. Refer to BODY. Disconnect CTS connector and remove CTS. Install the new CTS and torque to 18 N•m (159 lbf•in). Reinstall remaining removed parts. MANIFOLD ABSOLUTE PRESSURE SENSOR (MAPS) smr2009-030-036_d 1. Disconnect Install the D.E.S.S. key on its post. Briefly press the START button to wake up the ECM.
PAGE 272
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Using a multimeter and the ECM ADAPTER TOOL (P/N 529 036 166), check the resistance of circuit A-B4, A-G4 and A-H2. If wiring harness is good, check ECM. Refer to ENGINE CONTROL MODULE (ECM) in this section. Otherwise, repair the connectors or replace the wiring harness between ECM connector and the MAPS. MAPS Replacement Open seat. Remove rear ventilation box. Refer to AIR INTAKE SYSTEM. Remove deck extension. Refer to BODY.
PAGE 273
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) KNOCK SENSOR (KS) vmr2008-022-005_a If resistance value is correct, check ECM. Refer to ENGINE CONTROL MODULE (ECM) in this section. If resistance value is incorrect, repair the connector or replace the wiring harness between ECM connector and the EGTS. EGTS Replacement Remove the LH rear storage basket. Disconnect the exhaust hose from muffler. Unplug the EGTS connector. Unscrew EGTS from muffler.
PAGE 274
Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) vmr2008-022-005_a smr2009-030-038_a 1. KS connector Using a multimeter, check the resistance between both terminals on the knock sensor. If wiring harness is good, check ECM. Refer to ENGINE CONTROL MODULE (ECM) in this section. Otherwise, repair the connector or replace the wiring harness between ECM connector and knock sensor. KS Replacement smr2009-030-037_a The resistance should be as per the following chart.
PAGE 275
252
PAGE 276
Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) FUEL TANK AND FUEL PUMP SERVICE TOOLS Description Part Number DIAGNOSTIC HARNESS ............................................................... ECM ADAPTER TOOL................................................................... FLUKE 115 MULTIMETER ............................................................ FUEL HOSE ADAPTER.................................................................. FUEL PUMP MODULE SOCKET............................
PAGE 277
Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) FUEL TANK AND FUEL PUMP 4.5 Nm (39 lbfin) NEW NEW NEW NEW NEW 60 Nm (44 lbfft) NEW NEW NEW NEW 3.
PAGE 278
Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) FUEL SYSTEM DIAGNOSTIC FLOW CHART Fuel pump does not run Fuel pump runs for 2 sec. then stops Press Start button Install fuel pressure gauge on fuel pressure line Check fuses. Check fuel pump operation. Repair or replace if necessary.
PAGE 279
Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) GENERAL WARNING Fuel lines remain under pressure at all times. Always proceed with care and use appropriate safety equipment when working on a pressurized fuel system. Wear safety glasses. WARNING Always disconnect battery prior to working on the fuel system. Fuel is flammable and explosive under certain conditions. Always work in a well ventilated area. Do not allow fuel to spill on hot engine parts and/or on electrical connectors.
PAGE 280
Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) When the START button is pressed, the electrical system is powered. The fuel pump will come on for approximately 2 seconds to pressurize the fuel rail in preparation for the engine start. The ECM supplies the ground signal to turn on the fuel pump motor. The pressure regulator will ensure appropriate fuel pressure is supplied to the injectors. When the ECM receives a signal to shut down the engine (START/STOP switch, safety lanyard, or T.O.P.S.
PAGE 281
Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) smr2009-031-002_c 1. Outlet valve If pressure in fuel tank build up and exceed 2.8 kPa - 7.6 kPa (.4 PSI - 1.1 PSI), the outlet valve opens and let excess pressure evacuate outside fuel tank. smr2009-031-008_a 1. Ventilation box Visually inspect condition of hoses and clamps. Pull out inlet valve from its grommet. smr2009-031-002_d 1. Outlet valve INSPECTION smr2009-031-009_a 1.
PAGE 282
Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) smr2009-031-101_a TEST SETUP mmr2009-121-004_a 1. Y-fitting P/N 293 710 059 2. Check valve P/N 275 500 505 3. Apply compressed air here Install the vacuum/pressure gauge on inlet valve end. Slowly apply pressurized air. NOTE: If pressure rises quickly within a few strokes of pump, inlet valve is likely clogged. Refer to INLET CHECK VALVE TEST in this subsection. When pressure has reached 2.8 kPa - 7.6 kPa (.4 PSI - 1.
PAGE 283
Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) WARNING If a leak is found, do not start the engine. Wipe off any fuel that leaked and ventilate the hull thoroughly to remove any accumulated fuel vapors. Do not use electric powered tools on watercraft unless system has passed the leak test. Open fuel tank cap to release pressure in fuel tank. smr2009-031-102_a TEST SETUP Slowly apply pressurized air close to the pressure specification.
PAGE 284
Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) Set the vacuum/pressure pump to vacuum. smr2009-031-012_a 1. Pressure selected smr2009-031-013_a 1. Vacuum selected Squeeze the vacuum/pressure pump handle several times to pressurize air to the inlet valve. Install a SMALL HOSE PINCHER (P/N 295 000 076) near outlet valve. 295000076 Connect vacuum/pressure pump to the vent hose end. smr2009-031-015_b TEST SETUP Valve should hold 34.5 kPa (5 PSI) without leakage.
PAGE 285
Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) FUEL SYSTEM HIGH PRESSURE LEAK TEST WARNING A high pressure leak test must be carried out before starting the engine anytime a fuel system component has been disconnected for maintenance, or replacement. Visually inspect fuel system to ensure all fuel system connections are installed. Lightly pull on hoses at each connection to ensure they are properly locked at the quick connect fittings. Remove D.E.S.S.
PAGE 286
Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) MODELS FUEL PRESSURE (when pressing the START button) 1503 4-TEC supercharged intercooled 386 - 414 kPa (56 - 60 PSI) Test when Cranking or Starting Engine 529035709 smr2009-031-018_a 1. Connect to fuel pump 2. Connect to outlet hose Test when Engine Is Stopped Remove D.E.S.S. key from its post to prevent engine starting. Press the START button and observe fuel pressure. Repeat twice.
PAGE 287
Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) “B1” type hose approved by BRP for ventilation hoses. These hoses available from BRP meet our system requirements and will ensure continued proper and safe operation. WARNING Use of fuel lines other than those recommended by BRP may compromise fuel system integrity. WARNING Whenever removing a hose in the fuel system, always use new Oetiker clamps at assembly.
PAGE 288
Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) smr2009-030-024_a 1. Throttle body 2. Inlet hose 3. Connector Remove D.E.S.S. key from its post to prevent engine starting. Press START button. The fuel pump should run for 2 seconds to build up fuel system pressure. If fuel pump runs, carry out the FUEL PUMP PRESSURE TEST in this subsection. If the fuel pump does not run: – Ensure ECM is powered. Refer to ELECTRONIC FUEL INJECTION subsection. – Check fuse F6.
PAGE 289
Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) 529036166 Set multimeter to following table. and test pump circuit as per PUMP CIRCUIT TEST THROUGH FUEL PUMP TEST PROBES Fuse box #1 terminal C1 ECM connector B pin B-M1 smr2009-031-021_a RESISTANCE @ 20°C (68°F) Approx. 12 smr2009-031-021_b Repair or replace wiring as required. If every test succeeded and fuel pump still does not work, try a new ECM. Refer to ELECTRONIC FUEL INJECTION subsection.
PAGE 290
Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) smr2009-031-008_a 1. Ventilation box Disconnect the negative battery terminal, refer to CHARGING SYSTEM subsection. Disconnect fuel pump electrical connector. Disconnect the vent tube from the fuel pump. Wrap shop rags around the high pressure fuel hose fitting, then press on the release button of the quick connect fitting and disconnect the hose. smr2009-031-022_a 1. Fuel pump module socket 2.
PAGE 291
Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) WARNING Always wipe off any fuel spillage from the watercraft. When working with fuel or fuel system and its components, always work in a well ventilated area. Fuel Pump Installation Reverse the removal procedure however, pay attention to the following. Carefully insert fuel pump module in fuel tank so as not to bend float arm. Install a new fuel pump module gasket each time the module is reinstalled.
PAGE 292
Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) Press new filter on by hand. Ensure it is fully seated and locked onto the pump reservoir housing. Reinstall fuel pump as per procedure in this subsection. Carry out a FUEL SYSTEM HIGH PRESSURE LEAK TEST as described in this subsection. FUEL TANK NOTE: A fuel tank is comprised of 2 components: the tank and the filler neck. The necks are injection molded and the tank is then blow molded over the necks.
PAGE 293
Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) Place fuel tank retaining strap ends in anchoring clips. Temporarily use tape to hold straps on the top of fuel tank. smr2009-031-017_b 1. Quick connect fitting (high pressure fuel hose) 2. Vent hose 3. Harness connector Disconnect filler hose from fuel tank. NOTE: Removing retaining screws of the filler neck may help to disconnect hose from fuel tank. smr2009-031-027_a 1. Fuel tank retaining strap 2.
PAGE 294
Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) Fuel Level Troubleshooting FUEL LEVEL TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE Fuel gauge always display EMPTY – Wiring/connectors – Fuel level sensor – Float stuck in low position Fuel gauge always display FULL – Water in fuel pump connector – Float stuck in full position Fuel level sensor fault – Wiring/connectors code – Fuel level sensor smr2009-031-024_b INDEXING WITH FUEL TANK 1.
PAGE 295
Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) Remove diagnostic harness and reconnect connector. Fuel Level Sensor Resistance Test at Information Center 529036179 NOTE: Plug only the connector that has been disconnected. Briefly press the START button to wake up the ECM. Install the D.E.S.S. key on its post. Use the FLUKE 115 MULTIMETER (P/N 529 035 868) and select Vdc. Measure the voltage on the installed diagnostic harness connector as follows.
PAGE 296
Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) Fuel Level Sensor Removal smr2008-022-018_f TYPICAL — FUEL PUMP MODULE 1. Fuel pump module connector Alternately drain then fill fuel tank and measure the sensor resistance between pins C and D of the fuel pump connector. See table in FUEL LEVEL SENSOR RESISTANCE TEST AT INFORMATION CENTER. smr2008-022-029 FUEL LEVEL SENSOR Remove fuel pump module from fuel tank, see FUEL PUMP REMOVAL in this subsection.
PAGE 297
Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) Once the pressure regulator is rotate over the locking tab, pull up on it to remove it from the pump reservoir cover. smr2008-022-022_a 1. Pressure regulator 2. Ground wire contact on pressure regulator 3. Ground wire disconnected Using a flat screwdriver, press down on the locking tab just below the pressure regulator to release it from the pump reservoir cover, and rotate it clockwise simultaneously so that it slips over the locking tab.
PAGE 298
Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) Align the fuel pressure regulator tabs into the pump reservoir cover and turn it counterclockwise until it locks properly. smr2008-022-026_a 1. Fuel level sensor release tabs 2. Locking pins smr2008-022-025_b PRESSURE REGULATOR INSERTION INTO PUMP RESERVOIR COVER 1. Pressure regulator alignment tabs 2. Fuel pump reservoir alignment tabs smr2008-022-027_a 1.
PAGE 299
Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) Ensure fuel level sensor connector is locked into the module flange connector. smr2008-022-021_a 1. Fuel level sensor connector Carry out a FUEL LEVEL SENSOR RESISTANCE TEST as described in this subsection. Reinstall the fuel pump module. Refer to FUEL PUMP INSTALLATION in this subsection.
PAGE 300
Section 05 ELECTRICAL SYSTEM Subsection 01 (CONTROLLER AREA NETWORK (CAN)) CONTROLLER AREA NETWORK (CAN) SERVICE TOOLS Description Part Number Page ECM ADAPTER TOOL................................................................... 529 036 166 ......................................... 279 FLUKE 115 MULTIMETER ............................................................ 529 035 868 .........................................
PAGE 301
Section 05 ELECTRICAL SYSTEM Subsection 01 (CONTROLLER AREA NETWORK (CAN)) TROUBLESHOOTING DIAGNOSTIC TIPS Check the fault codes using B.U.D.S. software as a first troubleshooting step. Refer to MONITORING SYSTEM/FAULT CODES section. CAN Communication Problems The following chart gives some symptoms and behaviors relative to the CAN component in cause. The list is not exhaustive, only the most significant items are given to help troubleshooting.
PAGE 302
Section 05 ELECTRICAL SYSTEM Subsection 01 (CONTROLLER AREA NETWORK (CAN)) CAN Continuity Tests If a communication problem is present, perform the appropriate continuity test relating to the component reported by B.U.D.S. Test wire continuity between the corresponding terminal of the CAN bus bar in fuse box no. 2 and the suspected component as follows. Remove cover from fuse box no. 2. The following gives an example between the CAN LO wire and the ECM.
PAGE 303
280
PAGE 304
Section 05 ELECTRICAL SYSTEM Subsection 02 (POWER DISTRIBUTION) POWER DISTRIBUTION SERVICE TOOLS Description Part Number Page FLUKE 115 MULTIMETER ............................................................ 529 035 868 ......................................... 287 SERVICE PRODUCTS Description Part Number Page DIELECTRIC GREASE ................................................................... 293 550 004 .........................................
PAGE 305
Section 05 ELECTRICAL SYSTEM Subsection 02 (POWER DISTRIBUTION) SIMPLIFIED ELECTRICAL SYSTEM SCHEMATIC B-M4 D4 A1 A3 ECM (power) F17 (30 A) A5 FUSE BOX NO.
PAGE 306
Section 05 ELECTRICAL SYSTEM Subsection 02 (POWER DISTRIBUTION) GENERAL It is highly recommended to disconnect the battery when replacing any electric or electronic component. WARNING Always disconnect battery exactly in the specified order, BLACK (-) cable first, RED (+) cable last. Always reconnect BLACK (-) cable last. Do not place tools on battery. smr2009-027-011_d COMPONENT DESCRIPTION Fuse Boxes Fuse Box Location To access the fuse boxes, open the boarding platform and remove the RH storage bin.
PAGE 307
Section 05 ELECTRICAL SYSTEM Subsection 02 (POWER DISTRIBUTION) Fuse box Cover Installation When installing a fuse box cover, ensure the seal is properly seated. If the seal has been removed, ensure to reinstall it as illustrated. smr2009-016-011_a FRONT OF ENGINE 1. Engine grounds A cable connected to the engine behind the exhaust manifold, is connected at the other end to the battery ground post to complete the ground circuit. smr2007-027-003_a TYPICAL 1.
PAGE 308
Section 05 ELECTRICAL SYSTEM Subsection 02 (POWER DISTRIBUTION) smr2009-027-010_b FUSE BOX 2 — BUS BAR IDENTIFICATION 1. 12 Vdc from battery 2. 12 Vdc from battery 3. CAN LO 4. CAN HI 5. Ground bus-bar The power relay in FB2 is connected directly to one of two 12 Vdc bus bars in FB2. When the START/STOP button is pressed, it completes a 12 Vdc circuit to wake up the ECM, which in turn completes the power relay ground circuit. smr2009-027-011_a FUSE BOX 1 — BUS BAR IDENTIFICATION 1.
PAGE 309
Section 05 ELECTRICAL SYSTEM Subsection 02 (POWER DISTRIBUTION) If B.U.D.S. is being used for communicating with the electronic modules, or if the information center must be ON for testing, selecting modes of operation, changing key settings, or for other functions accessed through the information center, the D.E.S.S. key must be installed. NOTE: To prevent the electrical power from shutting down after approximately 3 minutes, press the START button before the three minute power-up period ends.
PAGE 310
Section 05 ELECTRICAL SYSTEM Subsection 02 (POWER DISTRIBUTION) – Check the ECM fuse in FB2. – Check the GAUGE fuse in FB1. If you cannot feel the power relay activating when pressing the START button, or if you suspect that it does not function correctly, refer to POWER RELAY in this subsection. PROCEDURES If no voltage is measured, test the wire jumper between FB1-D6 and FB2-A10. Also test for a voltage drop across the power relay main contact between the long bus-bar in FB2-B7 and FB1-D6.
PAGE 311
Section 05 ELECTRICAL SYSTEM Subsection 02 (POWER DISTRIBUTION) smr2007-027-060_a TERMINAL 30 288 87 RESISTANCE max. 0.
PAGE 312
Section 05 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) IGNITION SYSTEM SERVICE TOOLS Description Part Number Page ECM ADAPTER TOOL................................................................... 529 036 166 ......................................... 292 FLUKE 115 MULTIMETER ............................................................ 529 035 868 ......................................... 291 SERVICE PRODUCTS Description Part Number Page DOW CORNING 111 ........................................
PAGE 313
Section 05 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) ENGINE WILL NOT START (ENGINE TURNS OVER) 1. Fouled or defective spark plug - Replace. 2. Defective CPS - Check operation of CPS and replace if necessary. Refer to ELECTRONIC FUEL INJECTION section. 3. Defective trigger wheel - Check. Refer to PTO HOUSING/MAGNETO. 4. Defective ignition circuit - Check. ENGINE HARD TO START 1. Spark plug faulty, fouled or worn out - Check spark plug condition. Replace if necessary.
PAGE 314
Section 05 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) smr2008-024-005_b smr2009-032-001_a IGNITION COIL INPUT VOLTAGE TEST IGNITION COIL ACTIVATION 1. Activation tab 2. ECM tab 3. Click on the desired ignition coil You should hear the spark occurring. If in doubt, use a sealed vapor proof spark tester — available from tool suppliers — to prevent a spark from occurring in the bilge. If there is no spark, carry out the following checks.
PAGE 315
Section 05 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) smr2009-030-015_h If test succeeded, wiring and connectors are functional. If test failed, repair/replace wiring from fuse box terminal to ignition coil. Reinstall bus bar and cover. Ignition Coil Control Circuit Test Disconnect ECM connector "A". Refer to ELECTRONIC FUEL INJECTION. Install ECM connector on the ECM ADAPTER TOOL (P/N 529 036 166).
PAGE 316
Section 05 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) smr05-015-002_b SECONDARY WINDING CIRCUIT TERMINAL Secondary winding 1 and spark plug terminal RESISTANCE @ 20°C (68°F) 9.5 - 13.5 k If any test failed, replace ignition coil. Ignition Coil Removal Open seat. Remove rear ventilation box. Refer to AIR INTAKE SYSTEM. Disconnect ignition coil connector. sbs2009-011-001_a 1. Apply product here 3.
PAGE 317
Section 05 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) Unscrew spark plug then use the ignition coil to take spark plug out of spark plug hole. smr2009-032-004_a 1. Seal properly seated SPARK PLUGS Spark Plug Removal smr2009-032-003_a Open seat. Remove rear ventilation box. Refer to AIR INTAKE SYSTEM. Disconnect the ignition coil input connector. Remove ignition coil. Refer to IGNITION COIL REMOVAL in this subsection.
PAGE 318
Section 05 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) the spark plug at prescribed intervals, examining the plug face (i.e. the part of the plug projecting into the combustion chamber). Spark Plug Installation Prior to installation, ensure the contact surfaces of the cylinder head and spark plug are free of grime. 1. Using a wire feeler gauge, set electrode gap as specified in the following chart. ENGINE SPARK PLUG TORQUE GAP mm (in) 1503 NGK DCPR8E Hand tighten + 1/4 turn with a socket 0.
PAGE 319
296
PAGE 320
Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) CHARGING SYSTEM SERVICE TOOLS Description Part Number Page ENGINE LEAK TEST KIT................................................................ 295 500 352 ......................................... 302 SERVICE TOOLS – OTHER SUPPLIER Description Part Number ELECTRO SPECIALTIES BATTERY LOAD TESTER....................... 710 EXTECH INDUCTIVE AMMETER .................................................. 380941 Page ..............................
PAGE 321
Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) INSPECTION CHARGING SYSTEM OUTPUT First ensure that battery is in good condition prior to performing the following tests. NOTE: It is good practice to check for fault codes using the B.U.D.S. software as a first troubleshooting step. Refer to MONITORING SYSTEM/FAULT CODES section. Output Voltage Test Using B.U.D.S. Connect to the latest applicable B.U.D.S. software. Refer to COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE section. In B.U.D.S.
PAGE 322
Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) smr2009-034-002_c 1. Fuse box #2 Locate the RED/BLUE wire on terminal A9 of fuse box and clamp the ammeter over it. TEST ENGINE SPEED CURRENT 5500 RPM Approx. 10 A (while suspension does not move) NOTE: Initial current reading will be higher than specified due to the battery drain from the engine start. This is an indication that the charging system is operating normally. Current load will come down as the battery recovers its charge.
PAGE 323
Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) OUTPUT CURRENT TEST TEST ENGINE SPEED CURRENT (DC) 5500 RPM Approx. 10 A (while suspension does not move) NOTE: Initial current reading will be higher than specified due to the battery drain from the engine start. This proves the charging system works. Current load will come down as the battery recovers its charge.
PAGE 324
Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) Voltage Regulator/Rectifier Installation Installation is the reverse of removal procedure. However, pay attention to the following. Lock voltage regulator/rectifier in position. Wiggle it to make sure it is safely locked. NOTE: “Key Off” or parasitic loads may be loads due to installed accessories.
PAGE 325
Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) Use the vacuum/pressure pump in the ENGINE Set vacuum/pressure pump to VACUUM. LEAK TEST KIT (P/N 295 500 352). 295500352 Set vacuum/pressure pump to PRESSURE. smr2009-031-013_a 1. Vacuum selected Squeeze the vacuum/pressure pump handle several times to draw air in through the check valve. Check valve must hold air with 10 in Hg (-34 kPa) of vacuum without leaking. smr2009-031-012_a 1.
PAGE 326
Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) ssi2009-002-003_a 1. Storage bin 3. Disconnect the diagnostic connector from its holder. smr2006-023-003_a Battery Removal WARNING The BLACK negative battery cable must always be disconnected first and reconnected last. Never charge or boost battery while installed in watercraft. 1. Open the boarding platform. ssi2009-002-004_a 1. Disconnect 4. Disconnect the BLACK (-) battery cable.
PAGE 327
Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) 6. Remove the electrical component support from the battery holder. 6.1 Lift and push the top of electrical component support forward to unlock it from battery holder. smr2009-033-009_a 1. Disconnect here ssi2009-002-008_a 1. Electrical component support 6.2 Pull up the components support to unhook from battery holder and move it aside to make room for removing battery. 7.
PAGE 328
Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) NOTICE Should any electrolyte spillage occur, immediately wash off area with a solution of baking soda and water, then rinse thoroughly. Remove retaining screws from battery holder if applicable. smr2009-005-006 Remove battery holder from battery. smr2009-005-004_a 1. Remove screws Unlock the upper tabs then slightly open battery holder.
PAGE 329
Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) WARNING Battery electrolyte is caustic. To prevent spillage, ensure battery cell caps are sufficiently tight to properly seal each cell. Battery Electrolyte Level Check electrolyte level in each cell, add distilled water up to the upper fill level line. NOTICE Add only distilled water in an activated battery.
PAGE 330
Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) ELECTROLYTE TEMPERATURE °C °F 38 100 32 90 27 80 21 70 16 60 10 50 4 40 - 1 30 OPERATION TO PERFORM .012 Add to the reading: .008 .004 CORRECT READING .004 Subtract from the reading: .008 .012 .016 EXAMPLE NO. 1 EXAMPLE NO. 2 TEMPERATURE ABOVE 21°C (70°F): Hydrometer reading: 1.250 Electrolyte temperature: - 1°C (30°F) Subtract .016 Corrected: 1.234 TEMPERATURE ABOVE 21°C (70°F): Hydrometer reading: 1.
PAGE 331
Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) WARNING Failure to remove the sealing tube could result in an explosion. 1 1. Remove caps and fill battery to UPPER LEVEL line with electrolyte (specific gravity: 1.265 at 21°C (70°F)). NOTE: This battery may fill slower than others due to the anti-spill check ball design. 2 A17E0RB 1. Battery electrolyte 2. Upper level line 2 4. Connect a 2 A battery charger for 3 to 5 hours. 3 3 1 2 - + 1 A17E0FB 1. Sealing tube removed 2.
PAGE 332
Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) 1 2 - + 3 For best results, battery should be charged when it is at room temperature. A battery that is cold may not accept current for several hours after charging has begun. Do not charge a frozen battery. If the battery charge is very low, the battery may freeze. If you suspect the battery to be frozen, move it to a heated area for about 2 hours (or more if required) to let it thaw out before charging.
PAGE 333
Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) NOTE: Some chargers have a polarity protection feature which prevents charging unless the charger leads are connected to the correct battery terminals. A completely discharged battery may not have enough voltage to activate this circuitry, even though the leads are connected properly. This will make it appear that the battery will not accept a charge.
PAGE 334
Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) ssi2009-002-005_a 1. BLACK (-) cable 2. RED (+) cable 10. Apply dielectric grease on battery posts. 11. Verify cable routing and attachments. 12. Insert diagnostic connector in its holder. 13. Install remaining removed components.
PAGE 335
312
PAGE 336
Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) STARTING SYSTEM SERVICE TOOLS Description Part Number Page DIAGNOSTIC HARNESS ............................................................... 529 036 179 ......................................... 315 ECM ADAPTER TOOL................................................................... 529 036 166 ................................. 317–319 FLUKE 115 MULTIMETER ............................................................ 529 035 868 ...............
PAGE 337
Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) 3. Discharged battery - Check/recharge. Refer to CHARGING SYSTEM. STARTER TURNS, BUT STARTER DRIVE DOES NOT MESH WITH RING GEAR 4. Defective START/STOP switch - Check. 1. Worn starter drive gear - Replace starter drive. Refer to PTO HOUSING AND MAGNETO. 5. Battery connections - Check/clean/tighten. 6. Poor/bad or corroded ground contacts (engine, starter etc.) - Check/clean/repair. 7. Starter solenoid - Check. 2.
PAGE 338
Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) NOTE: The solenoid may be the cause of a burnt fuse (F4). If fuse is good, proceed with the STARTER QUICK TEST. ENGINE START/STOP SWITCH Measure resistance through switch as per following table. START/STOP SWITCH OPERATION TEST SWITCH POSITION Start/Stop Switch Operation Test Open the front storage cover and remove the storage bin. Lift suspension using the iS up button.
PAGE 339
Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) START/STOP SWITCH INPUT VOLTAGE TEST 8-PIN CONNECTOR OF DIAGNOSTIC HARNESS SWITCH POSITION Released Pressed and held Pins 1 and 2 VOLTAGE Battery voltage Close to 0 Vdc If test succeeded, problem is in the control circuit going to ECM. Perform the START/STOP SWITCH CONTROL CIRCUIT TEST. Start/Stop Switch Power Circuit Test Keep the same test setup as for the START/STOP SWITCH OPERATION TEST. Remove cover from fuse box 2.
PAGE 340
Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) CONTROL CIRCUIT TEST POWER CIRCUIT TEST 8-PIN CONNECTOR OF DIAGNOSTIC HARNESS FUSE BOX 2 Pin 2 Terminal B2 RESISTANCE 8-PIN CONNECTOR OF DIAGNOSTIC HARNESS ECM CONNECTOR B RESISTANCE Close to 0 (continuity) Pin 1 B-D1 Close to 0 (continuity) smr2009-030-033_f smr2009-030-033_g If test succeeded, the circuit is functional. If test failed, repair wiring/connectors. If test succeeded, circuit is functional.
PAGE 341
Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) smr2009-034-006_a If test succeeded, carry out a SOLENOID CON- TROL CIRCUIT TEST. smr2009-034-002_c 1. Fuse box 2 If test failed, carry out a POWER CIRCUIT TEST as follows. Solenoid Input Voltage Test (at Solenoid Connector) Solenoid Power Circuit Test Disconnect solenoid connector. Remove relay in fuse box 2. Set multimeter to . Test continuity of wiring as per following table.
PAGE 342
Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) SOLENOID CONTROL CIRCUIT TEST SOLENOID CONNECTOR ECM CONNECTOR B RESISTANCE Pin B B-L4 Close to 0 (continuity) smr2009-034-008_a If test failed, replace solenoid. If test succeeded, perform the following test. Disconnect battery negative cable. Test solenoid main contacts as per following table. smr2009-034-006_c If test failed, repair or replace wiring/connectors.
PAGE 343
Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) Solenoid Dynamic Test SOLENOID DYNAMIC TEST (ENGINE CRANKING) Ensure battery and starter solenoid are properly connected. Set ECM in engine drowned mode: Depress throttle lever and install a rubber band to hold lever in full throttle position. Set multimeter to Vdc. Install the D.E.S.S. key. Depress the START/STOP button. As engine is cranking, measure the voltage as per following tables.
PAGE 344
Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) smr2009-034-005_a smr2009-034-002_d 1. 2. 3. 4. 5. Fuse box 2 Diagnostic connector Electrical component support Voltage regulator/rectifier connectors Starter solenoid connector 7. Push locking tab and HOLD it. 1. Cables Solenoid Installation Revert removal operations and pay attention to the following. Connect cables to solenoid as shown. smr2009-034-003_a 1. Locking tab 8. Slide solenoid out. smr2009-034-005_b 1. Cable from battery 2.
PAGE 345
Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) NOTE: It may be necessary to pull retaining tab to ensure proper locking. Wiggle solenoid to ensure it is securely locked. Reinstall remaining components. Reconnect battery and test starter solenoid operation. BLACK booster cable: Connect one clip to the negative (-) battery terminal in the vehicle. Momentarily apply the second clip to the negative (-) terminal of the external battery.
PAGE 346
Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) Disconnect starter power cable. Remove starter retaining screws. Starter Gear Installation Installation is the reverse of removal procedure. However, pay particular attention to the following. Use a new circlip. Starter Installation Installation is the reverse of the removal procedure. However, pay particular attention to the following. Ensure starter and engine mating surfaces are free of debris.
PAGE 347
Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) WARNING To prevent electric shock whenever connecting the RED power cable to the starter motor, ensure the BLACK (-) battery cable is disconnected. Apply DIELECTRIC GREASE (P/N 293 550 004) on terminal and nut. Ensure to install rubber protector over starter power cable retaining nut. smr2007-025-008_b 1. Torque power cable retaining nut to 7 N•m (62 lbf•in) and apply dielectric grease 2. Install rubber protector A.
PAGE 348
Section 05 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.) SERVICE TOOLS Description Part Number Page DIAGNOSTIC HARNESS ............................................................... 529 036 179 ......................................... 330 ECM ADAPTER TOOL................................................................... 529 036 166 ......................................... 331 FLUKE 115 MULTIMETER ..........................
PAGE 349
Section 05 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) BEEPER SIGNIFICATION 2 short beeps Indicate a working D.E.S.S. key. Engine starting can take place. 1 long beep Indicates a wrong D.E.S.S. key is being used or something is defective. Engine starting is not allowed. Other beeps can be heard. The ECM features a self-diagnostic mode. Refer to MONITORING SYSTEM AND FAULT CODES for more information. Start B.U.D.S. and logon.
PAGE 350
Section 05 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) smr2009-035-003_c After approximately 10 seconds, the following window will pop up confirming the new key has been saved in the PC computer. smr2009-035-005_a 1. Key to be erased Click on Erase Key button at bottom of B.U.D.S. screen. smr2008-020-008 If programming is complete, write the changes to the ECM. Refer to WRITING CHANGES TO ECM in this subsection. Adding Another Key Remove the key on D.E.S.S. post.
PAGE 351
Section 05 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) If programming is complete, write the changes to the ECM. Refer to WRITING CHANGES TO ECM in this subsection. After the write operation, remove key from D.E.S.S. post. Try the key(s) on the watercraft. Erasing All Keys Click on Erase All Keys button at bottom of screen.
PAGE 352
Section 05 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) sdd2009-001-024_e 1. MODE button smo2009-002-114_c NOTE: Pressing the SET button twice will enable the Rental key setting function. 6. Press the UP or DOWN arrow button to toggle the key setting between 1 and 5. Refer to MAXIMUM WATERCRAFT SET SPEED TABLE. smo2009-002-114_b 5. Press the SET button to enable Learning key mode setting. The display will change to L-Key.
PAGE 353
Section 05 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) MAXIMUM WATERCRAFT SET SPEED TABLE D.E.S.S. KEY TYPE KEY SETTING APPROX. MAX. SPEED 5 58 km/h (36 MPH) 4 55 km/h (34 MPH) 3 50 km/h (31 MPH) 2 47 km/h (29 MPH) 1 42 km/h (26 MPH) 5 74 km/h (46 MPH) 4 69 km/h (43 MPH) 3 63 km/h (39 MPH) 2 58 km/h (36 MPH) 1 51 km/h (32 MPH) Learning key Rental key 529036179 NOTE: Plug only the connector that has been disconnected.
PAGE 354
Section 05 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) smr2009-035-001_b D.E.S.S. Key on Post Probe D.E.S.S. post terminals to check continuity as follows. smr2009-042-005_b 8-PIN CONNECTOR D.E.S.S. POST HARNESS 1. 8-pin connector here Set multimeter to . Probe D.E.S.S. post terminals to check continuity as follows. 8-PIN CONNECTOR D.E.S.S.
PAGE 355
Section 05 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) 8-PIN CONNECTOR ECM ADAPTER RESISTANCE D.E.S.S. POST VEHICLE TOOL @ 20°C (68°F) HARNESS 5 B-E4 4 B-B2 3 B-F2 Close to 0 smr2009-035-009_a Reinstall removed components. If any continuity test failed, check wiring harness between D.E.S.S. connector and ECM connector. If problem persists and all tests have been performed, try a new ECM. Refer to FUEL INJECTION section.
PAGE 356
Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) GAUGE SERVICE TOOLS Description Part Number Page FLUKE 115 MULTIMETER ............................................................ 529 035 868 ................................. 344, 353 SERVICE PRODUCTS Description Part Number Page DIELECTRIC GREASE ................................................................... 293 550 004 .........................
PAGE 357
Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) PROCEDURES INFORMATION CENTER Information Center Overview The information center (cluster) is a multifunction gauge that supplies several real time useful informations to the driver. The information can be displayed in three languages (English, French, or Spanish). Units of measurement can be displayed either in Imperial system or in the metric system. Use B.U.D.S. to change the language and units of measurement settings.
PAGE 358
Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) Gauge Description 9 3 7 8 2 1 4 4 6 10 11 13 12 14 5 smo2009-002-119_a 1. Speedometer 2. Tachometer 3. Digital screen 4. Indicator lights 5. Fuel level 6. VTS position 7. iS position 8. Numerical display 9. Multifunction display 10. Depth sounder indicator 11. Water temperature display 12. Hour meter display 13. iBR position 14.
PAGE 359
Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) The numerical and multifunction displays in the digital screen can be used to display various indications, or for selecting modes of operation and changing settings as explained in their respective subsections. PILOT LAMPS (ON) MESSAGE DISPLAY DESCRIPTION _ CRUISE mode or SLOW SPEED MODE engaged _ iBR system fault _ O.T.A.S.
PAGE 360
Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) A single segment of a bar gauge type indicator is turned on to indicate the relative position of the watercraft bow. pears and a single segment of the bar gauge is turned on to indicate the position of the suspension. Refer to SUSPENSION (iS) for more details. 8) Numerical Display A numerical display is used to provide a variety of indications as selected by the operator: – Engine RPM – Watercraft speed – Lake temperature – Water depth (GTX LTD iS).
PAGE 361
Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) 9) Multifunction Display When the watercraft is being operated, the multifunction displays provides and indication of compass direction, scrolling messages from the fault monitoring system, or a scrolling DOCK MODE ON message when the function is active.
PAGE 362
Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) – KEY MODE – SETTINGS. Press the SET button (or the UP or DOWN arrow button) to enter the desired function. NOTE: The fault codes function is available only when there is an active fault. The settings function is only available when the engine is shut off. Each available function is explained in its applicable subsection. For the DISPLAY function, refer to NUMERICAL DISPLAY in this subsection. For VTS MODE, refer to the IBR AND VTS subsection.
PAGE 363
Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) MESSAGE DISPLAY INFORMATION CALIBRATION CHECKSUM ERROR Cluster programming corrupted MAINTENANCE REQUIRED Watercraft maintenance required SUPERCHARGER MAINTENANCE REQUIRED Maintenance on supercharger required 10) Depth Sounder Indicator GTX Limited iS Model The NUMERICAL DISPLAY can be selected to provide an indication of the lake water depth. The system is capable of indicating water depth under the hull in single increments up to 50 m (164 ft).
PAGE 364
Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) Setting Language and Units of Measurement smo2009-002-114_u IBR POSITION - FORWARD ILLUSTRATED (F) 14) Compass A GPS incorporated in the information center provides the indication in the multifunction display. The cardinal points, intermediate cardinal points, as well as the azimuth the watercraft is travelling are displayed in the multifunction display by default when the watercraft is moving.
PAGE 365
Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) Clearing the Maintenance Reminder Indicators When the watercraft, engine or supercharger is due for maintenance, the maintenance reminder indicator light in the speedometer will come on, and a scrolling MAINTENANCE REQUIRED or SUPERCHARGER MAINTENANCE REQUIRED message will scroll in the digital screen. These maintenance reminders must be cleared using B.U.D.S. 1. Connect vehicle to the latest applicable B.U.D.S.
PAGE 366
Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) Double click the iS button to move the suspension to the up position. If the suspension does not move to the up position, the problem is related to the electrical power system. Refer to POWER DISTRIBUTION subsection. If the suspension moves to the up position, test the 3 A GAUGE fuse (fuse 1) in fuse box 1 (FB1). If the GAUGE fuse tests good, carry out an INFORMATION CENTER INPUT VOLTAGE TEST.
PAGE 367
Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) NO Speed or Compass Indication If there is no speed or compass indication, look for the GPS indicator icon. If the GPS indicator is off, either the GPS cannot uplink with the satellites, or the GPS system in the information center is at fault. If another watercraft nearby displays a good GPS uplink (GPS indicator light on in cluster), replace the information center.
PAGE 368
Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) 4. Carry out an input voltage test at the steering connector (vehicle harness side) as per following table.
PAGE 369
Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) smr2009-027-011_g VOLTAGE TEST AT FUSE CONTACTS smr2009-036-006_a BATTERY VOLTAGE TEST 7. Remove the cover from fuse box 2 (FB2). smr2009-027-011_d TYPICAL - CONTACT COORDINATES (FRONT VIEW FB1) If battery voltage is measured at A12 but not at A11 (with fuse installed), replace the fuse. If no voltage is measured at fuse contact A12, slightly lift one corner of the long bus-bar (12 contacts long). 10.
PAGE 370
Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) Continuity Test of Gauge Power Wire 1. Remove lanyard. 2. Disconnect gauge connector. NOTICE Pull connector lock out sideways. Do not twist the screwdriver. 5. Set multimeter to setting. 6. Test the information center power wire continuity as per following table.
PAGE 371
Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) Remove the RH rear storage bin, refer to BODY subsection. Remove the cover from fuse box 2. smr2009-036-005_a 12 PIN STEERING CONNECTOR PIN-OUT (VEHICLE SIDE) A. Connector alignment keys 2009-027-009_a 1. Fuse box #1 2. Fuse box #2 Remove the ground bus-bar. smr2009-027-011_d TYPICAL - CONTACT COORDINATES (FRONT VIEW FB1) 7. Repair or replace wiring/connectors as required.
PAGE 372
Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) 10 12 1 11 smr2009-036-003_a GAUGE CONNECTOR PIN-OUT smr2009-027-010_f TYPICAL - CONTACT COORDINATES (FRONT VIEW FB2) Repair wiring and connectors as required. Information Center Removal smr2009-036-005_b 1. Open the front cover. 2. Move the steering to its highest position, refer to BODY subsection. 3.
PAGE 373
Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) Information Center Installation smr2009-042-067_a 1. LH side tab 2. Upper retaining tabs 5. Disconnect the gauge connector. NOTICE Pull connector lock out sideways. Do not twist the screwdriver. Installation of the information center is the reverse of the removal procedure. However, pay attention to the following. 1.
PAGE 374
Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) smr2009-036-011_b 1. 2. 3. 4. Read Data button Vehicle page tab Total Hours Supercharger maintenance hours (approximate time left) 4. Add the approximate time left to supercharger maintenance hours to the total hours to calculate the hours at which the next supercharger maintenance is due. Example: 104.08 + 95.52 = 200 The next supercharger maintenance will be due at 200 hours (Total Hours in B.U.D.
PAGE 375
Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) If the MODE switch is pressed, 2 diodes are bypassed. The remaining two diodes in the circuit drop 1.2 Vdc (at pin B). If the SET switch is pressed, 1 diode is bypassed. The remaining three diodes in the circuit drop 1.8 Vdc (at pin B). The gauge senses these voltages through pin 17 of the gauge connector, and interprets them as signals that tell it which switch is activated.
PAGE 376
Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) If one or all of the indicator lights does not come on, refer to MODE/SET AND UP/DOWN ARROW SWITCH TEST USING A MULTIMETER. MODE/SET and UP/DOWN Switch Test Using a Multimeter 1. Remove the gauge support cover, refer to INFORMATION CENTER REMOVAL in this subsection. 2. Disconnect the gauge connector. NOTICE Pull connector lock out. Do not twist the screwdriver. 4. Test the MODE/SET and UP/DOWN arrow switches as per following tables.
PAGE 377
Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) If voltages measured on every switch are as specified (or very close to it), the switches and the wiring harness are good. The fault may be within the gauge. Replace the gauge and carry out a new MODE/SET AND UP/DOWN TEST USING B.U.D.S. to ensure the problem is solved. MODE/SET and UP/DOWN Switch Assembly Replacement 1. Remove steering cover, refer to STEERING AND O.T.A.S. 2. Disconnect connector from switch assembly. smr2009-036-013_a 1.
PAGE 378
Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) DEPTH SOUNDER Depth Sounder Removal GTX Limited iS Models 1. Open the boarding platform. Depth Sounder Troubleshooting DEPTH SOUNDER TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE Depth sounder not connected. Depth sounder not properly installed. Nothing is displayed in the information center 12 Vdc wire or ground wire to depth sounder open. REMEDY Properly connect depth sounder. Make sure depth sounder is properly installed in battery holder base.
PAGE 379
Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) 5. Remove the battery (with holder) from the watercraft, refer to CHARGING SYSTEM. WARNING Always disconnect the battery cables exactly in the specified order, BLACK (-) battery cable first then the RED (+) cable last. 6. Unlock the depth sounder clocking tabs from the battery holder base and pull the depth sounder out from the base. ssi2009-002-013_a 1. Gel pad 2. Depth sounder Depth Sounder Installation ssi2009-002-014_a 1. Locking tabs 2.
PAGE 380
Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) 6. Install the diagnostic connector in its holder. 7. Carry out the following procedure: TESTING DEPTH SOUNDER OPERATION. Testing Depth Sounder Operation 1. Press START/STOP button. 2. Install the D.E.S.S. key on the D.E.S.S. post. 3. Check information center to confirm depth sounder operation. The depth sounder icon is visible in the information center when the depth sounder is detected. ssi2009-002-018_a 1. Depth sounder icon 4.
PAGE 381
358
PAGE 382
Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) STEERING AND O.T.A.S. SERVICE TOOLS Description Part Number D.E.S.S. POST REMOVER ............................................................ ECM ADAPTER TOOL................................................................... FLUKE 115 MULTIMETER ............................................................ STEERING CABLE TOOL ..............................................................
PAGE 383
Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) 6 Nm (53 lbfin) 2.5 Nm (22 lbfin) 16 Nm (142 lbfin) 7 Nm (62 lbfin) 10 Nm (89 lbfin) 5 Nm (44 lbfin) 7 Nm (62 lbfin) 7 Nm (62 lbfin) 0.7 Nm (6 lbfin) 7 Nm (62 lbfin) 0.
PAGE 384
Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) GENERAL ADJUSTMENT During assembly/installation, use torque values and service products as in the exploded view. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete procedure. STEERING ALIGNMENT WARNING Torque wrench tightening specifications must be strictly adhered to. Locking devices (e.g.
PAGE 385
Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) smr2009-042-007_a 1. 2. 3. 4. Steering Steering Steering Steering column column clamp bolts column clamp cable adjusting nut smr2009-037-034_a After adjustment, torque steering column clamp bolts to 6 N•m (53 lbf•in). MONITORING AND IBR TABS 1. O.T.A.S. "LED" NOTICE Verify when the handlebar is turned completely to the left or right side, that there is no interference with jet pump or reverse parts. O.T.A.S.
PAGE 386
Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) smr2009-037-007_a smr2009-037-041_a 1. 2. 3. 4. 5. 6. Nozzle Nozzle arm Hexagonal screw Nozzle link rod Socket screw VTS trim ring Remove nozzle from watercraft. 1. Grip insert NOTE: Verify grip insert for damage. Handlebar Grip Installation When installing the grip insert in the handlebar, ensure that it is properly inserted in the slot at the end of the handlebar tubing.
PAGE 387
Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) smr2009-037-009_a 1. 2. 3. 4. 5. Grip insert Grip Flat washer Screw Cap HANDLEBAR SWITCH COVER (LH OR RH) Handlebar Switch Cover Removal (LH or RH) 1. Insert the end of a small screwdriver in one of cover slots. smr2009-037-012_a RH SIDE SHOWN 1. Front tab Press on the cover to lock it. STEERING COVER Steering Cover Removal 1. Using the D.E.S.S. POST REMOVER (P/N 529 035 943), remove the nut retaining the D.E.S.S. post.
PAGE 388
Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) 3. Unlock steering cover from steering. 3.1 Insert a small tool, such as an Allen key, into a steering cover hole. Press the tool against the retaining tab to unlock it. Repeat for the other side. NOTICE The tool must be inserted perfectly straight to avoid breaking the tab holder. smr2009-037-013_a 1. Allen key 3.2 In both cavities at the back of steering cover, release both inner retaining tabs using a long screwdriver. 3.
PAGE 389
Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) smr2009-037-019_a 1. Harness slots 5.2 Clip the top of the cover. 5.3 Stretch the bottom of the steering cover until the cover edge passes over the inner ribs. smr2009-037-031_a 1. 2. 3. 4. Retaining screw Washer Bushings Throttle lever 4. Clean throttle lever area from dust or any deposits. 5. Apply XPS SYNTHETIC GREASE (P/N 293 550 010) on shaft that receives throttle lever and on the end of the return tab.
PAGE 390
Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) 2. Remove the adjusting nut from steering cable end. 3. At the rear of the vehicle, disconnect ball joint from jet pump nozzle arm. smr2009-037-022_a 1. Steering cable 2. Steering cable nut 6. Remove steering cable nut, half rings and O-ring. smr2009-037-004_a 1. Steering cable bolt 2. Nozzle arm 4. Remove ball joint and jam nut from cable. smr2009-037-023_a PUMP AND IBR SYSTEM REMOVED FOR CLARITY PURPOSE ONLY 1.
PAGE 391
Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) A 2. Remove the gauge support. Refer to GAUGE subsection. 3. Disconnect the four connectors under moving deck. smr2006-031-006_a A. 9 mm ± 1 mm (.354 in ± .039 in) 11.2 Tighten jam nut to 2.5 N•m (22 lbf•in). 11.3 Position the steering cable ball joint to the nozzle as per following illustration. smr2009-042-005_a 1. Disconnect these connectors 4. Remove both screws securing the steering column. smr2009-037-025_a 1. 2. 3. 4.
PAGE 392
Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) 3. On both side of vehicle, remove both pivot bushings (steering column support and steering adjustment handle). smr2009-037-028_a 1. Upper bushing 2. Steering column support 3. Lower bushing Check wear sleeve behind the steering column arm. smr2009-037-033_a 1. Pivot bushing of steering column support 2.
PAGE 393
Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) O.T.A.S. SWITCH O.T.A.S. Switch Dynamic Test Connect B.U.D.S. software. Refer to COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE subsection. Briefly press the START/STOP button to wake up the ECM. Install the D.E.S.S. key on its post. Completely turn steering in one direction and keep it in this position. Look in B.U.D.S. to see if the O.T.A.S. system “LED” turns on. O.T.A.S. Switch Power Wire Continuity Test Check continuity between O.T.
PAGE 394
Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) STEERING POSITION Center position Fully turned MULTIMETER LEAD POSITION Pin "C" and vehicle ground O.T.A.S. MAGNETS RESISTANCE 1935 - 2365 324 - 396 If continuity test is out of specification, try any good magnet and bring it in front of the switch. If continuity test is now good, replace the magnets. If continuity test is still out of specification with a new magnet, check wires, connectors and terminals.
PAGE 395
372
PAGE 396
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) iBR AND VTS SERVICE TOOLS Description Part Number Page DIAGNOSTIC HARNESS ............................................................... 529 036 179 ................................. 384, 386 FLUKE 115 MULTIMETER ............................................................ 529 035 868 ................. 384, 389–390, 404 SERVICE PRODUCTS Description Part Number Page DIELECTRIC GREASE ......................................................
PAGE 397
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) 12 Nm Loctite 243 (106 lbfin) NEW 12 Nm (106 lbfin) 12 Nm (106 lbfin) 24 Nm (18 lbfft) NEW 24 Nm (18 lbfft) NEW 18 Nm (24 lbfft) NEW 12 Nm (106 lbfin) NEW 6 Nm (53 lbfin) Silicone sealant 5150 10 Nm (88 lbfin) NEW 8 Nm (71 lbfin) NEW 4 Nm (35 lbfin) 24 Nm NEW (18 lbfft) NEW 4 Nm (35 lbfin) NEW 24 Nm (18 lbfft) NEW 24 Nm (18 lbfft) Loctite 243 12 Nm (106 lbfin) NEW 8 Nm (71 lbfin) smr2009-038-100_a 3
PAGE 398
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) GENERAL During assembly/installation, use torque values and service products as indicated in the exploded view. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete procedure. WARNING Torque wrench tightening specifications must be strictly adhered to. Locking devices (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pins, etc.
PAGE 399
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) NOTE: The iBR lever must be pulled in at least 25% of its travel (approximately) before the iBR gate starts to move. The first 25% of iBR lever travel has no effect on the iBR gate. Every time the iBR gate moves when commanded by the iBR lever, engine RPM is momentarily reduced to idle speed as the gate moves.
PAGE 400
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) NOTICE An object or tool caught in the iBR gate, nozzle or linkages when using the iBR override function may cause damage to these components. Remove any foreign object that may obstruct the iBR gate travel. Activating iBR Override Function WARNING When using the iBR override function, ensure no personnel stands near the rear of the watercraft. Movement of the iBR gate may squeeze fingers.
PAGE 401
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) WARNING When moving the iBR gate using the iBR override function, ensure nobody stands near the rear of the watercraft. Movement of the gate may squeeze fingers. SYSTEM DESCRIPTION (VTS) smo2009-002-114_hh 7. Press the UP/DOWN arrow button (RH handlebar) to display OVR ON. smo2009-002-114_gg 8. Press the SET button to select the OVR ON function. The gauge will return to its normal display. 9.
PAGE 402
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) smr2009-038-026_a PULL DOWN SLIGHTLY ON iBR GATE sdd2009-001-042_a INFORMATION CENTER — VTS POSITION INDICATOR 1. Bow up 2. Bow down NOTE: Only the segment indicating the relative position of the VTS will be on. The illustration shows all segments on as can be seen during the self test function. 3. Using a machinists ruler, measure the distance between the bottom of the guard and the trailing edge of the iBR gate (example 48 mm (1.89 in)).
PAGE 403
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) 7. Check iBR gate backlash and gate operation after parts replacement and reassembly. FRICTION SLEEVE REPLACEMENT The 4 friction sleeves on the VTS trim ring should be replaced if they show signs of advanced wear (flat spots), or every 100 hours as per the maintenance schedule. smr2009-038-019_a 1. iBR guard 2. Lift up on iBR gate 3. Measurement "B" 5.
PAGE 404
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) IBR GATE LOCKING SLEEVE REPLACEMENT 4. Install new screw(s) with Scotch Grip threadlocker and torque as specified in exploded view. NOTE: The iBR locking sleeve (iBR key) should be replaced if it is cracked, broken, show signs of advance wear, is loose fitting in the "U" arm or on the iBR actuator shaft, or every 100 hours as per the maintenance schedule.
PAGE 405
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) Test With Watercraft on a Waterway 1. Start watercraft and allow engine to run at idle RPM. NOTE: If iBR gate is not in the neutral position before the engine start, it will move to the neutral position on engine start up. 2. Depress the throttle lever slightly, then release it. Forward movement of the watercraft confirms the iBR gate has moved to the forward position. 3. Depress the iBR lever fully.
PAGE 406
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) – Check the 30 A iBR power fuse in FB2 and the 5 A iBR control fuse in FB1 if the gate did not move using the iBR OVERRIDE function. – Connect the watercraft to B.U.D.S. to check for iBR system or CAN bus related fault codes. Carry out service actions as indicated in B.U.D.S. – If a CAN bus communication fault with the iBR module is indicated, or the iBR module is not visible in B.U.D.S.
PAGE 407
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) NOTE: Connect only the test harness 12 and 6 pin connectors to both sides of same steering harness connectors. smo2009-002-124_a Step 1: Push storage bin latches backwards (one each side) Step 2: Lift and tilt forward to remove storage bin 5. Remove the D.E.S.S. key and wait approximately 3 minutes for the electrical system power to shut off. 6.
PAGE 408
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) 6-PIN CONNECTOR OF DIAGNOSTIC HARNESS PIN iBR LEVER RELEASED iBR LEVER PULLED IN VOLTAGE (Vdc) 4 5 5 6 4.9 - 5.1 0.15 - 0.35 1.4 - 1.6 Continuity Test of BRLS Wiring Harness 1. Ensure the steering connector (C01-12 POS and C03-6 POS) pins are clean, make good contact, and properly connected. 2. Remove the steering cover, refer to BODY subsection. 3. Disconnect the BRLS connector.
PAGE 409
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) smr2009-036-004_c 1. Forward ventilation box 2. 12 pin steering connector to disconnect 3. 6 pin steering connector to disconnect smr2009-038-003_b Step 1: Disconnect the 12 pin connector 6. Measure for continuity from the BRLS connector to the 12 pin iBR actuator connector as per following table.
PAGE 410
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) CONTINUITY TEST STEERING CONNECTORS TO iBR CONNECTOR 12 PIN 6 PIN STEERING STEERING 12 PIN iBR Pin 5 (VI/YL) - Pin 7 (VI/YL) Pin 4 (BK) - Pin 9 (BK) Pin 3 (YL/WH) - Pin 5 (YL/WH) - Pin 4 (VI/YL) Pin 4 (VI/YL) - Pin 5 (BK) Pin 6 (BK) - Pin 6 (YL/BK) Pin 8 (YL/BK) RESISTANCE Close to 0 (continuity) 7. Repair or replace wiring/connector as required. BRLS Removal 1. Remove steering cover, refer to STEERING AND O.T.A.S. 2.
PAGE 411
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) smr2009-038-029_a 1. iBR position indication smr2009-038-028_a 1. Read Data 2. Activation page tab 3. iBR tab 6. Select the iBR UP and iBR DOWN s alternately and look for a change in iBR Position (Deg). 2. Press and hold the VTS UP button on the LH handlebar to position the iBR to the full up position and look for the iBR Motor Current indication in B.U.D.S. Also look for a change of iBR Position (Deg) indication.
PAGE 412
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) smr2009-038-030_a 1. iBR motor harness connector 2. iBR motor module connector smr2009-038-033_b Step 1: Note iBR current draw Step 2: Note iBR position indication change iBR ACTUATOR CURRENT DRAW DOWN SELECTION -5 to -15 A UP SELECTION +10 to +20 A 2. Set the FLUKE 115 MULTIMETER (P/N 529 035 868) to Vdc selection. 3. Install insulated clips on the multimeter leads and clip leads to pins in the motor connector on the iBR module.
PAGE 413
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) iBR Actuator Input Voltage Test 1. Disconnect the 3 pin and 12 pin connectors from the iBR actuator. sdd2009-001-019_c 1. VTS UP 2. VTS DOWN NOTE: Electrical power will shut off after approximately 3 minutes. Briefly press the START/STOP button to reactivate the electrical system when required. 5. Press the VTS DOWN button (or the iBR DOWN button on the iBR Activation page in B.U.D.S.), and read the iBR module motor output voltage.
PAGE 414
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) If battery voltage is not measured, check the following: – 30 A iBR fuse in FB2 – Battery voltage at fuse contact D11 of FB2 – Wire continuity pin 2 iBR 3 pin connector to D12 of FB2 – Jumper continuity fuse contact FB2-D11 to FB2-A6 of 12 Vdc bus-bar.
PAGE 415
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) 2. Open the boarding platform and remove the LH storage bin. 3. Disconnect the two aft electrical connectors from the iBR actuator. The forward electrical connector (iBR motor power) does not need to be removed. smr2009-038-002_a 1. Hexagonal screw(s) 2. Locking sleeve 6. Remove the five hexagonal screws securing the iBR actuator to the LH support plate. smr2009-038-003_a 1. iBR actuator 3 pin connector 2. iBR actuator 12 pin connector 4.
PAGE 416
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) iBR GATE iBR Gate Removal (with VTS Trim Ring and Steering Nozzle) 1. Move the iBR gate to the forward position (full up) using the iBR OVERRIDE function. Refer to SYSTEM DESCRIPTION (iBR) in this subsection. NOTICE Do not try to move the iBR gate by hand with the locking sleeve (iBR key) installed or component damage will occur. CAUTION Wait at least 5 minutes for watercraft electrical power to shut off before working in the iBR gate area. 2.
PAGE 417
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) iBR Gate and VTS Trim Ring Disassembly VTS Trim Ring Removal Remove the two hexagonal screws securing the iBR gate to the VTS trim ring. smr2009-038-008_a 1. Trim ring hexagonal screw (LH side) smr2009-038-011_a 1. iBR gate retaining hexagonal screws to remove smr2009-038-009_a Trim Ring Inspection 1. Inspect trim ring and metal spacers for cracks, oblong holes, evidence of wear and deformation. 2.
PAGE 418
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) smr2009-038-022_a TYPICAL - WORN AND DEFORMED PLASTIC BUSHING smr2009-038-025_a TYPICAL - WEAR MARK ON VTS RING AND iBR GATE CONTACT POINTS 1. Wear mark on VTS ring 2. Wear mark on iBR gate NOTE: Wear marks on VTS ring and iBR gate contact points are normal up to 3.175 mm (.125 in). This wear affects nozzle backlash, not iBR gate backlash. 4. Replace parts as required.
PAGE 419
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) 2. Replace as required. Steering Nozzle Lever Inspection 1. Inspect steering nozzle lever, steering arms, and spacers for cracks, elongated holes, evidence of wear, deformation and other damages. 2. Replace as required. smr2009-038-012_c 1. Socket head screws to remove (top and bottom) Steering Nozzle Lever Removal 1. Remove the hexagonal screws securing the steering arms (links) to the steering nozzle lever, top and bottom.
PAGE 420
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) smr2009-038-011_b 1. Small end of nozzle 2. Steering lever 3. Warning label iBR Gate Installation (with VTS Trim Ring and Steering Nozzle) Installation is the reverse of the removal procedure however, pay attention to the following: – Install new plastic bushings (as required). – Install all new hexagonal screws with Scotch Grip threadlocker.
PAGE 421
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) iBR GATE SUPPORT PLATES iBR Gate Support Plate Removal NOTE: The following steps must be carried out when removing the LH or RH support plates. 1. Open the boarding platform. 2. Remove the following listed items, see procedures in this subsection: – iBR gate, VTS trim ring, and the steering nozzle as an assembly – iBR "U" arm. NOTE: Two locking tabs on the inner plate locks it to the outer plate exhaust nozzle. 5.
PAGE 422
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) smr2009-043-006_a smr2009-039-002_a 1. Bailer hoses 3. Loosen the gear clamp and disconnect the water pressure hose from the jet pump. smr2009-039-003_a 1. Water pressure hose 4. Remove the LH storage bin, refer to the BODY subsection. 5. Disconnect the four hoses connected to the fitting plate mounted in the iBR support plate. smr2009-037 TYPICAL 1. Bailer hoses (x2) 2. Intercooler bleed hose 3. Pump water pressure hose 6.
PAGE 423
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) 4. Install 5 new hexagonal screws to secure iBR support plates and torque as per exploded view. 5. Install the fitting plate, refer to FITTING PLATE in this subsection. 6. Install remaining parts in reverse order of removal. Refer to appropriate subsections for procedures, products and torques. FITTING PLATE The fitting plate connects the bailer and pressure hoses inside the hull to the hoses that are connected to the jet pump.
PAGE 424
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) smr2009-043-005_a TYPICAL 1. Hexagonal screw 2. Metal fitting plate retainer smr2009-039-003_a 4. Cut the locking ties and disconnect the 2 bailer hoses from the jet pump venturi. 1. Water pressure hose 6. Pull the fitting plate out of the outer support plate from the jet pump side.
PAGE 425
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) Fitting Plate Installation Models With a Metal Retainer on Fitting Plate 1. Ensure the "O" ring seal is properly installed on the fitting plate and in good condition. 2. Insert the fitting plate through the outer iBR support plate. 3. Install the metal retainer and tighten the hexagonal screw until it is snug. NOTICE Do not attempt to torque the hexagonal screw or screw threads in the plastic fitting plate will be damaged.
PAGE 426
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) 7. Install remaining parts in the reverse order of removal, refer to appropriate procedure in this subsection. Models With Plastic Retaining Tabs on Fitting Plate NOTE: Installation is the same as the model with metal retainer except for the following. 1. Insert the fitting plate through the outer plate. 2. Push the fitting plate in until it bottoms out and the retaining tabs (x2) snap securely into position.
PAGE 427
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) 5. Depress and hold the VTS UP arrow button and ensure the iBR gate moves up to the forward position. NOTE: If the VTS button is released before full travel of the iBR gate, movement of the iBR gate will cease. If the iBR does not respond to VTS button commands (UP or DOWN), carry out the following VTS SWITCH TEST USING B.U.D.S. smr2009-041-051_b 1. VTS UP and VTS Down indicator lights VTS Control Button Test Using B.U.D.S. 1.
PAGE 428
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) fault may be within the gauge. Replace the gauge and carry out a new VTS BUTTON TEST USING B.U.D.S. to ensure the problem is solved. VTS Control Button Removal NOTE: The VTS and iS control s come as a switch assembly which must be replaced as a unit. 1. Remove steering cover, refer to STEERING AND O.T.A.S. 2. Remove connector from switch assembly. vmr2006-020-005 NOTE: Pay attention to multimeter lead position for diode biasing during test.
PAGE 429
Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) smr2009-038-035_b 1. START/STOP switch 2. Wiring routed in slot provided in support 3. VTS/iS switch connector 4. Insert switch assembly in switch support. 5. Install steering cover, refer to STEERING AND O.T.A.S. 6. Carry out an operational test of the VTS and iS systems to ensure proper operation of new switch assembly.
PAGE 430
Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) JET PUMP SERVICE TOOLS Description Part Number IMPELLER REMOVER/INSTALLER ............................................... IMPELLER REMOVER/INSTALLER ............................................... IMPELLER SHAFT BEARING TOOL ............................................. IMPELLER SHAFT PUSHER.......................................................... PRESSURE CAP ............................................................................
PAGE 431
Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) XPS synthetic grease 125 Nm (92 lbfft) Loctite 577 (thread sealant) NEW Jet pump bearing grease Loctite 767 (antiseize lubricant) Jet pump bearing grease (24 ml (.81 U.S. oz)) NEW 125 Nm (92 lbfft) Jet pump bearing grease (4 ml (.14 U.S. oz)) 8 Nm (71 lbfin) Jet pump bearing grease (23 ml (.78 U.S. oz)) 7.5 Nm (66 lbfin) 21 Nm (16 lbfft) NEW 1.
PAGE 432
Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) GENERAL During assembly/installation, use torque values and service products as in the exploded views. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENER and LOCTITE APPLICATION at the beginning of this manual for complete procedure. WARNING Torque wrench tightening specifications must be strictly adhered to. Locking devices (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pins, etc.
PAGE 433
Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 5290218002 smr2009-006-008_a TYPICAL — MEASURING IMPELLER SHAFT RADIAL PLAY 1. Dial gauge 2. Measure close to impeller hub end RADIAL PLAY 0 mm (0 in) Excessive play can come either from worn bearing or damaged jet pump housing bearing surface. LEAK TEST Whenever performing any type of repair on the jet pump, a leak test should be carry out. Proceed as follows: 1. Remove impeller cover. Refer to IMPELLER COVER in this subsection. 2.
PAGE 434
Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) Sacrificial Anode Removal Unscrew sacrificial anode hexagonal screw and remove anode. smr2009-006-002_a TYPICAL 1. Small leak here is acceptable 6. Disconnect pump and remove pressure cap. 7. Reinstall impeller cover. Refer to IMPELLER COVER in this subsection.
PAGE 435
Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 3. Loosen gear clamp and remove the hose from the water pressure outlet fitting on the jet pump housing. Jet Pump Housing Inspection and Cleaning 1. Visually inspect jet pump housing. Pay attention to the stator. Ensure the assembly is clean and free of any debris and defects. 2. Blow low pressure compressed air through the pressure outlet fitting and make sure it is clear. 3. Ensure the neoprene seal is in good condition. Replace as required.
PAGE 436
Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 2. Install the pump on a spare ride plate, the mounting screws should be tight, but it is not required to torque them. 3. Torque hexagonal screws retaining the adapters to the jet pump housing as specified in the exploded view. 4. Remove the jet pump housing from the spare ride plate and install it on the watercraft ride plate. Jet Pump Housing Installation smr2009-039-006_a 1.
PAGE 437
Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) VENTURI Venturi Removal Jet Pump Housing installed 1. Remove the iBR gate and VTS trim ring as an assembly. Refer to iBR AND VTS subsection. 2. Cut locking ties and remove the 2 bailer hoses from the venturi. 3. Refer to JET PUMP HOUSING REMOVED to continue procedure. Jet Pump Housing Removed 1. Remove the three hexagonal screws retaining the venturi to the jet pump housing. F18J0LA TYPICAL 3.
PAGE 438
Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 5. Remove both O-rings. Check impeller boot and O-rings condition on impeller. Replace as required. smr2009-006-004_a smr2009-006-003_a TYPICAL 1. O-rings 1. Impeller boot 2. Impeller O-ring 3. Pump housing O-ring Impeller Cover Inspection Impeller Cover Installation Check for presence of water in cover and bearing area. If water is found, replace seals on impeller side. Also replace O-rings and/or impeller cover. 1.
PAGE 439
Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 3. Install impeller cover by aligning the cover index mark with the pump top fin as shown. 1 sdd2009-001-114_c 1. Align mark with top fin NOTE: Cover can only be installed in one position as screw holes are not located symmetrically. 4. Secure cover with NEW self-locking screws. NOTE: Push cover against pump housing while alternately tightening screws. Make sure O-rings are positioned correctly and they are not damaged when pushing the cover.
PAGE 440
Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 529035820 TOOL FOR 130 AND 155 ENGINES smr2009-006-005_a TYPICAL 1. Flat side 2. Apply LOCTITE 767 (ANTISEIZE LUBRICANT) (P/N 293 800 070) on threads of impeller shaft. 529035956 TOOL FOR 215 AND 255 ENGINES 6. Unscrew the impeller counterclockwise. NOTE: It may be necessary to heat the impeller to ease removal. NOTICE Never use an impact wrench to loosen impeller. smr2009-006-002_b TYPICAL 1. Antiseize lubricant 3.
PAGE 441
Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) WEAR RING Wear Ring Inspection Check wear ring for: – Deep scratches – Irregular surface – Any apparent damage. Check IMPELLER/WEAR RING CLEARANCE, see procedure at the beginning of this subsection. Wear Ring Removal smr2009-006-007 TYPICAL 5. Mount in the impeller splines the appropriate impeller remover/installer tool according to engine type.
PAGE 442
Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 2. Mount in a vise the appropriate impeller remover/installer tool according to engine type. MODEL 130 and 155 engines 1 215 and 255 engines TOOL IMPELLER REMOVER/INSTALLER (P/N 529 035 820) IMPELLER REMOVER/INSTALLER (P/N 529 035 956) 1 2 F01J1DA 1. Rounded edge 2. Press wear ring 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.
PAGE 443
Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 8. Use the IMPELLER SHAFT PUSHER (P/N 529 035 955) to press impeller shaft out of pump housing. NOTE: Bearing will come out with the impeller shaft. smr2009-006-009_a TYPICAL 5. Remove impeller shaft nut. 529035955_a smr2009-006-010_a smr2009-006-003_b TYPICAL TYPICAL 1. Nut 6. Remove impeller as described in this subsection. 7. From the impeller side, remove circlip, seals, spacer and O-ring. smr2009-006-011 TYPICAL 9.
PAGE 444
Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) smr2009-006-012_a smr2009-006-006_a TYPICAL 1. Impeller shaft and bearing 2. Bearing tool on INNER race TYPICAL Impeller Shaft Nut Removal if Impeller has Loosened 1. Turn pump upside down and mount the flat sides of impeller shaft in a vise. 4. Turn pump upside down and retry unscrewing impeller shaft nut. smr2009-006-009_a TYPICAL smr2009-006-005_a TYPICAL 1. Flat side 2.
PAGE 445
Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) smr2009-006-019_a TYPICAL 1. Threads 2. Seal lip contact surface 3. Threads Inspect ball bearing for corrosion. smr2009-006-014_a Impeller Shaft and Bearing Installation Bearing Installation The installation is essentially the reverse of the removal procedure. However, pay attention to the following. 1. Using the IMPELLER SHAFT BEARING TOOL (P/N 529 036 168) on the bearing inner race, press the bearing on the impeller shaft. 2.
PAGE 446
Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 1 F18J12A F18J14B TYPICAL 7. Press a NEW double lip seal using the SEAL/BEARING PUSHER (P/N 529 035 819) until seal bottoms. Make sure seal lip are facing upwards. TYPICAL 1. Seal/bearing pusher 8. Install spacer and then the other seal (thin). Ensure seal lip is facing up. smr2009-006-016_a smr2009-006-015_a 1. Seal lip facing up 1. Seal lip up 1 9. Install circlip. smr2006-027-007_c F18J13A 1. Seal lip facing up TYPICAL 1.
PAGE 447
Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) smr2009-006-017_a TYPICAL 1. O-rings F18J0QA 12. Before installing any other parts, pressurize jet pump to insure proper seal installation. Refer to LEAK TEST in this subsection. 13. Install impeller. Refer to IMPELLER in this subsection. 14. Mount in a vise the appropriate impeller remover/installer tool according to engine type. MODEL 130 and 155 engines 215 and 255 engines TYPICAL 16.
PAGE 448
Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 19. Install the impeller cover. Refer to IMPELLER COVER in this subsection.
PAGE 449
426
PAGE 450
Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) DRIVE SHAFT SERVICE TOOLS Description Part Number Page DRIVE SHAFT ADAPTER............................................................... 529 035 985 ................................. 431, 433 DRIVE SHAFT WRENCH ............................................................... 529 036 167 ................................. 431, 434 SERVICE PRODUCTS Description Part Number Page LOCTITE 577 (THREAD SEALANT) ...................................
PAGE 451
Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) NEW Engine oil Loctite 577 (thread sealant) XPS synthetic grease 8 turns + 125 Nm (92 lbfft) LH threads smr2009-040-001_a 428 smr2009-040
PAGE 452
Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) GENERAL The jet pump must be removed to replace any component of the drive system. Refer to JET PUMP for removal procedure. During assembly/installation, use torque values and service products as specified in the exploded view. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete procedure.
PAGE 453
Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) PROCEDURES DRIVE SHAFT Drive Shaft Removal To prevent oil spillage when pulling out drive shaft, carry out the following: – Start engine. – Bring engine to 4000 RPM for 10 seconds. – Stop engine at this RPM. NOTE: If engine cannot be started, remove oil from the PTO area by following the procedure detailed in PTO HOUSING REMOVAL of the PTO HOUSING AND MAGNETO subsection. 1.
PAGE 454
Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) smr2009-040-003_a 1. Sealing ring smr2009-007-002_a TYPICAL 1. Drive shaft wrench 12. From rear of watercraft, install the DRIVE SHAFT ADAPTER (P/N 529 035 985) on drive shaft end. smr2009-007-001_a TYPICAL 1. Rubber protector 10. Remove all spark plugs from engine. Refer to IGNITION SYSTEM. NOTE: Spark plug removal will ease engine rotation for drive shaft removal. 11.
PAGE 455
Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) smr2009-007-006_a smr2009-007-003_b TYPICAL - CLOCKWISE TO UNSCREW CAUTION Ensure to unscrew clockwise on LH threads (opposite of usual threads). 14. Place rags under PTO housing to prevent oil spillage. If spillage occurs, clean immediately with the PULLEY FLANGE CLEANER (P/N 413 711 809) to prevent oil stains. 15. Pull out drive shaft. NOTE: A slight jerk to the rear may be required to remove the drive shaft from the PTO seal. 16.
PAGE 456
Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) 2. Remove the damper at the end of drive shaft and replace it with a NEW one. smr2009-007-010_a LOCTITE 577 APPLICATION A. First 5 threads B. 3 mm (1/8 in) smr2006-028-004_a 1. Damper 3. Wipe clean the sealing ring and the carbon seal contact surfaces. 4. Properly align sealing ring with carbon seal. 8. From rear of watercraft, engage drive shaft through the drive shaft boot. 9.
PAGE 457
Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) smr2009-007-002_a smr2009-007-003_a TYPICAL 1. Drive shaft adapter NOTE: Make sure all spark plugs are removed from engine. 12. Removing spark plugs helps to engage threads more easily thus preventing cross-threading the sealing ring. Carefully rotate drive shaft counterclockwise (LH threads) to engage threads in sealing ring. Be careful not to engage cross-thread. TYPICAL 1. Drive shaft wrench 15.
PAGE 458
Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) 23. Run watercraft then ensure there is no oil leak in PTO seal area. 24. Properly reinstall the deck extension, moving deck and ventilation box. Refer to BODY subsection. SEALING RING Sealing Ring Removal 1. Remove drive shaft. Refer to DRIVE SHAFT in this subsection. 2. Carefully pry out sealing ring from PTO seal working alternately from side to side while retaining PTO seal. smr2009-007-005_a 1.
PAGE 459
Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) smr2009-007-008_a WRONG 1.
PAGE 460
Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) SUSPENSION (iS) SERVICE TOOLS Description Part Number Page FLUKE 115 MULTIMETER ............................................................ 529 035 868 ................. 447, 449–450, 452 MAGNETO HARNESS 6 PINS....................................................... 295 000 136 ......................................... 447 SUPERTITANIUM DRILL BIT 3/16"................................................ 529 031 800 ....................................
PAGE 461
Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) FRONT 48 Nm NEW (35 lbfft) 10 Nm NEW (89 lbfin) NEW 12 Nm NEW (106 lbfin) 25 Nm (18 lbfft) NEW 25 Nm NEW (18 lbfft) NEW 12 Nm (106 lbfin) NEW 10 Nm NEW (89 lbfin) 10 Nm (89 lbfin) NEW NEW 25 Nm (18 lbfft) NEW 75 Nm (55 lbfft) 6 Nm (53 lbfin) NEW 25 Nm (18 lbfin) NEW 25 Nm (18 lbfft) 75 Nm (55 lbfft) NEW 85 Nm (18 lbfft) 10 Nm (89 lbfin) NEW NEW 4 Nm (35 lbfin) NEW 25 Nm (18 lbfft) NEW 25 Nm (18 lbfft)
PAGE 462
Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) REAR NEW 12 Nm (106 lbfin) NEW 25 Nm (18 lbfft) NEW 25 Nm (18 lbfft) NEW 12 Nm (106 lbfin) NEW 10 Nm (89 lbfin) NEW 25 Nm (18 lbfft) 25 Nm (18 lbfft) 25 Nm NEW (18 lbfft) 10 Nm NEW (89 lbfin) smr2009-041-002_a smr2009-041 439
PAGE 463
Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) GENERAL NOTE: For a complete overview of the vehicle electrical system, refer to POWER DISTRIBUTION subsection. It is highly recommended to disconnect the battery when replacing any electric or electronic component. WARNING Always disconnect battery exactly in the specified order, BLACK (-) cable first, RED (+) cable last. Always reconnect BLACK (-) cable last. Do not place tools on battery.
PAGE 464
Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) The suspension can be set to the AUTO or MANUAL mode. In AUTO mode, suspension height is factory preset and the iS module constantly monitors the stroke of the suspension and it automatically readjusts suspension height for changing water conditions and passenger load. In MANUAL mode, the driver may choose to set the suspension higher or lower by using the UP and DOWN s on the handlebar.
PAGE 465
Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) 5. Leak on hydraulic circuit. - Repair or replace defective part(s). 6. Faulty suspension position sensor. - Test sensor and replace as required. SUSPENSION BOTTOMS HARD. 1. Spring(s) out of specification or broken. - Replace the defective spring(s). 7. Actuator is damaged. - Replace the actuator. 2. Shock absorber is damaged. - Check shock absorber resistance. Replace shock absorber. 8. Hydraulic pump cannot build enough pressure.
PAGE 466
Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) DIAGNOSTIC FLOW CHARTS iS Electrical Troubleshooting Suspension does not move NO Can you see iS display? Check CAN bus YES Check for hydraulic or mechanical problem, see is hydraulic/mechanical troubleshooting flow chart Can you hear the hydraulic pump running when pressing iS button(s) on steering? YES NO Suspension moves? YES NO Install the latest version of B.U.D.S.
PAGE 467
Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) iS Hydraulic/Mechanical Troubleshooting Suspension does not move Can you hear the hydraulic pump running when pressing iS button(s) on steering? Check for an electrical problem, see iS electrical troubleshooting flow chart NO YES NO Level vehicle Is there something stuck under moving deck? YES Remove object(s) NO Suspension moves? NO NO Is vehicle level? YES YES YES Check hydraulic fluid level System is OK Is fluid level good? Susp
PAGE 468
Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) PROCEDURES SHOCK ABSORBER Shock Absorber Removal 1. Remove the moving deck. Refer to BODY subsection. 2. Remove tapes securing central bellows to mounting plate. 3. Move down central bellows to reach shock holder screws. 4. Remove and discard the four screws securing the shock holder. NOTE: Using lateral supports, raise front arm to reach front screws. smr2009-041-005_a 1. Shock absorber lower bolt (discard) 2. Shock holder 7.
PAGE 469
Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) 2. The shock should extend unassisted. Rod must come out at a steady speed. If any problem is detected, replace the shock absorber. Shock Absorber Installation The installation is the reverse of the removal procedure. However, pay attention to the following. Secure the shock absorber using NEW bolts. Tighten bolts to 75 N•m (55 lbf•ft). Install NEW shock holder screws and tighten them to 25 N•m (18 lbf•ft). smr2009-041-090_a 1.
PAGE 470
Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) Suspension Position Sensor Input Voltage Test At Sensor Connector SUSPENSION POSITION SENSOR CONNECTOR Pin 1 Pin 2 VOLTAGE 5 Vdc 295000136 5. Using the FLUKE 115 MULTIMETER (P/N 529 035 868), check voltage as per the following table. Using the 6-pin Magneto Harness Tool 1. Connect B.U.D.S. Refer to COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE subsection. 2. Using B.U.D.S., raise suspension in fully up position.
PAGE 471
Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) 529035868 smr2009-041-011_a SUSPENSION POSITION (% in B.U.D.S.) iS MODULE (6-pin connector) RESISTANCE All positions 4 6 1803 - 2203 100% 5 6 1957 - 2391 100% 4 5 1361 - 1663 88% 5 6 1904 - 2327 88% 4 5 1410 - 1724 75% 5 6 1871 - 2287 75% 4 5 1448 - 1770 53% 5 6 1799 - 2199 53% 4 5 1516 - 1852 35% 5 6 1752 - 2142 1. Sensor connector 2. Hydraulic pump reservoir 4.
PAGE 472
Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) NOTE: When reassembling parts, index sensor lever shaft with sensor inner slot. The sensor lever must be positioned to 180° with the sensor electrical connector. smr2009-041-055_a Repeat the test using a test light. TEST LIGHT POSITION Pin 1 of iS Module 6-pin connector smr2009-041-014_a 1. Lever 2. Lever shaft 3. Sensor 8. Reinstall and connect the sensor in vehicle.
PAGE 473
Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) iS Module Input Voltage Test (Battery Power) Continuity Test of iS Module Battery Power Wire Using the FLUKE 115 MULTIMETER (P/N 529 035 868), perform the following test. iS MODULE 3-PIN CONNECTOR BATTERY VOLTAGE (VDC) Pin 1 Positive post Battery voltage Pin 2 Negative post Battery voltage iS MODULE 3-PIN CONNECTOR FUSE BOX (FB1) Pin 2 A4 RESISTANCE .
PAGE 474
Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) smr2009-041-037_a smr2009-041-034_a 1. Suspension position sensor connector 3. Detach the retaining latch. 1. iS module input voltage connector NOTE: The locking tab of input voltage connector is located underneath. 6. Remove the iS module from vehicle. iS Module Installation The installation is the reverse of the removal procedure. iS BUTTON iS Button Overview smr2009-041-035_a 1. Retaining latch 4. Disconnect the hydraulic motor connector.
PAGE 475
Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) transmit it through the CAN bus. The module will react to the command, carry out the function, and transmit the result back through the CAN bus. The gauge will use the signals from the switches and the transmitted information from the other modules, convert them to an indication, and cancel the command signal it sent out once the function has been carried out. Command signals from the iS button are translate and sent to the iS module.
PAGE 476
Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) Hydraulic Pump Fluid Level Verification iS SWITCH TEST SWITCH POSITION Switch released UP depressed DOWN depressed MULTIMETER LEAD/GAUGE CONNECTOR VOLTAGE RED lead/Pin 14 BLACK lead/Pin 15 Approx. 2 Vdc BLACK lead/Pin 14 Red lead/Pin 15 OL RED lead/Pin 14 BLACK lead/Pin 15 Approx. 1.1 Vdc BLACK lead/Pin 14 RED lead/Pin 15 OL RED lead/Pin 14 BLACK lead/Pin 15 Approx. 1.
PAGE 477
Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) Reinstall reservoir plug and tighten it to 1 N•m (9 lbf•in). If the current draw is excessive, replace the hydraulic pump. Hydraulic Pump Operation Test Hydraulic Pump Removal (as a Unit with Actuator) Connect a jumper from the positive (30 A fused jumper) and negative side of the battery to the hydraulic pump connector (2-pins connector). The hydraulic pump should activate and suspension should go up or down.
PAGE 478
Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) smr2009-041-028_a 1. Actuator holder screws 7. Remove the suspension position sensor to avoid damaging it. 8. Remove screws securing both rear ends of front suspension arm to suspension base. smr2009-041-045_a VIEW FROM THE REAR OF VEHICLE 1. Secure hydraulic hose to hydraulic pump 2. Secure hydraulic hose, fuel hose and vehicle wiring harness smr2009-041-046_a VIEW FROM THE FRONT OF VEHICLE 1.
PAGE 479
Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) smr2009-041-016_a 1. Cut this locking tie 2. Hydraulic hose 6. Unscrew the retaining clamp completely and remove it. smr2009-041-019_a 1. Socket screw 2. Hydraulic hose lock 9. Remove hose from pump and plug hose to avoid oil spillage. 10. Place your finger on pump opening and remove pump from vehicle. NOTE: Wipe any oil spillage. Hydraulic Pump Installation (Without Actuator) smr2009-041-017_a 1.
PAGE 480
Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) 4. Secure hydraulic pump to suspension base. 4.1 Install pump retaining screw and tighten it to 10 N•m (89 lbf•in). 4.2 Install retaining clamp and tighten it to 2 N•m (18 lbf•in). 5. Secure hose to reservoir with a new locking tie. 6. Route pump harness and secure it with new locking ties. 7. Connect the hydraulic pump connector to iS module. 8.
PAGE 481
Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) smr2009-041-052_a 1. Hose fully inserted in lock slot 2. Position hydraulic hose in lock hook Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on threads of lock screw. Tighten screw to 8 N•m (71 lbf•in). Install the hydraulic pump in vehicle. Make sure to route the hydraulic hose properly. See HY- DRAULIC PUMP INSTALLATION (AS A UNIT WITH ACTUATOR) in this subsection.
PAGE 482
Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) smr2009-041-026_a smr2009-041-024_a 1. Lateral support screw 2. Decouple lateral support from suspension shaft. 3. Using the SUPERTITANIUM DRILL BIT 3/16" (P/N 529 031 800), remove all rivets (12) securing the lateral bellows ring to body. 529031800 1. Ring pin 2. Bellows alignment hole 3. Body hole Install new rivets.
PAGE 483
Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) 2. Using a marker, trace the shape of suspension base at the bottom of the hull to reposition it at the same place. 3. Remove and discard suspension base screws. smr2009-041-024_a RH SIDE SHOWN 1. Lateral support screw 4. Decouple lateral supports from suspension arm shaft. 5. Refer to HYDRAULIC PUMP REMOVAL (AS A UNIT WITH ACTUATOR) and remove the pump from the vehicle. 6. Remove screws securing both shaft supports to suspension base. 7.
PAGE 484
Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) Suspension Base Installation The installation is the reverse of the removal procedure. However, pay attention to the following. 1. Install the suspension base. 1.1 Position the base in accordance with the reference marks previously drawn at the bottom of the hull. NOTE: If no marks are available, see SUS- 4.2 If required, move suspension base until both distances are equal. 4.3 Tighten suspension base rear screws to 25 N•m (18 lbf•ft).
PAGE 485
Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) NOTE: If the upper arm shaft or one of its arm shaft support has been removed or loosened, refer to SUSPENSION ARM SHAFTS for proper installation procedure. 2. Tighten screws to 25 N•m (18 lbf•ft). 3. Carefully lower and secure the rear suspension arm to the fixed deck. 3.1 Position the rear suspension arm brackets in accordance with the reference marks previously draw on fixed deck. NOTICE If no mark was traced, refer to smr2009-041-073_a 1.
PAGE 486
Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) 5.3 Reposition rear suspension arm brackets on fixed deck until positioning of moving deck is satisfactory. 6. Secure the rear suspension arm to the fixed deck. 6.1 Install NEW screws to secure rear suspension arm brackets. 6.2 Remove and replace screws installed during alignment. 6.3 Tighten screws to 25 N•m (18 lbf•ft). 6. InstallNEW support screws and tighten them to 25 N•m (18 lbf•ft). 7. Secure both supports to shaft using NEW socket screws.
PAGE 487
Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) smr2009-041-078_a 1. Support pin 2. Holder hole 4. Tighten the LH support screws to 25 N•m (18 lbf•ft). 5. Apply a force on the RH support to move it on the left side. NOTE: A bar clamp can be used to compress both supports together. NOTICE Make sure arm shaft is fully inserted, it must lean against the arm shaft support. smr2009-041-067_a smr2009-041-079_a 1. Bar clamp 2. New socket screws Removal of Rear Suspension Arm Lower Shaft 1.
PAGE 488
Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) 5. Remove and discard socket screws securing rear brackets to arm shaft ends. smr2009-041-071_a 1. Bad installation 2. Good installation smr2009-041-069_a 1. Socket screw 2. LH rear bracket 6. Press one rear bracket against the suspension arm bushing and remove the circlip. Repeat for the other side. 3. Lower the rear suspension arm on fixed deck. 4. Tighten NEW socket screws to 10 N•m (89 lbf•in). 5. Refer to REAR ARM for reinstallation.
PAGE 489
466
PAGE 490
Section 07 BODY AND HULL Subsection 02 (BODY) BODY SERVICE TOOLS Description Part Number Page SUPERTITANIUM DRILL BIT 3/16"................................................ 529 031 800 ......................................... 485 SERVICE PRODUCTS Description Part Number Page BRP PLASTIC & VINYL CLEANER ................................................ 413 711 200 ................................. 481–482 LOCTITE 243 (BLUE).....................................................................
PAGE 491
Section 07 BODY AND HULL Subsection 02 (BODY) 2. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on threads of shock absorber body. 3. Tighten manually the attachment on gas shock. 4. Install the bellows and secure it using a locking tie. 5. Install the gas shock on cover. NOTE: The corrugated section of bellows must pointed downward. 6. Align boarding platform hinge openings with flat sides of fixed hinges. 7. Push in the boarding platform to assemble hinges. 8.
PAGE 492
Section 07 BODY AND HULL Subsection 02 (BODY) Deck Extension Installation 1. Position the deck extension. 2. Install screws retaining deck extension and air inlet. 3. Tighten these screws to 1.5 N•m (13 lbf•in). NOTICE Do not tighten screws over this recommended torque. Otherwise, the rubber grommet could turns and screw will be hard to remove. smr2009-016-001_a 1. Vent box 2. Retaining latches 3. Remove screws securing air inlet to deck extension. 4.
PAGE 493
Section 07 BODY AND HULL Subsection 02 (BODY) Tilting Moving Deck for Servicing Watercraft 5. Lift the rear suspension arm against seat handle and attach it with locking tie or strap. 1. Remove the BOARDING PLATFORM, see procedure in this subsection. smr2009-042-012_a ssi2009-002-002_a 1. Seat handle 2. Ski/wakeboard attachment 3. Locking tie 1. Boarding platform 2. Remove bolts securing both rear suspension arm covers. 6.
PAGE 494
Section 07 BODY AND HULL Subsection 02 (BODY) Removing the Moving Deck for Servicing Watercraft 1. Open the front storage cover and remove the front basket. 2. Remove the BOARDING PLATFORM, see procedure in this subsection. smr2009-042-066_a 1. Hoist 2. Lifting strap ssi2009-002-002_a 1. Boarding platform 3. Remove bolts securing both rear suspension arm covers. smr2009-042-023_a 1. Use this rivet as reference point A.
PAGE 495
Section 07 BODY AND HULL Subsection 02 (BODY) smr2009-042-011_a 1. Rear suspension arm 2. Reinstallation marks 3. Screws (discard) 6. Lift and attach the rear suspension arm against seat handle. smr2009-042-014_a RH SIDE SHOWN 1. Front carpet (discard) 2. Protective cap 8.2 Remove and discard screws securing moving deck to lateral supports. smr2009-042-015_a smr2009-042-012_a 1. Seat handle 2. Ski/wakeboard attachment 3. Locking tie 7.
PAGE 496
Section 07 BODY AND HULL Subsection 02 (BODY) 15. Install lifting straps. 15.1 Using both mooring cleats under steering, install two lifting straps. smr2009-042-005_a 1. Disconnect these connectors 14. Detach steering cable from steering column. 14.1 Remove bolt securing ball joint to steering column. smr2009-042-079_a 1. Front lifting strap hooks into steering mooring cleats 15.2 Install another lifting strap on seat handle. 16. Attach all lifting straps to an lifting device to lift the moving deck.
PAGE 497
Section 07 BODY AND HULL Subsection 02 (BODY) smr2009-042-074_a 1. Steering cable 2. Steering column 3. Install steering cable clamp and its bolts. Do not tighten bolts yet. smr2009-042-015_a RH SIDE SHOWN 1. Retaining screws (new) 6. Remove pieces of wood located under lateral supports and reposition one under moving deck front area. smr2009-042-007_a 1. 2. 3. 4. Steering Steering Steering Steering column column clamp bolts column clamp cable adjusting nut 4.
PAGE 498
Section 07 BODY AND HULL Subsection 02 (BODY) 10. Install two homemade alignment pins on suspension mounting plate. 10.1 Take two M8 x 50 bolts and cut their heads. 10.2 Make into a round shape the cut ends. 16. Carefully lower and secure the rear suspension arm to the fixed deck. 16.1 Position the rear suspension arm brackets in accordance with the reference marks previously draw on fixed deck.
PAGE 499
Section 07 BODY AND HULL Subsection 02 (BODY) STORAGE COMPARTMENT COVER smr2009-042-029_a 1. Cover hinge key 2. Front body module slot smr2009-042-024_a 1. Storage compartment cover Storage Compartment Cover Removal 1. Open cover. 2. Cut locking tie retaining the bellows of gas shock. Storage Compartment Cover Installation The installation is the reverse of the removal procedure. However, pay attention to the following. Remove gas shock attachment from cover.
PAGE 500
Section 07 BODY AND HULL Subsection 02 (BODY) 3. Install the new mirror and tighten wing nut. 3.1 The mirror adjustment is correct when the spring length is between 10 mm and 12 mm (13/32 in and 15/32 in). smr2009-042-031_a 1. Lower attachment in its cavity Close cover to lock the bottom of the gas shock. MIRRORS Mirror Replacement 1. Remove the mirror trim. 1.1 Using a small screwdriver, unlock both front tabs securing the front of mirror trim. 1.2 Tilt the trim forward and remove it.
PAGE 501
Section 07 BODY AND HULL Subsection 02 (BODY) GLOVE BOX COVER FRONT GRILLE smr2009-042-055_a 1. Glove box cover Glove Box Cover Removal 1. Move steering in its upper position. 2. Open glove box cover until cover hinges are aligned with front body module openings. smr2009-042-056_a LOCATED UNDER STORAGE COMPARTMENT COVER 1. Front grille Front Grille Removal 1. Remove the STORAGE COMPARTMENT COVER, see procedure in this subsection. 2. Press on both tabs securing front grille to front body module.
PAGE 502
Section 07 BODY AND HULL Subsection 02 (BODY) BODY COVER ssi2009-003-004_a LH SIDE SHOWN 1. Remove this plastic push-in clip smr2009-042-057_a 1. Body covers Body Cover Removal 6. Open seat and using a 3/16" drill bit, drill the rivets securing the seat trims. 1. Remove the STORAGE COMPARTMENT COVER, see procedure in this subsection. 2. Remove the FRONT GRILLE, see procedure in this subsection. 3. Remove the plastic push-in clip securing the upper trim. ssi2009-003-008_b LH SIDE SHOWN 1.
PAGE 503
Section 07 BODY AND HULL Subsection 02 (BODY) – Storage bin – Glove box cover – Body covers and front grille – Steering and steering lock – Speed-Tie unit (if equipped). 2. Remove both screws and washers located between seat and glove box. smr2009-042-059_a RH SIDE SHOWN 1. Center retaining tab 10. Unlock the four retaining tabs securing the front of body cover. smr2009-042-061_a 1. Rear retaining screws 3. On each side of front body module, remove both retaining screws.
PAGE 504
Section 07 BODY AND HULL Subsection 02 (BODY) smr2009-042-064_a 1. Front body module retaining tabs 6. Remove front body module. Front Body Module Installation The installation is the reverse of the removal procedure. SEAT Seat Removal 1. Open seat. 2. Attach the seat to support it during removal. 3. Remove Allen socket screw retaining the lateral arm to moving deck (one each side). smr2009-042-027_a 1. Central arm 2. Retaining bolts 5. Remove seat from vehicle.
PAGE 505
Section 07 BODY AND HULL Subsection 02 (BODY) For dirt build-up, use BRP PLASTIC & VINYL CLEANER (P/N 413 711 200), Vinyl Finish Vinyl Cleaner or an equivalent. Let soak for approximately 10 minutes, then gently scrub with a soft bristle brush. For specific stain removal, refer to your cleaning and care card. Do not use any silicone-based protectants. They will extract the plasticizers, leaving the vinyl hard and brittle, and eventually cracking will occur.
PAGE 506
Section 07 BODY AND HULL Subsection 02 (BODY) smr2009-042-045_a smr2009-042-048_a 1. Front bumper 2. Protective caps 1. Rear bumper 2. Protective cap 2. Remove side screws securing front bumper to body. 2. Remove side screws securing rear bumper to body. smr2009-042-046_a smr2009-042-049_a FROM RH SIDE OF VEHICLE 1. Front bumper 2. Retaining screw 3. Side bumper FROM RH SIDE OF VEHICLE 1. Rear bumper 2. Retaining screw 3. Side bumper 3. Remove screws located under front bumper. 3.
PAGE 507
Section 07 BODY AND HULL Subsection 02 (BODY) smr2009-042-053_a smr2009-042-051_a 1. Protective skin 1. Trace a line here 3. Pull the top of bumper to unclip it from body. NOTE: A heat gun can be used to soften side bumper. 4. Insert bumper over body lip. 4.1 Insert lower section first. 4.2 Insert upper section last. smr2009-042-052_b smr2009-042-052_a Bumper Installation Front and Rear Bumper The installation is the reverse of the removal procedure. Tighten bumper screws to 5 N•m (44 lbf•in).
PAGE 508
Section 07 BODY AND HULL Subsection 02 (BODY) ssi2009-003-003_a 1. Upper trim smr2009-042-034_a 4. Remove the plastic push-in clip retaining the LH trim. 1. Retaining tabs 7. Using a small screwdriver, release both retaining hooks securing the cam trim on locking mechanism. ssi2009-003-004_a 1. Remove this plastic push-in clip ssi2009-003-015_a 5. Open seat and using the SUPERTITANIUM DRILL BIT 3/16" (P/N 529 031 800), drill the rivet securing the LH body cover and the seat trim. 529031800 1.
PAGE 509
Section 07 BODY AND HULL Subsection 02 (BODY) smr2009-042-036_a 1. Retaining screws 4. Remove the Speed-Tie unit from vehicle. ssi2009-003-010_a 1. Rear locking tab Front Speed-Tie Unit Installation 13. Lightly pull the top of LH trim and remove the reel of the Speed-Tie unit from its location as shown. 1. Ensure both double cage nuts are correctly inserted into Speed-Tie unit cavities. ssi2009-003-007_a 1. Double cage nut 2. Positioning tab ssi2009-003-011_a 1.
PAGE 510
Section 07 BODY AND HULL Subsection 02 (BODY) 5. Lift the lever and insert the locking mechanism so that the lever is pointing toward the front of vehicle. ssi2009-003-010_a 1. Rear locking tab 2.3 Lightly pull the top of LH trim and insert the reel of the Speed-Tie unit in its location as shown. NOTE: Insert the unit with the marking outside. ssi2009-003-013_a 1. Locking lever 2. Rope 6. Align the reel with the locking mechanism and secure them using four M6 x 45 tapered screws. 7.
PAGE 511
Section 07 BODY AND HULL Subsection 02 (BODY) 9. Install the front trim. 9.1 Insert top tabs and align lower tabs with openings. ssi2009-003-102_a 1. Locking lever 2. Boarding platform slot 4. Position a double cage nut on the locking mechanism. ssi2009-003-016_a 1. Tabs 9.2 Press trim in place. 10. Test Speed-Tie operation. 11. Reinstall all removed parts. Rear Speed-Tie Unit Installation 1. Lift up the boarding platform. 2.
PAGE 512
Section 07 BODY AND HULL Subsection 02 (BODY) ssi2009-003-109_a 1. Tabs 2. Alignment pin ssi2009-003-105_a 1. Speed-Tie unit 9. Close boarding platform. 10. Tighten tapered screws securing the locking mechanism to 2.5 N•m ± 0.5 N•m (22 lbf•in ± 4 lbf•in). 12.2 Press trim in place. 13. Test Speed-Tie operation. Speed-Tie Unit Cleaning A minimum of maintenance is required to keep the Speed-Tie unit and the rope in serviceable condition.
PAGE 513
Section 07 BODY AND HULL Subsection 02 (BODY) ssi2009-003-018_a 1. Untie this knot 2. 4. Remove the locking mechanism and let the rope retracts into housing. 5. Remove the back cover. ssi2009-003-021_a 1. Retaining screw 8. Split the rewind unit and remove damaged rope. ssi2009-003-019_a 1. Back cover 2. Retaining screws 6. Remove the rewind unit. ssi2009-003-020_a ssi2009-003-022_a 9. Before discarding rope, remove and keep the inner stopper. ssi2009-003-023_a 1. Rewind unit 1.
PAGE 514
Section 07 BODY AND HULL Subsection 02 (BODY) ssi2009-003-025_a 1. Inner stopper A. 106 mm ± 6 mm (4-1/8 in ± 15/64 in) 11. On rewind unit base, identify the short tongue. ssi2009-003-028_a 1. Cover notch 13.2 Press in the cover until both parts are completely pressed together. ssi2009-003-026_a 1. Short tongue 12. Install the rope end (with the knot) over the short tongue as shown. ssi2009-003-029_a 13.3 Install the retaining screw. ssi2009-003-021_a 1. Retaining screw ssi2009-003-027_a 1.
PAGE 515
Section 07 BODY AND HULL Subsection 02 (BODY) ssi2009-003-030 15. Lock the end of rope as shown. ssi2009-003-033_a 18. Unlock the end of the rope and pull it out by the housing opening. NOTE: Be careful not to release the rope and the spring. Otherwise you will need to remove drum and repeat the cranking operation. 19. Install locking mechanism and rope. 19.1 Pull out rope end. 19.2 Insert end of rope through locking mechanism. ssi2009-003-031 16. Install rewind unit into housing. 16.
PAGE 516
Section 07 BODY AND HULL Subsection 02 (BODY) 21. Check Speed-Tie operation. 22. Reinstall the Speed-Tie unit on vehicle. DECALS Decal Removal Using a heat gun warm up one end of decal for a few seconds until decal can roll off when rubbing with your finger. NOTE: When heating near light surfaces, duct tape should be applied to protect the surface. Otherwise the light color could become a yellowish color.
PAGE 517
Section 07 BODY AND HULL Subsection 02 (BODY) WARNING Protect skin, wear gloves when in contact with resin, hardeners and gelcoat. A barrier skin cream may also be used. Do not expose area to open flame or lit cigarette. Some of the materials are flammable. Protect eyes, wear safety glasses when grinding, sanding or spraying. Use a dust mask when sanding or grinding. When spraying wear a respirator or paint mask. Always read warning labels on products.
PAGE 518
Section 07 BODY AND HULL Subsection 02 (BODY) then additional reinforcement may be necessary. This subject will be covered in COMPOUND FRACTURES. buffing with a white medium compound. Finish off using a fine compound. While buffing, pay close attention to avoid overheating the surface. Preparing the Surface 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.
PAGE 519
Section 07 BODY AND HULL Subsection 02 (BODY) pieces evenly. Try to work quickly, you may only have 15 or 20 minutes. You may clean the brush with acetone. Wait until the repair has hardened before moving on to the interior repair. If the size of the opening is too large for the pieces to maintain the proper shape, you will have to use a backing support. It is a shaped piece of cardboard that fits flush to the interior surface and has a plastic layer on the repair side.
PAGE 520
Section 07 BODY AND HULL Subsection 03 (HULL) HULL SERVICE PRODUCTS Description Part Number BRP HEAVY DUTY CLEANER ....................................................... LOCTITE 5150 (SILICONE SEALANT) ........................................... LOCTITE 577 (THREAD SEALANT) ............................................... LOCTITE 5900 ............................................................................... 293 293 293 293 smr2009-042 110 800 800 800 001 086 050 066 Page .....................
PAGE 521
Section 07 BODY AND HULL Subsection 03 (HULL) Hull NEW 14.5 Nm (128 lbfin) Hull Loctite 5150 (silicone sealant) NEW 14.5 Nm (128 lbfin) Loctite 5150 (silicone sealant) 50 Nm (37 lbfft) 25 Nm (18 lbfft) 25 Nm DEVCON (18 lbfft) HP250Q DEVCON HP250Q DEVCON HP250Q 25 Nm (18 lbfft) Loctite 577 (thread sealant) 16 Nm (142 lbfin) Loctite 5900 25 Nm (18 lbfft) Loctite 5150 (silicone sealant) 10 Nm (89 lbfin) NEW 14.
PAGE 522
Section 07 BODY AND HULL Subsection 03 (HULL) All Models 5 Nm (44 lbfin) 5 Nm (44 lbfin) Loctite 5900 (300 ml) 7 Nm (62 lbfin) NEW 35 Nm (25 lbfft) NEW 35 Nm (25 lbfft) Loctite 5900 (300 ml) NEW 35 Nm (25 lbfft) Loctite 567 pipe sealant (250 ml) 8 Nm (71 lbfin) smr2009-043-100_a smr2009-042 499
PAGE 523
Section 07 BODY AND HULL Subsection 03 (HULL) GENERAL Verify condition and operation of hinges and latching mechanisms. Replace any damaged components. During assembly/installation, use torque values and service products as specified in the exploded views. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete procedure.
PAGE 524
Section 07 BODY AND HULL Subsection 03 (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/driveshaft/pump alignment must be checked. Refer to ENGINE REMOVAL AND INSTALLATION. 1.
PAGE 525
Section 07 BODY AND HULL Subsection 03 (HULL) Ride Plate Installation 1. Install the jet pump support on the ride plate, see procedure in this section. NOTE: The jet pump support must be installed on the ride plate before installation of the ride plate on the watercraft. 2. Reinstall hose fittings on ride plate and torque to 7 N•m (62 lbf•in). 3. Apply LOCTITE 5900 (P/N 293 800 066) sealant on ride plate and jet pump support circumference as seen in the following illustration. smr2009-043-036_a TYPICAL 1.
PAGE 526
Section 07 BODY AND HULL Subsection 03 (HULL) 9. Reinstall coolant hoses on ride plate fittings, pay attention to gear clamp positioning. See following illustration. 3. Sealant is applied between the jet pump support and the ride plate. Using a heat gun, heat the base of the pump support to soften the sealant and carefully pry the pump support off the ride plate. smr2009-043-016_b 1. Gear clamp positioning 10. Install jet pump, refer to the JET PUMP subsection. 11.
PAGE 527
Section 07 BODY AND HULL Subsection 03 (HULL) Thru-Hull Fitting Removal Inner Fitting Removal 1. Remove drive shaft, refer to DRIVE SHAFT subsection. 2. Using a heat gun, heat the glue at the joint between the hull and the inner thru-hull fitting to soften the glue applied. smr2009-043-020_a 1. Apply loctite 5900 here (underside of pump support) 3. Torque jet pump support screws as specified in exploded view. smr2009-043-022_a 1. Heat here 3.
PAGE 528
Section 07 BODY AND HULL Subsection 03 (HULL) 2. Insert the outer fitting into the hull from the jet pump side of the hull towards the inside. Ensure fitting is pushed in against the hull. 3. Continue with INNER FITTING INSTALLATION procedure. Inner Fitting Installation 1. Apply DEVCON HP 250 Q completely around the joint where the outer fitting comes through the hull. smr2009-043-023_a TYPICAL 1. Cut sealant around outer fitting here 2.
PAGE 529
Section 07 BODY AND HULL Subsection 03 (HULL) 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. Bailer Pick-Up Inspection smr2009-043-023_a TYPICAL 1. Fitting properly seated, excess sealant removed 1. Open boarding platform and remove the storage bins. 2.
PAGE 530
Section 07 BODY AND HULL Subsection 03 (HULL) smr2009-043-032_a smr05-005-001_A 1. Elbow fitting holes DRAIN PLUGS NOTE: The two drain plugs on the stern are each connected to a bailer. When watercraft is on dry land, the drain plugs can be removed to manually drain the bilge. DRAIN PLUG REMOVAL 1. Drain plug 2. Drain neck 4. Using a ratchet handle and extension of appropriate size, unscrew the drain neck from the hull. Drain Plug Neck Removal 1.
PAGE 531
Section 07 BODY AND HULL Subsection 03 (HULL) der the splash deflector indicates the exact location of the piece to cut out. Carry out the following steps. 1. Remove splash deflector, refer to BODY subsection. 2. Using a drill bit 6 mm (1/4 in) in size MINIMUM, drill a hole at each of the five corners of the piece to cut out of the fixed deck as per following illustration. smr2009-043-027_a CUT HERE AT AN INWARD ANGLE 4. Unscrew and discard both elastic stop nuts holding the bow eyelet in place.
PAGE 532
Section 07 BODY AND HULL Subsection 03 (HULL) 4. Clean any residue of silicone sealant from the hull. Stern Eyelet Installation smr2007-034-110_a 1. 2. 3. 4. 5. 6. 7. 1. Install small washers and nylon washers to stern eyelet and insert it through the hull. 2. Inside hull, apply LOCTITE 5150 (SILICONE SEALANT) (P/N 293 800 086) all around holes. 3. Install eyelet and other parts using NEW elastic stop nuts as per following illustration.
PAGE 533
Section 07 BODY AND HULL Subsection 03 (HULL) smr2009-043-025_a 1. Passe thru insert smr2009-043-026_b BLIND HOLE INSERT 1. Excess glue on head 3. Use a six pan socket of appropriate size and a ratchet wrench to unscrew the insert from the hull. NOTE: An impact tool may be used to facilitate removal of the insert. Insert Installation 1. Clean the insert hole in the hull to remove any dirt or loose glue using clean, dry, oil free filtered air. smr2009-043-026_a 1.
PAGE 534
Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (RXT iS 255/GTX LIMITED iS 255) RXT iS 255/GTX LIMITED iS 255 MODEL RXT iS 255 GTX LIMITED iS 255 ENGINE Engine type ROTAX 1503 4-TEC, 4-stroke, Single Over Head Camshaft (SOHC) Induction Supercharged intercooled 3 Number of cylinders Number of valves 12 valves with hydraulic lifters (no adjustment) Standard Bore 1st Oversize Stroke 100 mm (3.9 in) 100.25 mm (3.95 in) 63.4 mm (2.5 in) Displacement 1 493.8 cm³ (91 in³) 8.
PAGE 535
Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (RXT iS 255/GTX LIMITED iS 255) MODEL RXT iS 255 GTX LIMITED iS 255 ENGINE (cont'd) Piston ring type Ring end gap Ring/piston groove clearance 1st Upper compression ring, rectangular 2nd Lower compression ring, tapered face 3rd Oil scraper ring Rectangular New 0.30 mm to 0.50 mm (.012 in to .02 in) Taper-face New 0.30 mm to 0.50 mm (.012 in to .02 in) Oil scraper ring New 0.30 mm to 0.50 mm (.012 in to .
PAGE 536
Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (RXT iS 255/GTX LIMITED iS 255) MODEL RXT iS 255 GTX LIMITED iS 255 ENGINE (cont'd) Connecting rod small end radial play Wear limit 0.080 mm (.0031 in) New Piston pin diameter 22.996 mm to 23.000 mm (.9054 in to .9055 in) Wear limit Balance shaft journal diameter 22.990 mm (.9051 in) New 31.980 mm to 32.000 mm (1.2591 in to 1.2598 in) Wear limit 31.950 mm (1.2579 in) Balance shaft radial clearance Wear limit 0.070 mm (.
PAGE 537
Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (RXT iS 255/GTX LIMITED iS 255) MODEL RXT iS 255 GTX LIMITED iS 255 ELECTRICAL SYSTEM Fuse box #1 Fuses and relay Fuse box #2 #1: Gauge 3 A #2: CAPS 3 A #3: Depth sounder 3 A #4: Starter solenoid 5 A #5: iBR control 5 A #6: Fuel pump 6 A #7: Inj/Ign cyl 1 10 A #8: Inj/Ign cyl 2 10 A #9: Inj/Ign cyl 3 10 A #10: OTAS switch 3 A #11: iS control 5 A Relay 30 A #15: Charging syst 30 A #16: iS power 30 A #17: Batt power 30 A #
PAGE 538
Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (RXT iS 255/GTX LIMITED iS 255) MODEL RXT iS 255 GTX LIMITED iS 255 STEERING AND PROPULSION Steering Adjustable tilt 26° Steering nozzle pivoting angle O.T.A.S. (Off-Throttle Assisted Steering) Jet pump Type Grease type Rotation (seen from rear) Impeller Impeller shaft New Wear limit Counterclockwise 14°/25° 159 mm ± 0.06 mm (6.26 in ± .002 in) 0 mm to 0.23 mm (0 in to .009 in) 0.35 mm (.
PAGE 539
Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (RXT iS 255/GTX LIMITED iS 255) MODEL RXT iS 255 GTX LIMITED iS 255 iS SUSPENSION (cont'd) Type Oil type Hydraulic pump Oil quantity Motor Radial piston Automatic transmission fluid (ATF) Dexron III Reservoir is full when oil level reaches 130 mm ± 5 mm (5-1/8 in ± 13/64 in) from bottom 12 V, 30 A. Reversible PWM (pulse-width modulation) motor WEIGHT AND LOADING CAPACITY Dry weight 446 kg (990 lb) Number of passenger (driver incl.
PAGE 540
Section 09 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM INFORMATION) WIRING DIAGRAM INFORMATION GENERAL WIRING DIAGRAM LOCATION The wiring diagram is in the back cover pocket. WIRING DIAGRAM CODES 1 1 Wire Color Codes YL - BK 1 2 F04H6LA smr05-026-002_a 1. Wire main color 2. Tracer (thin colored line) TYPICAL 1.
PAGE 541
Section 09 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM INFORMATION) smr2009-045-007_a 1. CAN wire 2. Wire destination FB2: Fuse box #2 C7: Terminal C7 in fuse box #2 On the wiring diagram, corresponding CAN links are identified in fuse box #2 using the following coding. smr2009-045-008_a 1. CAN wire 2. Wire origin 3. Destination terminal (was referenced at ECM) Fuse Box Terminal Reference Refer to POWER DISTRIBUTION subsection.
PAGE 542
Section 09 WIRING DIAGRAM Subsection 02 (CONNECTOR INFORMATION) CONNECTOR INFORMATION SERVICE TOOLS Description Part Number CRIMPING TOOL (HEAVY GAUGE WIRE) .................................... ECM ADAPTER TOOL................................................................... ECM TERMINAL REMOVER 2.25................................................. ECM TERMINAL REMOVER 3.36................................................. 529 529 529 529 035 036 036 036 730 166 175 174 Page .......................
PAGE 543
Section 09 WIRING DIAGRAM Subsection 02 (CONNECTOR INFORMATION) Connector Disassembly 1 3 3 2 F18Z0NA 2 1 TYPICAL 1. Deutsch connectors 2. Press release button Engine Connector Insert a small flat screwdriver between the support and the Deutsch connectors. Pry while sliding out connectors in the direction shown. F00H1CA 1. 2. 3. 4. 4 Male connector Female connector Secondary lock Sealing cap NOTICE Do not apply dielectric grease on terminal inside connector.
PAGE 544
Section 09 WIRING DIAGRAM Subsection 02 (CONNECTOR INFORMATION) 6. After all required terminals have been inserted, the lock must be installed. 1 1 V01G0PA MALE CONNECTOR 1. Male lock 1 F04H6LA 1. Wire identification numbers NOTE: Before extraction, push wire forward to relieve pressure on retaining tab. 1. Insert a 4.8 mm (.189 in) wide screwdriver blade inside the front of the terminal cavity. 2. Pry back the retaining tab while gently pulling wire back until terminal is removed.
PAGE 545
Section 09 WIRING DIAGRAM Subsection 02 (CONNECTOR INFORMATION) smr2009-045-013_b smr2009-045-011_a Rotate connector lock until it stops. Install connector to ECM. Rotate connector lock until it snaps locked. smr2009-045-012_a Pull out connector. smr2009-045-011_b 1. Locked here ECM Connector Inspection smr2009-045-013_a ECM Connector Installation Fully open connector lock. 522 Before replacing an ECM, always check electrical connections.
PAGE 546
Section 09 WIRING DIAGRAM Subsection 02 (CONNECTOR INFORMATION) ECM Connector Probing The most recommended and safest method to probe ECM connector terminals is to use the ECM ADAPTER TOOL (P/N 529 036 166). This tool will prevent deforming or enlarging terminals which would lead to bad ECM terminal contact creating intermittent or permanent problems. 529036175 Remove rear protector from connector. Pull out the connector lock.
PAGE 547
Section 09 WIRING DIAGRAM Subsection 02 (CONNECTOR INFORMATION) smr2009-045-015_a WARNING smr2009-045-027_a WARNING Before terminal installation, ensure all terminals are properly crimped on wires. After plugging connectors, ensure they are properly fastened. BRLS, TAS AND STARTER SOLENOID CONNECTORS (DELPHI) Before terminal installation, ensure all terminals are properly crimped on wires. After plugging connectors, ensure they are properly fastened.
PAGE 548
Section 09 WIRING DIAGRAM Subsection 02 (CONNECTOR INFORMATION) WARNING Before terminal installation, ensure all terminals are properly crimped on wires. After plugging connectors, ensure they are properly fastened. SPS CONNECTORS (BOSCH) To remove a terminal from connector, use a special tool such as the AMP TERMINAL EXTRACTOR (P/N 726503-1). smr2009-045-020_a 1. Pry out locking cap smr2009-045-018_a 1. Unlock terminal here smr2009-045-021_a 1.
PAGE 549
Section 09 WIRING DIAGRAM Subsection 02 (CONNECTOR INFORMATION) A A32E2QA smr2009-045-023_a A. 10 mm (3/8 in) 1. Pry out locking cap NOTE: Make sure not to cut wire strands while stripping the wire. Install the appropriate terminal on the wire according to the requirement. Refer to appropriate PARTS CATALOG. smr2009-045-024_a 1.
PAGE 550
Section 09 WIRING DIAGRAM Subsection 02 (CONNECTOR INFORMATION) 1 Install the protective heat shrink rubber tube on the terminal. Heat the heat shrink rubber tube using the heat gun so that it grasps the wire and the terminal. NOTICE Make sure that the protective heat shrink rubber tube has been properly installed and no part of wire is exposed. 2 A32E2SA POSITIONING THE CRIMPING PLIERS Step 1: Press Step 2: Rotate After positioning the crimping pliers, crimp the terminal already installed on wire.
PAGE 551
PAGE 552
NOTES
PAGE 553
NOTES
PAGE 554
2009 Sea-Doo 4-TEC iTC iS Series RXT iS 255 GTX Limited iS 255 smr2009-045-001
PAGE 555
STARTING SYSTEM IGNITION SYSTEM CHARGING SYSTEM smr2009-045-002